In combustion, hydrocarbons react with oxygen to produce carbon dioxide and water. Despite ample oxygen, small amounts of carbon monoxide (CO) are still formed, an environmental pollutant regulated by the Federal Immission Control Act. Although having excess oxygen helps reduce CO, it doesn’t necessarily enhance efficiency. Heating unnecessary air is inefficient, and since oxygen and nitrogen have lower emissivity than combustion products, efficiency is further decreased.

Incomplete combustion can lead to coking or damage from CO afterburning in heat exchangers. Additionally, unburnt gas from non-igniting nozzles poses significant safety risks.

Optimal Strategies for Safe Combustion Control

To effectively manage combustion processes, it is crucial to:

• Minimize CO production by ensuring adequate oxygen presence.
• Limit oxygen use as much as possible while maintaining safety parameters.
• Use measurement technology to monitor combustion gases like methane.

This is where TDLS (Tunable Diode Laser Spectroscopy) becomes essential.

The Best Approach

Cross-stack laser in the combustion proces

Utilizing the TDLS8200 cross-stack laser offers numerous advantages:

• Measures three key parameters: O2, CO, and CH4.
• Provides an integrated measurement across the combustion chamber, not just a point measurement.
• Conducts measurements right over the flames, minimizing external influences.
• Offers selective measurements without interference from CO or water.
• Includes a reference gas cell for accurate CO and O2 detection at low concentrations.
• Operates in-situ without contact, eliminating the need for sample preparation.
• Delivers fast readings every twelve seconds with TruePeak evaluation to avoid background gas interference.
• AutoGain ensures reliable measurements even with low transmission due to dust and soot.
• Requires no calibration, allowing for inline validation checks.
• Safe for use in ATEX Zones with optical measurement.
• SIL2 and SIL3 certified for redundancy and designed for tough environments.
• Easy to operate with no calibration or maintenance needs.

A Cost-Effective Solution

Lance laser in the combustion process

For smaller and stable furnaces, the TDLS8200 probe-type laser offers:

• All the benefits of TDLS technology with a process temperature up to 600°C.
• Integrated measurement through the probe’s optical path length.
• Compatibility with existing device flanges or sampling probes for cost-effectiveness.

Note: This is an updated version of an older article

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Oxygen content measurement may be required

This generally means nitrogen is blown in by means of mechanical pressure reduction and pressure relief valve so that nitrogen overpressure of approximately 25 to 35 mbar is maintained in the gas system. In the past, people relied on the equipment functioning correctly and, at best, only measured overpressure. The idea was to ensure a degree of certainty that everything would work as planned. However, in these times of ever stricter safety and security requirements, this is no longer adequate when carrying out a safety assessment. Instead, measuring the actual oxygen content is essential – especially if the equipment concerned has been classified as a SIL (safety integrity level) application.

This was recently the case with one of Yokogawa’s customers in Germany. The company in question had to demonstrate that there was no oxygen in its tank farm. The relevant application was classified as SIL2. An extractive measurement would have cost the customer too much money in this specific instance, and, above all, the need for constant maintenance was a major deterrent. It was decided to seek a largely maintenance-free solution that meets the requirements for SIL2. Yokogawa was able to meet those requirements exactly with the TDLS8200 (Tunable Diode Laser Spectrometer).

Attractive package solution with TDLS

In this particular scenario, the oxygen content had to be determined in the gas balance pipe of a tank farm, which is used to monitor the inerting of the system. That kind of application can be found in virtually any chemical plant that has tank farms or production tanks. It was almost certainly a big advantage for Yokogawa with this project that Yokogawa has long made a name for itself as a supplier of laser systems. From the very first meeting to the final commissioning, Yokogawa was able to provide the client with an attractive package solution, and Yokogawa was obviously really pleased about that. Yokogawa has already realized similar applications in this field in Germany on previous occasions, some of them with the predecessor TDLS8200, which has been used there successfully for more than 10 years now. The laser spectrometer’s high measuring accuracy, combined with its ease of maintenance, is one of the outstanding features of this solution for monitoring inerting.

Incidentally, Yokogawa is set to expand the product range shortly. The TDLS8200 is a probe-type Tunable Diode Laser Spectrometer. It is perfect for this application alongside the standard TDLS8200 because there should typically only be oxygen in the gas system or the gas balance pipe.

(Note: This is an updated version of an older blog article)

What’s new with NAMUR MTP?

https://www.yokogawa.com/eu/blog/chemical-pharma/en/namur-workshop-der-prozesstaugliche-tdls/

Process capable laser spectrometry – fast, reliable, selective

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On the other hand, the plant itself is due to be replaced five years from now, so there won’t be any more investments in new analytics for the time being. Luckily, Steve is an expert and has always sorted it out somehow or otherwise. In two years, though, Steve will be retiring. What will we do when he’s gone?

Someone will have to apply themselves to that shelter more fully – and see if it might be an option, after all, to keep it going for another few years without having to scrap the whole thing. The gas chromatograph (GC) is actually in quite good shape. Let’s face it: you don’t buy a new car just because the tires have worn down. It can’t be that complicated!

Check out our new and free webinar “GC AI” here:

Couldn’t we get one of the analyzer system integrators to apply themselves? Unfortunately, they’re all interested in those big, fat, greenfield projects. They’re probably not interested in making one small part of a brownfield plant fit again.

Is that the case? Does that situation sound familiar to you?

One-stop shop

Yokogawa has been doing ASI — Analyzer System Integration — for over 50 years. Until recently, ASI was on show at a trade fair called ACHEMA. The message is “one-stop shop” — everything from one supplier. Yokogawa has proven its ability to handle large-scale greenfield projects with, say, 75 gas chromatographs in 15 analyzer shelters time and time again. Those are flagship projects, of course.

When less is more

Yet, regardless of how great ASI is for greenfield projects, it won’t help Steve solve his problem. He’s not out to build a new refinery. What Steve needs instead for his brownfield plant is a customized solution. In other words, he’d be very happy to settle for less than the full month.

The analytical solution no longer works as it should, even though the GCs are still in fairly good condition. On the other hand, the sample conditioning system looks certain to give up the ghost sometime soon – it’s becoming increasingly difficult to keep it alive. Moreover, some requirements have changed over the years for operational reasons. A completely new plant would be a waste. That’s why an upgrade is the most sensible and economical answer, preferably with training for the plant’s maintenance technicians.

Steve could imagine a scenario like this: a colleague from Yokogawa drops by, looks at the shelter, and makes suggestions – a bit of engineering by an expert, a system foundation nearby, as well as installation, commissioning support, and briefing where necessary. Operation and maintenance are routine, and there are unlikely surprises in those areas. On the other hand, the supplier will likely make repair visits at short notice and should ideally be nearby. ASI light, as it were.

Support with services

Can we arouse your interest with another scenario? Perhaps you’ll recognize this one.

The analytical solution has been around for a long time, but it’s no longer easy with your resources. Moreover, the person who built the plant is not sitting just over the road controlling repair and maintenance assignments with his remote. And, because of the plant’s age, it’s a safe bet that those assignments will be necessary more often. Regrettably, the investment in a replacement plant will probably not materialize for a while yet, pending strategic decisions by the company management (it’s the same everywhere today). However, the customer is keen to take advantage of maintenance and troubleshooting by the local Yokogawa branch office.

Pocket-sized ASI

Incidentally, the smallest project that Yokogawa has ever handled is this:

Can you see the blue CD on the left to give you an idea of the scale?

This is a utility panel for a laser spectrometer. The project management comprised a single page in Excel and a small amount of text. The panel was manufactured by a nearby Yokogawa partner (near to the customer and Yokogawa, that is), and then shipped to the client. It makes a good testimonial for a project that was realized comparatively easily.

Feel free to contact us if your solution is getting old and causing you headaches—or if you’re searching for a very specific spectrum of services.

Check out our new and free webinar “GC AI” here:

Link to our website: ASI

(This is an updated article from 2018)

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Today, with the increasing electronification of mobile solutions like cars, the storage of Li-ion batteries requires extra attention because of the risk associated with battery storage. The possibility of aging can lead to a difficult fire to control. The best way to avoid this is to have an early detection system.

“The last line of defense”

Using the fiber optic heat detector DTSX1, however, not only achieves early discovery, which has been difficult up until now with point sensors, but also resolves issues such as longer installation work periods, initial expenses, and increased maintenance costs. This averts unexpected shutdowns and helps ensure stable operation.

The fiber optic heat detector DTSX1 can comprehensively monitor all shelves as fiber optic cable is installed even in large individual shelves.

This is being adopted as a new means of resolving issues such as a longer construction period, initial expenses, and increased maintenance costs resulting from the use of point sensors. It can be flexibly configured and set to suit on-site environments to detect abnormal temperature in a way different from point sensors, as it supports a difference with external thermometer alarms in addition to simple upper limit and rate-of-change alarms.

This leads to discovery at an early stage and a quick initial response, which limits damage to a minimum.

What is DTSX1?

DTSX1 is a fiber optic-based linear heat detector specifically developed for fire prevention and detection in large facilities and infrastructure such as tunnels and warehouses. It analyzes temperature data with high accuracy by measuring with fiber optic sensor cable and performing high-temperature heat detection. It stores the alarm functions required for heat detection in one box.

DTSX conforms to EN54-22, the EU fire detection and fire alarm system standard. It is currently used as a fire detection sensor and is being adopted in automatic physical distribution warehouses, lithium-ion battery production processes, and various other applications.

Sensing Fiber Cable

The temperature sensor is a standard multi-mode optical fiber.

The fiber optic cable is passive in nature. And it has no individual sensing points and therefore can be manufactured based on standard telecoms fibers. This offers excellent economies of scale, special in warehouse where you have many shelves. Because the system designer/integrator does not have to worry about the precise location of each sensing point the cost for designing. And installing a sensing system based on distributed fiber optic sensors is greatly reduced from that of traditional sensors.

Additionally, because the sensing cable has no moving parts, an in-service life of more than 30 years is not unrealistic. Maintenance and operation costs are also considerably less than for conventional sensors.

Integrated monitoring solutions

For integrated monitoring purposes The DTSX1 can be easy interface with HMI and/or SCADA applications.

e.g with GA10 HMI and data acquisition software enables you to build an HMI/data acquisition system without programming. They are designed for maximum compatibility with Yokogawa DTSX1.

You can also use the CI Server SCADA solution or comprehensive, fully integrated SCADA applications. Powerful and flexible, the CI server gives you a complete overview of the Warehouse temperature monitor system, including advanced graphics, a full alarm management function, and long-term data storage.

Click HERE to visit our website and learn more about the DTSX or to contact our experts.

The post Rapid-fire detection and downtime prevention of EV Li-ion battery production appeared first on Chemical Pharma Blog.

What is DTSX1?

DTSX1 is a fiber optic-based linear heat detector specifically developed for fire prevention and detection in large facilities and infrastructure such as conveyor belts, cable trays, buildings, and tunnels. It stores the alarm functions required for heat detection in one box. DTSX1 analyzes temperature data with high accuracy by measuring with a fiber optic sensor cable and performing high-temperature heat detection.

DTSX1 belongs to the Yokogawa OpreX product strategy. OpreX is the comprehensive brand for Yokogawa’s industrial automation and control business. The OpreX brand stands for excellence in the technology and solutions that Yokogawa cultivates through co-creating value with its customers. Under this brand, all the Yokogawa control products may be found. As well as services and other solutions that customers use to digitalize and transform their businesses and drive growth in this time of unprecedented change. Under the OpreX brand name and based on the Co-innovating tomorrow corporate brand slogan, Yokogawa will continue to co-create value with its customers and thereby help to create a brighter future for all.

Fire detection for 3D Automatic Warehouse

Although it is desirable to efficiently store flammability products such as batteries and spray cans in a 3D automatic warehouse, the fire risk increases because it is difficult to monitor from top to bottom. With existing spot-type temperature sensors and fire detectors, monitoring all shelves in a three-dimensional automatic warehouse is impossible. However, DTSX contributes to safer operation by continuously monitoring the shelves’ temperature continuously by laying optical fibers on the shelves.

Which application areas is DTSX1 used for?

DTSX1 has been certified by the Vds in Germany according to EN54-22 since 2020. And the fiber optic heat detector is designed for civil constructions (buildings, tunnels, parking garages, etc.) and industrial applications. It is used for monitoring industrial plants. The concept of the DTSX1 is designed for harsh industrial environments such as dust, corrosion, heat, smoke, vibration, and exhaust fumes. With the DTSX1, abnormal temperature conditions can be detected quickly and assigned to the corresponding zone.

A brief summary of the most important points of DTSX1

• The DTSX1 is designed to withstand the effects of dust, corrosion, heat, smoke, vibration and exhaust gases in industrial environments.
• Zone-exact localization of the fire location in the shortest possible time.
• Simple configuration and standardized interfaces (HW & SW).
• VdS approval according to EN 54-22.

Click HERE to visit our website and learn more about the DTSX or to contact our experts.

The post DTSX1 – Fire detection for multi-storey warehouse appeared first on Chemical Pharma Blog.

“The PAT Colloquium is an ideal platform for exchanging knowledge and information and also for thinking outside the box. You can always take away a few impressions and use them in your day-to-day work,” said Reinhard Gehrmann, Product Manager Analytical Solutions, adding: “In addition to the exhibition, the numerous presentations were of course also very interesting. The outlook for the future of PAT is particularly exciting.”

Presentation of the GC8000

The main goal of the most important German-language event in the field of process analytics is the so-called “trialogue” between scientists, manufacturers/suppliers and end-users in order to cross the boundaries between disciplines and thus bring together people with different cultures from the various process industry landscapes.

“Last year, we were able to organise the colloquium at our European headquarters in Amersfoort. Just like then, it was great to meet so many experts from the industry and exchange ideas with them again this year. But of course it was and is always a great opportunity to present ourselves, our expertise and this year also the GC 8000,” explained Arthur Groenbos, Product Marketing Manager, who also gave a sponsor pitch entitled “Gas Chromatograph Artificial Intelligence Maintenance Support by GCAI” as part of the popular industry get-together (click here to go directly to the presentation in the video).

To the event video on our Youtube channel

The post Yokogawa at the PAT-Colloquium 2023 appeared first on Chemical Pharma Blog.

As part of the “Trialogue”, questions such as “What’s new in PAT?”, “How does PAT help with the intended product quality?” or “How are samples taken and prepared?” will be discussed and answered at the tried-and-tested industry get-together between users, manufacturers and scientists. At the most important German-language event on the topics of process analysis and process analysis measurement technology, four sessions plus round table discussions and poster exhibitions will focus on successful projects from the field, sampling and sample preparation, PAT and its communication, and PAT innovations. In addition, lectures and posters on new real-time methodologies, multi-sensor technology and miniaturisation will be presented under the PAT innovations theme.

You are welcome to visit us at the PAT Colloquium on the 28th and 29th at stand 16. Our team is looking forward to exciting discussions and interesting dialogue.

Click here for the information page of this year’s PAT Colloquium

Are you interested in the topic of gas chromatography? Then take a look here: Free BROCHURE

Directly to our Life Cycle brochure

The post PAT Colloquium 2023: Yokogawa is on site as a sponsor at the industry event appeared first on Chemical Pharma Blog.

Vielen Dank an Yokogawa Europa, dass Sie Ihr Versprechen, trotz der Herausforderungen dieser Zeit unser Gastgeber und Hauptsponsor zu sein, eingehalten haben.”

Werner Worringen, who was a Yokogawa employee for many years and has been a member of the PAT working group for some time, said with satisfaction: “We had a great PAT colloquium with around 100 participants from numerous European countries, meeting in persona at Yokogawa Europe B.V. in Amersfoort. This was a successful step for the AK PAT (working group process analytical technologies of GDCh and DECHEMA) towards a more European approach in this impressive environment. The large hall supported the exhibition of posters and PAT solutions and especially our major intention at the colloquium: discuss the presentations, sharing views and exchange ideas. Many thanks to Yokogawa Europe that you kept your promise to be our host and major sponsor despite the challenges of these times (the board of AK PAT).

Success stories

The colloquium of the AK PAT offers best practice and success stories on sustainability and the circular economy. All-time favourites include updates on PAT and Data, Design of Experiments, Process Modelling, Data Architecture and Data Security. These topics have been addressed in the lectures and discussion sessions.
Innovations in real-time methods, multi-component PAT, miniaturisation and process analytics – from the laboratory to production – have been presented. As always, the colloquium was the meeting place for prospective and established Trialogue experts and all those interested in PAT.

Geschichte Yokogawas und Poster Slam

Monday started with a guided tour of the European headquarters in three groups, which included a look not only at some of the departments but also at the history of Yokogawa. Tuesday, the first actual conference day started with an opening held by Prof. Dr. Martin Jaeger. From 9 a.m. to 6 p.m., there were many exciting lectures and round table discussions on various topics as well as the well-known poster slam, for which 15 posters had been submitted. The winners of the poster session were:

First Prize
B. Evers; InProcess-LSP, Oss/NL
“A unique PAT method for real-time, inline size characterization of concentrated, flowing nanosuspensions”

Second Prize
F. Braun; A. Hien; S. Schwolow; Optoquant GmbH, Neustadt/D
“From laboratory to hazardous process environments – Optoquant’s rapidly deployable Raman sensor”

Third Prize
J. Kurmann; R. Kinsinger; M. Theuer; BASF SE, Ludwigshafen/D
“ppm Detection of Chlorinated Hydrocarbons in Ambient Air using a Fixed Gas Monitor with Pyrolysis Unit”

The presentations and discussions were divided into the areas “European Success Stories”, “PAT Innovation: Lab to large scale” and “PAT and data”. At the end of the day, the evening came to an atmospheric close.
Wednesday started as the last day of this year’s PAT Colloquium with presentations on “PAT Innovation: Noval real time PAT”, before the poster session and lunch were followed by a discussion on “PAT Miniturisation”. In the afternoon, the event came to an end for the guests, while the general meeting of the AK PAT followed.

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First, let’s take a look at how initially industry has changed our world, and now our world needs to change the industry:
⇾ people started industrialization which boosted greenhouse gases emissions
⇾ higher concentration of GHG results in global temperature increase
⇾ global warming starts to change our climate
⇾ society requests a change (sustainability)
⇾ politics start addressing this issue (Paris Agreement which led in Europe to Green Deal and now “Fit for 55”)
⇾ industry embraces legislation and stakeholders expectations by the energy transition

Needed revolution has a very limited timeframe

As these are global activities, each step is a significant period of time, but we can see that with every action time is significantly decreasing. We have started to destroy our planet almost 200 years ago¹, real effects on temperature increase have been noticed 80 years ago¹, so as a result, 10 years later, we have organized First Earth Day. Politics started addressing this issue at the UN conference in Rio almost 30 years ago, but the global consensus and commitment signed in Paris were just 6 years ago. Then in Europe, just 2 years ago, we came up with a strategy called Green Deal (similar strategies were announced in other parts of the world), and today we have an action plan called “Fit for 55” which in reality is no longer evolution of our energy systems and way we live — it is a revolution which needs to happen in a very limited time frame.
And it is not all, report² from the United Nations’ body responsible for climate change — The Intergovernmental Panel on Climate Change (IPCC) reveals that we have failed over the last decades to properly address global warming. An increase of the temperature (comparing the preindustrial era) by 1.5 °C will be achieved 10 years earlier (in 2030). From this perspective, revolutionary Fit for 55 may not be revolutionary enough.

“It is indisputable that human activities are causing climate change … ” IPCC²
On top of this, the same report² is closing all discussions about the cause of global warming. It is not the natural life-cycle of our plant, we, as humanity, are simply overheating the Earth. Take a look at the snapshot from report² to have a clear visualization of the quote above. It is indisputable.

Summarizing this long introduction, Energy Transition is not a question of if or when it will happen, it is a matter of how and if we manage to change on time.

Race against time

Time starts to play a crucial role in this revolution.

Energy Transition is driven by three major forces: technology, society, and legislation. Till now technology had a leading role, as companies and governments were waiting for technology breakthroughs and reasonable Return On Investment to proceed with “green” projects. Either we are talking about wind turbines, photovoltaic, carbon storage and use, hydrogen, batteries, EVs, etc. — all new technologies are scaled up only if it pays off in a reasonable time horizon. These are the cardinal rules of the economy that allowed us to develop our society, significantly reduce poverty and create a wealth of the “western” world.

Yet, society thanks to better insight and inter-connectivity were fed with more detailed data and start to push companies and politicians to be bolder in their sustainability agendas. As we see today, this push is only successful through stakeholders of the industry. Capitalism at its finest.

Breakthrough in awareness

As mentioned in the introduction, all of this is followed by legislation that till now was voluntary and not globalized. A strong push from Europe and the USA does not have the same response in other parts of the world and as we can see Paris Agreement as a breakthrough in awareness, it is still up to countries to force any changes.

With the latest research (IPCC report) and plans (“Fit for 55”) we have a new deal, at least in Europe. Legislation is taking the driving seat and start forcing new economic order around sustainability (carbon taxes, EVs, deleting CO₂ allowance). We can also see society to be braver in their claims towards major companies (i.e., a sentence in Haga against Shell).
By setting a new paradigm of sustainable economy companies and governments will be forced to speed up with implementing and developing new technologies not on ROI principles as it was till now but simply to maintain a license to operate.

Three directions

This is the best moment to look at how Energy Transition can influence our industry and planet. In my first article I described the new role of the market — prosumer, as a central point of the whole transition. Around prosumer, active participant of the energy market, we can outline three major directions of limiting global warming (as an end goal of energy transition):
Energy Efficiency — Looking for opportunities to limit the amount of consumed energy.
Decarbonization — Smarter qualification of energy sources based on their carbon footprint.
Decentralization — Scaling up network and energy sources combined with agile management.

Each of these themes has different aftermath to The Future Digital Energy Systems and impacts different layers like operations, investment, reliability, etc. Yet to properly assess the contribution
to the end goal we need to bring them down to a common denominator which is ….

Stay tuned with me. In coming articles I will disclose what energy efficiency, decarbonization and decentralization really mean and how we can genuinely evaluate its impact on saving our planet.
With The Future Digital Energy Systems articles series, I’d like to address the main drivers and enablers of our future energy landscape. Analyzing available technology, required changes in the
organizations, legislation, and society, I want to disenchant and simplify all actions needed to fulfill net-zero commitments and limit global warming.

References:

1. Early onset of industrial-era warming across the oceans and continents
   https://www.nature.com/articles/nature19082
2. IPCC. 2021 “Climate Change 2021: The Physical Science Basis.”
   https://www.ipcc.ch/report/sixth-assessment-report-working-group-i/

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