PIOX / Analytical Measuring & Sales Methods. FLEXIM GmbH

Transcription

1 PIOX / Analytical Measuring & Sales Methods

2 PIOX - Process Analyzers PIOX S Non-intrusive Ultrasonic Measurement Concentration Mass Flow Density HCL Nitric Acid Sulfuric Acid PIOX R - Process Refract meter Measurement with Laboratory Accuracy Concentration Refractive Index Density Urea Ammonium Nitrate Glycol / Water

3 PIOX S - Speed of Sound of Liquids Speed of Sound is a physical property of a liquid at a given temperature: Water Crude Oil Hexane Butan Caustic Soda 10% Caustic Soda 50% 1480 m/s 1300 m/s 1080 m/s 943 m/s 1800 m/s 2450 m/s Within mixtures or solutions, the Speed of Sound changes with the concentration Thus, the liquid soundspeed can be used for concentration measuring

4 PIOX S Measurement of Sound Velocity Sound Speed is calculated by path length of the signal traveling in a medium and the average transit time within the medium. c Fluid t down l t 2 Fluid up t 0 To achieve highest accuracy the transit time and path length of the signal traveling within the sensor and the pipe wall has to be taken into account and a field calibration is necessary.

5 Sound Velocity vs. Concentration Specifically at concentration levels above 55%wt, the sonic velocity has a clear measuring effect due to the steep slope of the nitric acid Accuracy above 60%wt concentration, accuracies better than 0.1%wt absolute are dependant upon temperature.

6 PIOX S - Flow Measurement Principal Transit Time Difference Calculation of Volume Flow [Q] Q - Volume Flow K RE - Fluid Mechanical Correlation Factor A k a - Cross-Sectional Area of Pipe - Transmitter-Constant D t - Transit Time Difference t t - Transit Time in Medium

7 PIOX S - How to calculate concentration, density or mass flow Outputs : Concentration Volume flow Temperature or Density or Mass flow Volume = Mass/Density Density = Mass/Volume Mass = Density x Volume

8 PIOX S - Capabilities Ultrasonic Clamp-on Flow velocities: from up to 45 m/sec Accuracy flow measurement: +/- 1.6% of reading with standard calibration +/- 1.2% of reading with extended calibration +/- 0.5% of reading with field calibration Repeatability: 0.15% of reading Accuracy concentration measurement depends on fluid properties E.G. - In Nitric Acid from 60 to 98%wt typically < 0.1%wt absolute Fluid properties: no influence of conductivity also for high viscous liquids up to ~10% gas/solid/2-phase content

9 PIOX S Advantages Low Investment Cost Low Cost of Ownership Zero Downtime Triple Purpose Volume Flow, Concentration and Mass Flow No Bypass piping required Non-intrusive No custom piping or materials Instrument costs are independant to pipe size or pressure ratings Measurement up to 750F pipe temperature Maintenance and drift free (highly durable and robust) Corrosion free Long life cycle of ownership Low energy consumption compared to intrusive metering Maintenance free No process shutdown during installation and commissioning Almost not effected by deposits and blisters Product Quality No Contamination risk of process fluid Fast measuring response quick detection of process measurement changes Plant Security No leakage risk

10 Concentration curve comparison Sound Speed Refractive Index When PIOXS is not the best fit, we can go with PIOXR

11 PIOX R - Process Refractometer Unique Transmitted Light principle Patented bi-prism Zero point calibration not required Drift free Refractive Index measurement Calculation of m%, density, g/l, mol/l, Brix Integrated high accuracy Pt1000 RTD Allows for measuring of Turbidity Independent of fouling and accumulation Various materials for corrosive liquids High precision ( nd typ. 0.01M%) Capable of high temperatures (150 C / 302 F) Intrinsic safety (ATEX Zone 0/1)

12 Competition - Critical Angle Refractometer Light from a point source meets the surface between the optical prism and the liquid at different angles Light with a small incident angle is refracted into the medium Light meeting the surface at larger angles is totally reflected and is detected by a CCD Sensor The position of the slope is calculation basis for the refractive index Total reflection: α = arcsin (n 1 / n 2 )

13 Real World Examples of light refraction Long angles reflect Short angles refract

14 Competition - Critical Angle Refractometer Critical angle principle at laboratory refractometer only small sample volumes necessary easy sample change easy cleaning

15 Competition - Critical Anlge Refractometer Critical angle refractometer in process surface measurement: only the medium in direct contact with the prism is measured therefore already tiny particles at prism surface contribute to reflection the calculated refractive index is influenced Drift and faulty measured values

16 Competition - Critical Angle Refractometers All use critical angle design All subject to drifting with coating buildup

17 Flexim - Transmitted Light Refractometer A beam of parallel light crosses the medium and is refracted at an optical prism The light beam is focussed to an image sensor (CCD) The refractive index is calculated from the light spot position on the sensor Additionally the amplitude of the signal is measured n 1 sin α = n 2 sin β

18 Transmitted Light Principle in Process Only the light passing through contributes to the measurement The light beam passing the fluid is parallel, therefore the direction does not change, even if the whole beam does not pass through The signal position on the CCD sensor remains the same Only the signal amplitude is reduced correct measurement of process medium no drift!

19 Refractometer Principles Critical Angle measures surface of medium all particles on the prism influence value => faulty measurement therefore high cleaning frequency no possibility to check validity of measurement Transmitted Light measures through the medium parallel light beam, therefore: despite build-up correct measured value signal amplitude indicates validity of measurement and build-up on prism

20 Differential Measurement Transmitted light principle with bi-prism two symmetrical signals are detected on the CCD sensor zero point is mean value between both signals calculation of R.I. according distance of both signals differential principle establishes drift free refractive index measurement temperature normalization of refractive index through integrated Pt1000 temperature probe From refractive index and temperature other physical properties will be calculated: e.g. m%, density, g/l, mol/l, Brix

21 Use of Signal Amplitude shows that measured value is valid Fouling / build-up indicator Turbidity indicator Monitoring of solving processes wide range 1 : 10000

22 Advantages PIOX R400 Unique Transmitted light refractometer for process Patented differential measurement with bi-prism: no drift correct measurement even with build-up possibility to detect build-up additional highlights: high precision (0,00002 nd typ.0,01 m%) wide measuring range ATEX Zone 0/1 Max. Temp. 150 C

23 PIOX R Improved Sensor design Internal Gaskets Improvements of sapphire Optics Increased reliability Maximized Durability in aggressive and corrosive liquids Chemical & Hygienic designs

24 PIOXR Stainless Steel Design 3 Tri-Clamp Design Flow Chamber Design Threaded or Flanged ANSI150 Direct Flange Mount Design

25 PIOXR TEFLON Design PFA Lined Flow Chamber ANSI150 Direct Flange Mount Design

26 PIOX R - Refractive Index of Nitric Acid Nitric Acid Concentration vs. refractive index (20 C) nd Nitric Acid Concentration vs. refractive index (20 C) nd Also the Refractive Index of Nitric Acid is in distinct relation to its concentration over a wide range PIOX R and PIOX S can be complimentary tools for concentration measurement over the whole concentration range of Nitric Acid

27 PIOX R Advantages Cost of Ownership Predictive Maintenance Diagnosis implemented Drift free, 5% transmittance capable for operation Free of Corrosion with a variety of wetted materials Long life cycle in comparison to similar measuring No moving mechanical parts Plant Availability Almost no effect by deposits Easy to maintain, including diagnostic output No drift from surface fouling Factory Calibrated and certified Product Quality Laboratory accuracy directly in proccess Proccess temperatures up to 150 C Plant Security Durable design for chemical applications

28 PIOX - Process Analyzers PIOX S Non-intrusive Ultrasonic Measurement Concentration Nitric Acid Density Mass Flow PIOX R - Process Refract meter Measurement with Laboratory Accuracy Concentration Density Refractive Index

29 Nitric Acid Application Example Truck filling station Simultaneaous measurement of: concentration mass flow stainless steel 304 pipe DN100 (4 ) inline temperature probe for fast reaction

30 PIOX S for Nitric Acid Installed Measurements: YARA Sluiskil, Netherlands YARA Ambes, France YARA Rostock, Germany AgroLinz / Borealis, Austria El Dorado Nitrogen, Texas

31 PIOX - Process Analyzers PIOX S Non-intrusive Ultrasonic Measurement Concentration Ammonium Nitrate Mass Flow Density PIOX R - Process Refract meter Measurement with Laboratory Accuracy Concentration Density Refractive Index

32 Ammonium Nitrate Concentration and Flow How do you measure the Flow around your AN pumps? Flow measurement of Ammonium Nitrate Solution 80%...97% temperature 140 C 190 C pipes DN80 DN150 Advantages: Accurate, non-intrusive measurement with PIOX-S ultrasonics No plant shutdown during installation & commissioning No life cycle replacement due to liquid corrosion No equipment damage from product solidification at ambient temperature Concentration measurement via dilution %

33 Ammonium Nitrate Concentration Ultrasonic sound speed vs. concentration C USS C USS 20 C USS C USS 10 C USS 70 C USS 65 C USS 60 C USS M% 40.00M% 50.00M% 60.00M% 70.00M% 80.00M% 90.00M% 55 C M% USS 50 C USS

34 PIOX - Process Analyzers PIOX S Non-intrusive Ultrasonic Measurement Concentration Urea Mass Flow Density PIOX R - Process Refract meter Measurement with Laboratory Accuracy Concentration Density Refractive Index

35 Urea - Concentration

36 Urea - Concentration Refractive Index of Urea Urea 1,41 1,4 1,39 1,38 nd(20) 1,37 nd 1,36 1,35 1,34 1, content weight%

37 PIOX - Process Analyzers PIOX S Non-intrusive Ultrasonic Measurement Concentration Urea Ammonium Nitrate Mass Flow Density PIOX R - Process Refract meter Measurement with Laboratory Accuracy Concentration Density Refractive Index

38 Urea Ammonium Nitrate Total N-content Combinational method

39 Urea / Ammonium Nitrate PIOX Solution

40 Urea and UAN CF Industries, Donaldsonville Nitrogen Complex, Louisiana UAN is produced at 32% - refractometry used for qualitiy control combined with a density meter PIOX R300 and PIOX R400 Prior solution: critical angle refractometer: drifting measured values due to deposit building

41 CF Industries, Donaldsonville Concentration of Urea Ammonium Nitrate Used Critical Angle Refractometer PIOXR Advantages: Continuous Process Control Precise Measurement Drift Free Selling Points Increase of Product Quality Avoidance of waste batches Cost savings by elimination of maintenance

42 Measuring Point Cherokee Nitrogen (US) Parameter Pipe Mat.: Stainless Steel Outer Diameter: 88,9 mm, Wall Thickness: 2,8 mm CDM Transducer 2 soundpath 38,1mm distance Offset: 13m/s Diagnostics GAIN: 53 db SCNR: 51 db PIOX-S SNR: 33 db R400 Flexim flange Flow Chamber ANSI 3 Ampl.: 95,0 Qual.: 48,5 PIOX-R

43 PIOXR Application Examples

44 PIOXR Application Examples

45 PIOXR Application Examples

46 PIOXR Application Examples

47 PIOXR Application Examples

48 PIOXR Application Examples

49 PIOX FAST Form Combination form for both PIOXR & S Contains required information to prepare a quotation Customer supplied data needed to generate concentration files Outlines installation, Area Classification and electrical requirements Orders cannot be processed without FAST form. Part of production process

50 oming Soon September 2014 FLEXIM PIOXS 2014 Flow Control Innovation Award winner Hello Oliver, I would like to congratulate Flexim Instruments on being named among this year s Flow Control Innovation Awards winners for the key innovations represented by its PIOX Mass Flow Measuring System Innovation Awards winners will be announced in the September issue of Flow Control magazine with short overviews of each winning technology and with voter comments. Amy Richardson / Flow Control

51 Thank You PIOX R Transmitted Light PIOX S Speed of Sound