GPO Application Dataset

Oxygen Measurement Application Examples Application Dataset Urdorf, January 2010

Application Overview Storage & Environment Upstream & Processing Recovery & Waste Downstream & Purification Headspace blanketing Stirrer blanketing Extruder Oxidation Spray Towers Wort Areation Centrifuge Inertization Cristallisation Grinder blanketing Deodorization Waste Gas Reclaim Air Scrubber CO 2 Recovery Tank Storage Tank Storage Off-gas Tank Storage Off-gas Chemical Food & Bev. Biopharm

Add these Application specific slides to the Customer Presentation ! BioPharma

Successful Applications Pharmaceutical API manufacturing Vessel blanketing Germany-based company USA operations

Blanketing in API Manufacturing Several processes utilize volatile, corrosive, and flammable solvents Reactors are blanketed with nitrogen to prevent oxygen intrusion into head space Vapors are collected in a vent header and sent to an incinerator, operation occurs under a slight vacuum Process Step Why is this parameter measured? Challenges Safety critical systems required measuring oxygen in the head space of five reactor systems Systems in use for over a decade utilizing a sample conditioning system that condenses all moisture and measures dry gas for oxygen content Any vapor content resulted in failed cell $1000 replacement cost and 4 hours of labor with two people & 4 hours of downtime (total cost approximately $4000)

Key Decision Points Reliable, accurate, and repeatable results to less than 1% oxygen Ability to mount directly in the reactor Ability to withstand corrosive environment Ability to handle moisture in the gas phase without harming the sensor Class I, Div 1 rating on all parts Intrinsically safe rating on system components Easy to calibrate and to do span checks

METTLER TOLEDO Solution InPro 6800 G with Hastelloy C22 medium-wetted parts M420/XH Gas Phase Transmitter 777e Manually retractable housing with Hastelloy C22 wetted parts, SS body, and Kalrez o-rings 1-point Calibration to start (1 time per year) and span checked prior to each batch 1-2 $70 membrane changes per year

Successful Applications Pharmaceutical API manufacturing Stirrer blanketing Indonesia-based company

Blanketing in Mixing Stirrers Process Step Protein (amino acid) and water are mixed in inert conditions to formulate liquid infusion Why is this parameter measured? Challenges The presence of O 2 needs to be controlled to avoid the oxidation of amino acid. Control by sampling method creates problem to measure below 100 ppm The production of liquid infusion, requires to follow pharmaceutical regulations. This is the most critical point for batch product acceptance Mixing tank with stirrer Reduced consumption of N 2 due to controlled O 2 level Reduced risk of product waste because oxidation of amino acid

Your Benefits Consistent product quality Minimized the cost of purging N2 gas. Easier batch release by QA due to traceable production conditions Easy, fast and low maintenance at minimized costs Risk of batch contamination through sampling is eliminated The trial installation, backed-up with a ROI calculation, resulted into the installation of our system in bigger vessels. More reliable and accurate measurements increase the process safety and improve the yield.

Successful Applications Pharmaceutical OEM manufacturing Centrifuge inertization India-based company

Safety in Reactor & Centrifuges Batch reaction process in Glass-lined reactor Highly flammable/ volatile organic solvents with strong chemically corrosive properties are used Solvent recovery by centrifugation where flammable vapors are involved Reactor Inertization Centrifuge Inertization Ensuring safety in reactor and centrifuge with oxygen gas monitoring: cost-efficient and reliable solution

Critical Reactions and Extraction Processes Why is Oxygen measured? Oxygen presence of more than 5% could lead to a dangerous explosion. In order to minimize oxygen intrusion, inert nitrogen gas is purged into the reactor and centrifuge Headspace. Safety critical systems are required to measure oxygen reliably and accurately Explosion Ensuring safety in reactor and centrifuge with oxygen control is cost-efficient and improves yield

METTLER TOLEDO Solution 2-wire loop powered Certified for use in hazardous areas HART capability ISM technology O 2 M420/XH InFit761e InPro 6800 G 2-minutes maintenance Easy zero and span calibration Long term stability Insensitive to moisture and dust ATEX, FM approved 3.1 certificate PED rated Large selection of process adaption Customizable

Your Benefits Reliable, accurate, and repeatable results to less than 1% oxygen Sensor mounting directly in the reactor Sensor can withstand corrosive environment Sensor can withstand moisture without affecting performance Certified for hazardous Area application Easy to calibrate and to do span checks Based on the performance the customer decided to purchase more loops for all their centrifuge and reactors Excellent sensor performance and rugged solution for direct in-line measurements

Successful Applications General manufacturing Tank Storage

Inerting - Nitrogen Blanketing O 2 O 2 Process Step Storage of organic solvents and powders often involves nitrogen blanketing: measurement of oxygen concentration in headspace of storage tanks, reactors, centrifuges etc. Typical Conditions Presence of solvents Hazardous area Why O 2 Measurement? O 2 measurement controls oxygen for safety reasons and keeps the O 2 levels low (typically 4-10%) Too high O 2 levels may lead to explosive gas/dust mixtures or product degradation Storage tank Centrifuge O 2 measurement reduces consumption of inertization gas (N 2 ) and increases safety (cost saving)

Add these Application specific slides to the Customer Presentation ! Chemical

Example: Chemical Process O 2 Gas O 2 Gas O 2 Gas O 2 Gas O 2 Gas O 2 Gas N 2 Blanketing Inertization Offgas Monitoring O 2 Gas O 2 Gas O 2 Gas Combustion / Vapor recovery O 2 Gas Mixing tanks Stirred tank reactor Centrifuge Crystallizer Filter Storage tank Off-gas pipe Gas scrubber Synthesis Separation Purification Storing /Packaging Numerous installations for gas measurement possible in upstream and downstream processes

Successful Applications Chemical manufacturing Oxydation in extruder Singapore-based company

Minimizing Oxidation in Extruder Process Step The mixture of powder and water is processed through an extrusion machine which mix and melt the raw materials. Why is this Parameter Measured? O 2 measurement is required in the gathering chute as they need to monitor the ingress of the oxygen during the process. Presence of oxygen will cause the pellet to oxidize which will cost them to send the pellet for rework or sell it at a lower price to other end user Raw material Water Gathering Chute Extrusion Machine Pelletizer Cutter Storage in Hopper

Initial Situation Past System Paramagnetic system Challenges O 2 system gets plugged/clogged every 3 to 4 days and gives a false reading resulting product to be oxidized as the presence of oxygen is not reflected on the SCADA system. Cooling system is required and it requires additional maintenance work.

METTLER TOLEDO Solution Redundant measurement loop with one transmitter: 1 x M700 Coated Transmitter 2 x O 2 Module Ex 2 x InPro 6900i G Gas Sensor

Value Add Calculation 50 tons of m-PPE (modified PPE version) is produced every 2 days of continuous process 1 ton of m-PPE sells for US $2,500 Oxidized products will be sold to end user at a cheaper price or sent for rework. 1 ton of Oxidized m-PPE sells for US$1,000 (estimated) It was shown that MT’s O 2 Gas system can help reduce Oxidized m-PPE from by 60% upon installation At a rate of 10 tons of oxidized m-PPE per month, customer expects to save 6 tons Hence: (US$2,500 – US$1,000) x 6 Savings per month would be US$9,000 Initial cost of system = US$8,700 Investment is returned almost after one month when purchasing the amperometric oxygen system

Successful Applications Chemical manufacturing, Chlor-alcali Waste-gas reclaiming China-based company

Waste Gas Reclaiming Process Step In Chlor-Alkali manufacturing, waste gas can be reclaimed during the reaction, the O 2 concentration must be measured all through the process to improve the course of reaction (from 10% to 60%). Why is Oxygen measured? The customer want to conclude the relation between O 2 concentration and the course of reaction, to improve the productivity. By monitoring the O 2 concentration during the reaction, the yield can be maximized. With oxygen monitoring, better process control can be reached in a cost-efficient way O 2 gas

METTLER TOLEDO Solution 2-minutes maintenance Easy zero and span calibration Long-term stability Insensitive to moisture and dust InPro 6850i G InFit 761e M700 Transmitter Modular & expandable Multi-channel ATEX, FM approved Wide selection of software options ATEX, FM approved 3.1 certificate PED rated Large selection of process connections Sanitary design

Your Benefits Customer statement: “ We are very pleased that we could save 30% investment using Mettler- Toledo product compared to our competitors. Furthermore, they helped us to save to 40% cost if we take full advantage of our measuring system in the process.” In figure terms: Initial costs: MT: 7000 $ competitor: 14000 $ Maintenance 1 year: MT: 400 $ competitor: 3000 $ For waste gas reclaiming, the ROI is less than 6 months

Successful Applications General manufacturing Off-gas monitoring

Off-Gas Monitoring In piping that lead synthesis off-gases to the central gas combustion. Also called vent header gases Safety too much Oxygen  EXPLOSIVE Where is it measured? Why is it measured? Synthesis off-gas piping Quality Optimal Oxygen  complete combustion Cost saving controlled Nitrogen adding  less consumption Measurement of oxygen allows for optimized combustion of synthesis gases in order to comply with environmental regulations

Add these Application specific slides to the Customer Presentation ! Food & Bev.

Successful Applications Food additives manufacturing Spray towers inertization Germany-based company

Inertization in Spray Towers Process Step Fine centrifugal spraying of a liquid solution into the spray tower The liquid solution consists of water, aroma and a carrier The aroma will be tied up in the carrier The water will be vaporized due to steam The dry aroma in powder form trickles down the spray tower O 2 Why is Oxygen measured? Safely during filling: reduction of the risk of explosion for hybrid mixtures Challenges Keep O 2 level <8% Ensure safety & comply with hygienic regulations

Oxygen Measurement System Sensor InPro6810 with T-6800 Membrane body 3A, EHEDG certified USP Class VI InPro 6810 G InTrac 797 M700 Transmitter M700XS 24 V AC/DV Module O 2 4700 (X)ppb PID700X Option: Accessories Combination with retractable housing InTrac 797e

Your Benefits Measurement of oxygen concentration during the filling Permanent purge of the headspace by nitrogen gas Reduction of the oxygen concentration in the spray tower Keeping the upper limit of 8 Vol-% Reducing the Nitrogen consumption Intention: explosion prevention during the filling of the flavors According to the regulations Key Benefits Increase of process safety Prevention: oxygen leads to oxidations and favors explosions Improvement of product quality and yield i.e. flow characteristic and processing quality of some flavors

Successful Applications Food additives manufacturing Crystallization with solvents Thailand-based company

O 2 Gas in Crystallization Process Step “ AJITIDE I+G” is the name of Ribonucleotides,a kind of food seasonings, that creates “Umami taste” (scientifically accepted as 5th Basic taste). Purification: Separation of Guanylate (G) and Inosinate (I) by crystallization. And mix it again (50:50) to make I+G prior to packing Why is this parameter measured? Crystallization occurs in 99.5% pure Methanol reaction vessels (Ex-zone). Oxygen level must be kept below 5% (LOC) with nitrogen for safety control Raw Material Fermentation Isolation Phosphorylation Purification pH DO pH Trb Trb O 2 Oxygen control allows to increase product quality and ensures safe environment at low operating costs

Key Challenges Current electrochemical cell is not working to full satisfaction Limited sensor lifetime (1 year) Results are influenced by dust and moisture Resource intensive maintenance and calibration

METTLER TOLEDO Solution Customer Benefit Easy calibration and maintenance to the sensor After sales service for whole analyzer Reliable measurement influenced by process conditions Extended calibration period, no need to calibrate frequently InFit 761 e InPro 6800 G M420/XH Operating costs significantly reduced & process reliability increases with amperometric systems

Successful Applications Food processing operations Grinder O 2 monitoring China-based company

Cocoa Facts Cocoa Tree with fruits Top: Cocoa Bean inside the fruit Bottom: Dried Cocoa beans Chocolate, one of the many final products

Before the Grinder Process Step Why is this parameter measured? Cocoa beans are grinded into powder in order to gain better extractability of the cocoa butter. N2 is purged in to control the O 2 level below 9 % to prevent any explosion in the grinder. O 2 Inert Gas (N 2 ) Grinder Filtered Air Nib powder must be inertized before the grinder due to the risk of ignition during grinding

METTLER TOLEDO Solution 2-minutes maintenance Easy zero and span calibration Long-term stability Insensitive to moisture and dust InPro 6800 G InFit 761e M700 Transmitter Modular & expandable Multi-channel ATEX, FM approved Wide selection of software options ATEX, FM approved 3.1 certificate PED rated Large selection of process connections Sanitary design

Your Benefits Lower operating costs, less downtime and increased productivity by using Mettler-Toledo O 2 Monitoring system. Virtually no maintenance for our O 2 system as compared with competitors. Long life-span of sensor and with the M700, data is so much easier to maintain and easy for troubleshooting with the data recorder software option. With an investment of only USD 4,500.00, the customer uses able to save USD 70,000.00 per year and increase of productivity which amounted to USD 100,000.00 per year.

Successful Applications Food additives manufacturing Crude Palm Oil refining Thailand-based company

Crude Palm Oil (CPO) Refining Tanker with CPO Reining, Bleaching and Deodorizing CPO Storage Tank Fractionation Process Step Storage of CPO prior to processing Why is O 2 measured? Inertization of CPO to prevent product oxidation and loss of product quality INGOLD Solutions InPro 6850i G M700 C with 4700 i module InTrac 777e O 2

CPO Plant - Deodorization Applications Bubbling with nitrogen gas to clear all smell from the purified palm oil Typical Conditions & Requirements Temperatures control: 180°C to 220°C Pressure: 3 to 4 bar INGOLD Solutions InPro 6850i G InTrac777e M M700C O 2 4700 Module O 2 To fractionation plant GasN 2

O 2 Solution for Nitrogen Blanketing O 2 Gas Sensor Transmitter Housing InPro 6850iG Durable and rugged sensor design for increased resistance to harsh environments Reduced CAPEX and OPEX compared to extractive oxygen analyzers Easy installation, no sampling system required Ultra low maintenance demand ISM technology for reduced maintenance InTrac 777e Access to sensor without interrupting the process Tri-Lock safety system, performance and safety in poisonous environment Integrated flushing chamber for cleaning and calibration No exposed o-rings M420 State of the art versatile transmitter Two wire loop powered HART capable Full ISM functionality Certified for use in hazardous area

Successful Applications Food additives manufacturing H2S elimination in air scrubbers Thailand-based company

Air Scrubber for H 2 S Elimination Natural Palm Oil “ The Natural palm oil” is extracted from crude palm oil and palm kernel oil from fruit of oil palm tree. This extracted oil will be sent to edible oil refining plants. Process Step Biogas from the waste water treatment is used for power generation Why O 2 Measurement? Air scrubber for H 2 S elimination in biogas for higher yield & toxic air pollution reduction Wastewater pH Adjust Tank Anaerobic Fermentation Biogas Air Scrubber O 2 in gas

H 2 S Elimination in Air Scrubber Why is Oxygen measured? To control the elimination of H2S To control the gas mixture for efficient power generation To prevent toxic air pollution To have highest yield possible Process conditions: Measuring at the gas outlet from air scrubber Pressure in vacuum 10 mbar (-10m bar gauge) Moisture and dust may present in the line Temperature around 30-40°C 0-3 Hydrogen Sulfide (H 2 S) 1-5 Hydrogen (H 2 ) 0-0.3 Nitrogen (N 2 ) 20-45 Carbon Dioxide (CO 2 ) 55-75 Methane (CH 4 ) % Matter

H 2 S Elimination in Air Scrubber Challenges Automatic stop if H 2 S exceed limitations  (Downtime) Unreliable measurement Effects on moisture and dust Higher production of electricity and less downtimes with the METTLER TOLEDO solution

METTLER TOLEDO Solution 2-wire loop powered Certified for use in hazardous areas HART capability ISM technology O 2 M420/XH InFit761e InPro 6850i G 2-minutes maintenance Easy zero and span calibration Long term stability Insensitive to moisture and dust ATEX, FM approved 3.1 certificate PED rated Large selection of process adaption Customizable

Your Benefit Easy calibration and maintenance to the sensor After sales service for whole analyzer Reliable measurement due to no effects from humidity and dust) Stock and delivery time Longer lifetime of sensor Customer process run smoothly without downtime and higher electricity produced

Successful Applications Beer manufacturing Wort aeration & CO 2 Recovery Germany-based company

Fermenter Process Steps Why an Oxygen Measurement? O 2 injection for yeast propagation Conversion from sugar into alcohol by yeast enzymes (anaerobic glycolysis) Production of CO 2 and taste influencing byproducts CO 2 Recovery Exhaust DO O 2 During wort aeration: concentration of 10…15 ppm is crucial for initializing yeast propagation In the inlet of the CO 2 recovery plant purity of CO 2 : if O 2 concentration is too high recovery plant performance decreases Air Yeast

CO 2 Recovery Process Steps PURGE O 2 O 2 Yeast fermentation Foam removal Gas purification Gas compression Gas deodorization Gas drying Gas liquefaction

Oxygen Loops for Wort Aeration & Raw CO 2 InPro 6800 G Sensor Clark sensor principle with 2-minute maintenance features EHEDG certified sensor Suitable for O 2 gas measurements in CO 2 recovery plant inlet if concentration is higher than 1000 Vol-ppm Compatible with retractable housings for comfortable maintenance InPro 6800 G InFit 761 M700 M700 Transmitter 4-20 mA input for process pressure compensation in gas phase ISM capable InFit 761 Housing 3A, EHEDG certified Wide selection of process connections 3.1 certified, PED Customizable

Your Benefits Defined DO concentration in wort minimizes costs for aeration and guarantees defined beer taste (influence of byproducts like SO 2 ). Defined O 2 concentration in recovery plant inlet ensures quality of recovered CO 2 . Quick membrane body exchange guarantees reduced maintenance for liquid and gas phase applications. Reduced installation and maintenance cost for gas measurements compared to Zirconicum Oxide or paramagnetic analyzers.

In the CO 2 Delivery / Network Process steps Additional CO 2 is delivered to the brewery. CO 2 is stored in liquid form and distributed within the brewery over a CO 2 pipe system Why Oxygen Measurements? Online quality control of the delivered CO 2 before feeding it into the CO 2 system. CO 2 quality monitoring within the CO 2 brewery’s distribution system.

Oxygen System for Recovered CO 2 InPro 6950i G Sensor Low detection limit of 5 Vol-ppm ISM Technology for advanced diagnostics 4-electrode principle leads to longer electrolyte exchange intervals InPro 6950i G M700 InTrac 777 InTrac 777 retractable Housing Access to sensor without process interruption TRI-Lock TM System Integrated flushing chamber M700 Transmitter 4…20 mA input for process pressure compensation ISM capability

GPO Application Dataset

More Related Content

What's hot (20)

Viewers also liked (9)

Similar to GPO Application Dataset (20)

GPO Application Dataset

Editor's Notes