4. • Global HQ in Schiedam, Netherlands
• Development, Production, Global Distribution
• North America Operations
• Tampa, FL
• Analyzer Assembly Operations
• Application Support
• Technical Support
• Houston, TX
• Demos & Training
• Technical Support
• Service Operations
• Application Support
• Toronto, Ontario
• Sales Operations
• Service Operations
Metrohm-Applikon
5. • A wide array of methods available for on-line, in-line,
and at-line analysis
• Most common techniques:
• Titration
• Ion Selective Electrodes
• Dynamic Standard Addition
• Photometry/Colorimetry
• Voltammetry
• Near-Infrared (NIR)
• From % to trace (parts per trillion)
Analysis Methods
6. • Chemical
• Petro-Chemical
• Textile
• Pulp & Paper
• Food & Beverages
• Mining
• Steel/Metal/Galvanic
• Semiconductor
• Automotive
• Pharmaceutical & Biochemical
• Utilities & Environmental
• Power Plant (Cooling, High Purity)
• Potable Water
• Surface Water
• Municipal WWTP
• Industrial WWTP
Industries
7. • Petrochem Scrubber Monitoring
• Caustic, Carbonate
• Plating process monitoring
• Plating baths (Cu, Cr, Ni, Zn, F, Mixed Acids)
• Chlor-Alkali Plants
• Hardness in Brine
• Hypo/Thio
• Water monitoring
• pH and Alkalinity
• Chlorine and Ammonia (cooling towers)
• Iron and manganese
• Wastewater (Ammonia, Phosphate, Sulfate, etc)
• Produced Water
• Frac Fluid components (e.g. Calcium)
• Boiler/Cooler Chemistry (Silica, Sodium, Phosphate, etc)
Typical Industrial Applications
8. Applikon Analyzer Options
ADI 201Y - Online
ADI 2045VA - Online Fully integrated solutions
ADI 2045TI - Online
ADI 2045PL - Atline
ADI Alert - Online
9. ADI 2045TI – Online
Example Analyzer Configurations
17. Power
Plant
Boiler water conditioning:
to prevent corrosion.
Monitoring:
Ion-exchange exhaust or,
condenser leaks or,
other calamities.
Typical measuring range:
0-50 µg/l (ppb)
Boiler-Cooler Applications
18. Crude Oil Processing Applications
Applications
• NH3/H2S in SWS
• KF in Crude Oil
• TAN in Oil
• Salt in Crude Oil
19. • “Sour water” – water that contains sulfur and ammonia
• Formed when H2S is liberated in crude oil units during the
refining process. When H2S dissolves in water sour water
is the result.
• Reuse or disposal of sour water requires removal of
sulfides and ammonia. Vital for water recycling.
Sour Water Stripping
Sour Water with
NH3 & H2S
Stripped Sour
Water without
NH3 & H2S
Sour Water Stripper
Sour/Acid Gas Removal
22. • Sodium/potassium analysis indicates process
conditions in a chlorine scrubber
• A single upset can lead to:
• Loss of up to $100,000 of raw material
• Product that is off-spec and can’t be sold
• Reprocessing of product – costs $$$
• Example plant – 4 upsets per year
• Compare losses to cost of an analyzer and sample
conditioning system, $125,000
Caustic Scrubber
23. • DCS Flow Control
Caustic Scrubber
A Chlorscrubber DCS Flow Control
0
1
2
3
4
5
6
7
8
9
03/07/200916:00
03/07/200918:30
03/07/200921:00
03/07/200923:30
04/07/200902:00
04/07/200904:30
04/07/200907:00
04/07/200909:30
04/07/200912:00
04/07/200914:30
04/07/200917:00
04/07/200919:30
04/07/200922:00
05/07/200900:30
05/07/200903:00
05/07/200905:30
05/07/200908:00
05/07/200910:30
05/07/200913:00
05/07/200915:30
Date/Time
Caustic%
Actual Caustic Average = 4.81%
Actual Caustic Standard Deviation = 1.61
Chlorscrubber DCS Flow Control
24. • ADI Control – Metrohm-Applikon
Caustic Scrubber
A Chlorscrubber Titration Control
0
1
2
3
4
5
6
7
8
9
21/07/200911:45
21/07/200914:15
21/07/200916:45
21/07/200919:15
21/07/200921:45
22/07/200900:15
22/07/200902:45
22/07/200905:15
22/07/200907:45
22/07/200910:15
Date/Time
Caustic%
Actual Caustic Average = 2.97%
Actual Caustic Standard Deviation = 0.43
Chlorscrubber Titration Control
26. Process Optimization – Improve quality, speed, safety,
less waste, less variance, and save money
DCS Average: 4.8% Caustic
ADI Average: 2.9% Caustic
(Now reduced to 2.0%)
Cost Savings:
Approx. $1,000 a day savings
Leads to $200,000 a year savings
(4 on, 2 off schedule)
Caustic Scrubber
30. Safety Improvements
• Decrease number and frequency of personnel
crisscrossing the plant
• Reduce trip/fall chances
• Reduce loss of sample
• Improve sample integrity
• Improve efficiency
Safety
The global headquarters for the Applikon group are in Schiedam, Netherlands, and this is where development, production and global distribution take place. The North American operations are based outside of Tampa, Florida, in Riverview. Here we perform the custom assembly of analyzers, perform custom application development, and provide technical support. We also have offices in Houston, TX and Toronto, Ontario where demonstrations and training take place, along with sales, service, and technical support.
Earlier I mentioned there are some relatively easy measurements, such as temperature or pressure that may take place in a process. Process analysis on the other hand can require a wide array of much more advanced analysis methods. Some of the most common techniques that we offer are shown here, and include various kinds of titrations, ion-selective electrodes, colorimetry, and of course near-infrared, which you will be hearing a lot more about later on. This array of methods mean that you have analysis options that span the range of percentage of a species in a sample down to ppt – parts per trillion.
To serve the need for a wide array of samples and sampling situations we have an equally wide range of analyzers and configurations. What I am showing here is the range of Applikon Process Analyzers. Later in the presentation you will have the opportunity to see the near infrared analyzer options. As you can see we offer on-line and at-line analyzers along with fully integrated solutions, including enclosures and sample pre-conditioning.
Let’s transition now and talk about a couple of example process analysis applications. I want to start off by showing a diagram of a potential crude oil processing layout. I know the image is a bit busy, and may not be easy to see all the details, but it effectively demonstrates a complex processing environment. I have indicated just a few points where a process analyzer might come into play. Later in the talk you will hear more about where near infrared methods can fit into this picture.
Also I have indicated a few relevant types of analysis that can be performed by a process analyzer. Some of these applications include analysis of water in crude oil – performed by a Karl Fisher titration, total acid number or salt in oil. The last one, analysis of ammonia and hydrogen sulfide in sour water stripping we will talk more about on the next few slides.
For those who may not know, let’s first define what sour water is, and then what sour water stripping is. Sour water is water that contains sulfur and ammonia. Sour water is typically formed when hydrogen sulfide and other contaminants in crude oil, or natural gas, dissolve in water during processing. To reuse the water, the sulfides and ammonia need to be removed, or stripped, from the sour water using steam. Effective monitoring of the sour water stripping process means improved removal of the sulfides and reduction of the amount of steam used in the process, and that means cost and time savings.
In our second example we’ll talk about the benefits of good process control. For this example we’ll look at a caustic scrubbing process. The process analysis monitors the sodium and potassium in the scrubbing solution. Effective monitoring leads to better control of the concentration of caustic in the solution. In turn this improves the scrubbing conditions, which leads to improved process control and cost savings. If there is an upset in the process it can lead to a loss of up to $100,000 in raw materials, off specification product that can’t be sold, and reprocessing of the product. In the plant where this analysis was implemented they previously had 4 upsets per year typically. Compare those losses to the cost of an analyzer and sample conditioning system and the analyzer proves it value very quickly.
Let’s start by looking at what was in place originally – a distributed control system using flow control for the caustic scrubber. As you can see in the result chart shown, the caustic concentration was varying from almost 0% up past 8%. The average caustic concentration was 4.81% with a standard deviation of 1.61. Let’s see what happens when our process analyzer is brought on-line.
And here are the results of using a process analyzer to monitor the caustic concentration. Please note that I have tried to match the y-axis, representing percent caustic, as closely as possible to the previous slide, so that you can visualize the full impact. Now the variance has been limited to a range between 1.5 and 4%, with one spike to about 5%. The average caustic concentration has been lowered to 2.97%, with a much lower standard deviation of 0.43. Overall the system is now kept much more stable and more closely maintained.
The optimization of the scrubbing process has had many benefits – improved quality, production speed, less variance, improved safety, less waste, and of course saves money. To recap, the average caustic concentration was dropped from 4.8 to 2.9%, and since then the average has been lowered to 2%. The process improvement has led to savings of approximately $1,000 a day, or $200,000 a year, since the process is run on a 4 day on, 2 day off schedule.
As I mentioned on the previous slide, taking a sample from the process and then taking it to a laboratory for analysis can be time consuming. As shown on the left side of this slide the entire sampling and response cycle can take an average of 30 to 60 minutes, maybe longer. By implementing an analysis that is at-line, on-line, or in-line the response cycle can be shortened significantly to only a few minutes, even shorter than that depending on the type of analysis being performed. This reduced response time means more effective monitoring of a process, leading to safer operating conditions, cost savings, and a better product. Also it means that the process is more closely monitored so that unwanted or unsafe conditions can be avoided, or if there is a problem it can be detected more quickly.
