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Discussion of available CO/combustion sensing technologies and gas appliance industry views on sensor technology

Discussion of available CO/combustion sensing technologies and gas appliance industry views on sensor technology

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  • 5
  • GRAF-5710
    Vertriebspartner, Weltkarte, Vertrieb
  • BT300, Brennersteuerung, Vertrieb, Load Controller Modul LCM
  • GRAF-5111; 2720; 9389; 4970,
    CarboSen, Titelfolie, Messsysteme, Vertrieb,
    Measurement System
  • 28
  • GRAF-4164,
    CarboSen, Größenvergleich 10 Cent Stück, Messsysteme, Vertrieb,
    Measurement System

  • GRAF-5120,
    CarboSen1.000, Messprinzip, Vorderseite, Rückrückseite, Zeichnung, Messsysteme, Vertrieb,
    Measurement System

  • GRAF-5122,
    CarboSen, Sensoraufbau, Messsysteme, Vertrieb,
    Measurement System

  • GRAF-5121,
    CarboSen, Kennlinie, Emissionskante manuell angefahren, Messsysteme, Vertrieb,
    Measurement System
  • CarboSen 1.000, KS1D, Testanlage Öl-Blaubrenner, Anlagenbeispiel, Messsysteme, Vertrieb,
    Measurement System

  • GRAF-5111,
    CarboSen1.000ST, Eigenschaften, Einsatzgebiete, Messsysteme, Vertrieb,
    Measurement System

  • GRAF-2720,
    CarboSen1.000, Eigenschaften, Einsatzgebiete, Messsysteme, Vertrieb,
    Measurement System

  • EN Schlussfolie, Danke für Ihre Aufmerksamkeit
  • EN Schlussfolie, Kontaktdaten

Transcript

  • 1. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Ceramic Gas Sensors for Optimisation of Combustion Processes Dr.-Ing Frank Hammer
  • 2. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Outline › Overview of LAMTEC › Sensor Technology › Manufacturing Technology › Combustion Optimisation › Application › Summary › References
  • 3. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Overview of LAMTEC - Company Profile › LAMTEC Sensors and Systems for Combustion Engineering (LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG) Wiesenstraße 6, 69190 Walldorf, Germany › Established: 1st Juli 1995 as MBO from ABB › Shareholders: Dipl.-Ing. Hans-Jürgen Altendorf, Dipl.-Ing. Bernd Jülg, Dipl.- Ing. Harald Weber, Olaf Winne › Subsidaries/ Associated Companies: • LAMTEC-Leipzig GmbH & Co. KG, Germany (100%) • LAMTEC EA Buchon EA Buchon South Korea (80%) Jan. 2006 • LAMTEC Poland • LAMTEC SEA Ltd. Kuching Malaysia (2010) • OOO LAMTEC Moscow (2012), • Escube GmbH & Co. KG Stuttgart, Germany (100%) › Employees: 100 (2 trainees) › Turnover 2013: 14.3 Mio. €
  • 4. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Overview of LAMTEC - Locations Headquarter Walldorf LAMTEC EAST ASIA Ltd. Buchon, South Korea LAMTEC Leipzig Development of hard- and software Manufacture of flame scanners LAMTEC Neu Anspach Development of electronics
  • 5. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Overview of LAMTEC - Products/Applications LAMTEC Products/Applications Customers Electronic burner control system Fuel-/air ratio control IR/UV Flame monitoring system Process and fault indicator system O2 measurement devices Option: Detection of non-burned CO/H2 Boiler manufacturer Plant manufacturer Measurement device manufacturer Burner manufacturer Industry Applications: Power plant/waste combustion Chemical industry Industrial application Measuring- and control technology Research facilities and development
  • 6. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Overview of LAMTEC - Sales Partner
  • 7. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Overview of LAMTEC - Product Range Burner Control Electronic Fuel-/Air Ratio Control Volume Flow Measurement Flame Detection O2 Optimization O2 Measurement CO/O2 Monitoring Process and Fault Indicator System Product Range
  • 8. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Sensor Technology – Non-Nernst Principle Design of a CO measurement cell Non-Nernst Sensor Voltage cathode Ad. phase: Gas phase: pO2=21%, pCO=1%, (Rest N2) O2,ad= 99%, COad= 1%O2,ad= 90%, COad= 10% US Solid Electrolysis          Aad Kad CO CO S C C F T U , , ln 2
  • 9. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Sensor Technology – The Sensor Voltage › Langmuir adsorption isotherm • monomolecular adsorption layer • ads./des. in stationary state condition (SS) › US is a function the coverage of anode and cathode  A,  K • KA=KK :identical reaction kinetics SS-constants through identical reactions (TE=TK=TS, one measurement element) • Dg ad,A  Dg ad,K :Comparison of Gibbs enthalpies through similar adsorbents/adsorbate binding strength (identical basic materials of electrodes on three phase boundary, alloy of two phase layer for modification of adsorption on the anode)                   DD            AK AKKadAad K A S S S T gg F T U )1( )1( lnln 2 ,,  D          S ad ad T g CO e K c ( 1 1
  • 10. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Sensor Technology – The CO Sensor Characteristics of Sensor › planar › multi-layer › miniaturised Functions of Sensor › Solid electrolyte › Non-Nernst principle › electrocatalytic electrode Carrier substrate 3,5 20 t=0,6 Contact point Zirkonia Heating coil Glass cover Electrode 1 Electrode 2
  • 11. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Manufacturing Technology – Thick Film Technology Screen process engineering: › flexible › cost-efficient › reproducible › mass producible squegee Screen jump screen tension screen squegee angle pressed thick film screen printing pastecarrier substrate
  • 12. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Manufacturing Technology – Raw Materials Sensor materials › Al2O3-carrier substrate › YSZ-functional ceramics › Pt-heating coil › Pt cathode/Pt-alloy anode › Special glass cover Innovative aspects › laser technology › hybrid layer technology › sub- and nano-powder › ceramic printing pastes Solution II Solution III Solution IV printing Medium Solution V paste HO destilled 2 Solution I stir 400 U/min 25 °C 400 U/min 60 °C, 5 min 400 U/min 25 °C, 2 min 400 U/min 25 °C, 2 min 400 U/min 25 °C, 2 min 400 U/min 25 °C, 2 min Cool down 500 U/min 65 °C, 45 min 100 Umin 25 °C, 60 min Solution V Binder I Plasti- cisers Disperging agents Binder II Defoamer Ceramic powder Moisturi- zers screen printing Screen stir stir stir stir stir stir
  • 13. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Manufacturing Technology – Process Optimisation Simplification of the production steps through › Co-firing which is used in the multi-layer process of the manufactured sensors A decrease in › Production steps › Production time › Tempering processes › Sintering time › Energy costs › Manufacturing costs Production chains with integrated process controls co-firing Printing Electrode 1 Drying Printing Electrode 2 Check/Testing Drying Printing heating oil Drying Printing YSZ-Ceramic Presintering Paste preparation Ventilation Portioning Positioning Screen /SMD moulding Cleaning of substances Mechanism Positioning Carrier substrate Cleaning of substances Degreasing Positioning Activation Electrode 2 Preliminary test Hard machining Final testing Check/Testing Check/Testing Check/Testing Check/Testing Check/Testing Check/Testing Check/Testing Check/Testing Check/Testing Check/Testing Check/Testing Check/Testing
  • 14. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Manufacturing Technology – Sensor Optimisation Thermal analysis › instationary heating performance › stationary temperature distribution › stationary voltage distribution  optimal sensor geometry Thermography measurement › comparison between theory and practice › calculation of the sensor temperature TS from the electrical operating data Rh  optimal operating temperature 500 600 700 800 900 13 15 17 19 21 23 25 y = 0.7673x2 +17.139x+ 76.959 R2 = 0.997 c) Heating resistor Rn in Ω SensortemperatureTsinK
  • 15. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Application – The Sensor System Sensors / Housing › small (< 3W) › robust (> 3 Jahre) › temperature stability (< 200°C / 500°C) › cost efficient (< 15€) › fast (< 1s) Elektronics (exaple) › supply unit 14-20 V › temperature control › signal processing › analogue outputs 0-10 V or 0/4-20mA › relay outputs
  • 16. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Application: Combustion Technology Today: Combustion Systems › Fossil fuels • Limited resources (coal, gas, oil) › Pollutant emission • CO, NOx, CO2 etc. › Danger: Global warming Monitoring and Control of Combustion Systems Tommorow: Fuel Cells › Chemical reacting agents • Unlimited resources (H2+ atmospheric oxygen) › Pollutant emission • No › Potential for damage: H2 Safety Monitoring of fuel cells and hydrogen infrastructure
  • 17. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Application – Combustion Characteristic Pollutant makers › Traffic › Industry › Household and small-sized burners Existing sensor systems › Automobile:  probe › Industry:  / flue-gas probe › Small-sized burners: not available!  Development of miniaturised CO-Sensors for combustion optimisation CO CHnmRuß 0.1 0.2 0.4 0.6 0.8 1 2 4 6 8 1,911,301.031.005 Incomplete combustion Flue gas heat loss  Ruß,CO,CHnm efficiency Emissionedge Combustionfuels
  • 18. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Application – Combustion Regulation Combustion Control increases › The operational range › reliability of operation › safety Combustion Optimisation › increases the efficiency › lowers fuel consumption › Minimises pollution S2 S1 Processor Air Fuel Burner Flue gas channel Exhaust air Probe Electronic control Combustion chamber
  • 19. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Sensor element Status: series Function tested in oil, gas and solid fuel firings since 1999 Production more than 20.000 pieces since 2002 Reproducibility Heater side Sensor side 9±1, requirements are fulfilled requirements are fulfilled for combustion optimisation Field tests no blackouts of the sensor element since March 2002 Life time tests tests in oil and gas since Mai 2003, two peripheral blackouts, tests go on Price now: 250€ per piece; goal: 5-10€ per 100.000 piece Summary – State of the Art
  • 20. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Housing: Status: „series“ Function around 2000 housings in operation (three different types) Production Integration standard high temp. experiences with series: without problems up to 200°C, condensing atmospheres up to 450°C, condensing atmospheres Life time tests tests in gas and oil since Mai 2003, two blackouts, problems solved, tests go on Price now: 250€ per piece; goal 3-6€ per 100.000 pieces Summary – State of the Art
  • 21. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Electronics Status: series Function around 1000 units in operation since Mai 2003 Development Feb. 2003: prototype Mai 2003: pre-series Oct. 2003: redesign pre-series March 2004: zero series Life time tests no blackout since Oct. 2003 Price 500 € per piece Summary – State of the Art
  • 22. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Summary – State of the Art Field tests (excerpt) electronics Status: „ pre-series with demonstrator Burner Boiler Testing site Testing time Oil, blue flame Buderus LAMTEC/Odenheim since Sept. 2002 Oil, blue flame Viessmann VITO/Belgium Jan.-Feb. 2002 Oil, blue flame Rotex HLK/Stuttgart Jan. 2003 Gas, atmospheric Senertec VITO/Belgium Jan.-Feb. 2002 Gas, atmospheric Klöckner LAMTEC/Walldorf since Dec.1999 Gas, condensing Bosch Junkers HLK/Stuttgart Feb. 2003 Gas, condensing Buderus LAMTEC/Reisen since Aug. 2002 Gas, condensing Buderus LAMTEC/Östringen March 2004 Bio mass Hoval CSEM/Switzerland Feb.-March 2001 Bio mass Brunner FH Karlsruhe/KarlsruheSept. 2003
  • 23. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG References – Long Term Measurement Endurance test over 11 months › identical characteristics › no identifiable deterioration › sensitivity increases slightly
  • 24. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG References – Sensors in Application (1) Front view of a dual boiler 50-1.000kW › 16 CarboSen1000 sensors were tested: • in condensing flue gas Tmax = 80°C 100% condensation ! • directly in the combustion chamber Tmax = 600° !! No condensation ! Sturzbrenner
  • 25. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG References – Sensors in Application (3) Mounting position in the condensing flue gas channel › 4 CarboSen1000, plugged in › 4 CarboSen1000, hanging › 1 Lambda probe, plugged in
  • 26. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG References – Sensors in Application (4) Mounting position in the hot incinerator › 1 CarboSen1000 immersion probe
  • 27. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG CarboSen 27
  • 28. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG CarboSen Miniaturised Sensor for Detection of Non-burned (CO/H2) in Combustion Exhaust Gas 28
  • 29. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG CarboSen 29
  • 30. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Measurement Principal of CarboSen1.000 30
  • 31. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG CarboSen Sensor Assembling › 11 layers incl. carrier › Measure: 20mm x 3,5mm x 0,7mm › Material: ceramics, glas, platinum, gold • Thermally and chemical robust › Production in thick and thin film process • Cost-effective, suitable for mass market 31
  • 32. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG CarboSen Characteristic 0 20 40 60 80 100 120 140 3000 3010 3020 3030 3040 3050 3060 3070 3080 3090 3100 Zeit in s UseninmV 0 50 100 150 200 250 300 350 400 450 500 COreferenzinppm U Sen 01 in mV U Sen 02 in mV U Sen 03 in mV CO MRU in ppm 32
  • 33. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Test Plant of Oil-Blue Burner Qualification or reference measurement in pipe of oil-blue burner 4 CarboSen1.000 in flue gas pipe Reference System (KS1D) 33
  • 34. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG CarboSen1.000ST 34 Characteristics: › Measurement of COe directly in humid flue gas up to 150°C, also condensing › No reference air necessary › Protection class IP67 Applications: › Natural gas, fuel oil EL
  • 35. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG CarboSen1.000 35 Characteristics: › Measurement of COe directly in humid flue gas up to 400°C › Elektronic is integrated in sensor head › No reference air necessary › Protection class IP67 Applications: › Natural gas, fuel oil EL, pellet, piece wood
  • 36. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Thank you for your attention Questions?
  • 37. LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG Contact: Steven Craig – President, Hays Cleveland Phone: (216) 398-4414 Fax: (216) 398-8558 E-Mail: scraig@unicontrolinc.com