Chicago Research Center ... CO, and TTemperature monitoring for high temperature harsh ... â¢Near-IR diode lasers operate near room temperature. â¢Fiber optic ...
Tunable Diode Laser Sensors for Monitoring and Control of Harsh Combustion Environments by W. Von Drasek
DOE/OIT Sensors and Controls ‘01 Annual Meeting New Orleans, LA June 6-7, 2001
RESEARCH AND DEVELOPMENT
Chicago Research Center
Outline ØMotivation ØProject Team ØTechnology Description ØProject Status §TDL Development §Pilot Test Platform ØProject Planning ØBudget Review
RESEARCH AND DEVELOPMENT
Chicago Research Center
Motivation Objective To fabricate and test an industrial multi-gas diode laser sensor system for O2, CO, CO and Temperature monitoring for high temperature harsh environments. Combustion Process Output Exhaust Gas
Input
CO2 , CO, H2O, NO, NO2 , N2 , O2 , etc.
Fuel Oxygen Air
Tunable Diode Laser üFlue Temperature üFlue Composition Control System RESEARCH AND DEVELOPMENT
Chicago Research Center
TDL Technology Advantages üDeveloped around telecommunication components •Near-IR diode lasers operate near room temperature •Fiber optic compatible
üFast response time
•10 msec measurement time •Time averaged 10 Hz sampling rate
üSimple electronic detection •Reduced cost •Compact
üMulti-functional •Multiple-species •Temperature
RESEARCH AND DEVELOPMENT
Chicago Research Center
Project Objective Beam Transport and Collection
System Features üHarsh Environment Acceptable •T>1600 oC •High Particle densities üMulti-species Monitoring O2,CO, H2O üMulti-functional •Temperature •Air Entrainment •Particle Density üFast-Time Response 1-10 Hz üCalibration Free üIntegrate with Processes Control üAutonomous Operation üCost Effective
Processes Supervision System
Controller & Processing
lSystem
Ready for Testing Sept.-Nov. 2001
RESEARCH AND DEVELOPMENT
Chicago Research Center
Project Team To address the technical issues associated with traditional monitoring techniques Air Liquide and Physical Sciences, Inc. formed a project team for the development of an Advanced Sensor utilizing Tunable Diode Laser Technology. Du Pont (Chemical) Industrial Partners
Charter Steel (STEEL) Johns Manville (GLASS)
DOE/OIT W. Von Drasek K. Mulderink O. Charon
Air Liquide ØCombustion ØFlue gas analysis ØIndustrial Process Characterization ØProcess Control
M. Allen S. Wehe
Physical Sciences, Inc. ØDiode Laser Technology ØSpectroscopy ØOptoelectronics
RESEARCH AND DEVELOPMENT
Chicago Research Center
IOF Partners and Applications
Industry GLASS
CHEMICAL
Partner Johns Manville
Application Fiber Glass Melting Tank •Energy Efficiency •NOx Reduction
Du Pont
Sulfuric Acid Recovery •O2 Optimization •NOx Minimization
STEEL
Charter Steel
Reheat Furnace
EAF Furnace
•Energy Efficiency •Scale Reduction
•Energy Efficiency •Carbon Balance
RESEARCH AND DEVELOPMENT
Chicago Research Center
Multi-species Measurement Strategy Waveform Generator
Temp Control
I(t)
Process Gas
O2 Laser TIME
Waveform Generator
I(t)
Current Control
Collimator
Temp Control
Reference λ1+λ λ2 +λ λ3
CO, H2O Laser
BRD
Current Control TIME
Detector
Signal λ2+λ λ3 λ1+λ
PC
RESEARCH AND DEVELOPMENT
Chicago Research Center
Measurement Principle
Resonant absorption described by the Beer-Lambert Relation:
I v = I v,o exp[− S(T)g(v − vo )Nl ] Linestrength
Ivo
k(v)
l
Iv
Lineshape
Number Density X Pathlength
Number Density
æ I vo ö 1 N= lnçç ÷÷dv ò S(T)l è Iv ø
RESEARCH AND DEVELOPMENT
Chicago Research Center
Technology Development Considerations Q Beam Transport and Collection Two Separate Technology Development Issues üMutiplex Beam Interface üDemultiplexed üRadiation Rejection üNoise suppression
PROCESS
Controller & Processing
R Laser System üControl Circuitry üSignal Circuit (BRD) üMultiple Laser Integration
Processes Supervision System RESEARCH AND DEVELOPMENT
Chicago Research Center
Technology Developed in DoE Program
l
l
l
Multi-parameter Sensor system - O2 -CO Evaluation on a Diverse -H2O Range of Industrial Processes -Temperature
BRD Industrial Testing -Cost effective -Reduce system complexity HT Spectroscopy
RESEARCH AND DEVELOPMENT
Chicago Research Center
700 kW Oxy-Fuel Pilot Furnace Oxy-Fuel or Air-Fuel
Combustion Chamber Characteristics Dimensions: 4.0 m x 1.0 m x 1.0 m Firing Rate: Up to 720 kW (varying load) Operating Temperature: Up to 3000°F (1650°C) Heat-up rate: Up to 500 °C/h Controls: PLC and PC Supervision (Real Time Heat and Mass Balance)
RESEARCH AND DEVELOPMENT
Chicago Research Center
Dynamic Process Monitoring Absorbance
Data Voigt Fit
5.2% Excess O2
O2 Number Density
440 kW
5.0E+18
FuelFuel-Lean
4.5E+18 4.0E+18 3.5E+18 3.0E+18 2.5E+18 2.0E+18 0
0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 -0.1
Conditions: T=1244 K 10% CO by AAL GC
BL Subtracted Voigt fit
15 20 25 30 35 40 45 50 55 60 65 70 75 80
Scan Time (au)
FuelFuel-Rich CO Number Density (cm-3)
Absorption (au)
Relative Frequency (cm
-1 )
.2 Hz
3.00E+16
20
40
60
100
Time (sec)
FuelFuel-rich
2.50E+16
80
.5 Hz
2.00E+16 1.50E+16 1.00E+16 5.00E+15 0.00E+00
200
210
FuelFuel-lean
220
230
240
250
Time (sec)
RESEARCH AND DEVELOPMENT
Chicago Research Center
Temperature Measurement 0.0035
Absorbance
0.0030 0.0025 0.0020
Temperature
R2(13) Voigt Fit Data
0.0015 0.0010 0.0005
R(45) Q(46)
R2(43)
é − hc∆E æ 1 1 öù æ S1 ö çç − ÷÷ú ÷ ç R = ç ÷ × exp ê è S 2 øTo ë k èT To øû Ratio of integrated absorbance for two transitions
0.0000 -0.0005
Relative Frequency (cm-1)
O2 lineshape at 1540 K, 100 cm path
Sample 1 3 2
lRef.
TDL 1756 1632
1477
ST 1702 1613 1540
% Error 3.17274 1.17793 -4.0909
T= 1495 K
RESEARCH AND DEVELOPMENT
Chicago Research Center
LINE SELECTION PROCESS 1.57
W avelength [ µ m ] 1.56 1.55
1.54
1.53
400
100 GHz ITU Channel Spacing
300
-2
Linestrength[10 [10-6cm cm-2/atm] Linestrength
T = 1700 K
SH
2
O
-6
ITU Ch. 200
100
0 6350
6400
6450 -1 Frequenc y [c m ]
6500
6550
Over 28000 Lines Accessible! RESEARCH AND DEVELOPMENT
Chicago Research Center
Selection Process Criteria H2O Present at High Concentration Levels in all Combustion Processes
l
Line Selection Process (HITEMP) k üOptimum Energy Separation, ∆E '' = 2T hc üMinimum Linestrength Required, Smin üSpectrally Isolated üSpectrally accessible (1.5 µm) üValidation Required (Experimental)
Two Pair of H2O lines Best Solution LTà Low Temp HTà High Temp
RESEARCH AND DEVELOPMENT
Chicago Research Center
Theoretical HITRAN Selection
150
H T-2 HT-2
-2
-6 cm Linestrength cm-2/atm] /atm ] Linestrength [10[10
200
-6
LLT-2 T-2 100
LLT-2 T-1
HT-1 H T-1
S m in Smin 50
0 0
2
4 6 8 3 -1 L o w e r S ta te E n e rg y , E " [ 1 30 c m -1 ] Lower State Energy, E’ [10 cm ]
10
12
RESEARCH AND DEVELOPMENT
Chicago Research Center
LABORTORY SETUP To BRD 1x2 Fiber Optic Splitter Detector
ECDL
Flat Flame Burner
Signal from Detector Digital Scope
Fiber Optic Switch
BRD
Reference Channel Shield Gas
M ass Flow M ete rs
N2
CH4
N2
Oxidizer
Diluent
Co-Flo w
Fuel
Needle Valves
Confocal Etalon
Etalon Detector
Wavemeter
O2
Supply Gas
RESEARCH AND DEVELOPMENT
Chicago Research Center
Spectral Survey Summary Empirical Line Selection l25
l7
lines examined üYield 300 possible line pairs
lines Identified üGood SNR üNo Interference üLow Temp pair ± 15 K üHigh Temp pair ± 35 K üNear Isolated CO line
Laser Selection Completed
RESEARCH AND DEVELOPMENT
Chicago Research Center
FLUE GAS CHARACTERIZATION Combustion Chamber
4 m x 1m x 1m
.3m x .3m Flue Gas
Long Path Access Port Particle Monitoring
Suction Pyrometer
TDL Furnace Interface Integrating Sample Probe
Real-time H2O Monitoring Dilution Probe
RESEARCH AND DEVELOPMENT
Chicago Research Center
Dirty Process Gas Simulator 100%
3
Particle Loading (mg/Nm )
250 200 150
50%
100 15%
50 0 0
2
4
6
8
10
12
14
16
18
Time (min.)
Seed Particles ØAl2O3 ØZrO2
RESEARCH AND DEVELOPMENT
Chicago Research Center
Integration Sampling Probe 8.0 7.5
Excess Oxygen (%)
7.0 6.5 6.0 5.5 Point Measure No Purge 5.0
Point Measure with Purge
4.5
Averaged Discrete Measure with No Purge Averaged Discrete Measure with Purge
4.0
Integrated Measure no purge 3.5
Auxiliary Access
Integrated Measurement with Purge
3.0 0
40
80
120
160
200
240
280
Distance Across Flue (mm)
Integrating Probe
TDL Position Front View
RESEARCH AND DEVELOPMENT
Chicago Research Center
Milestone Status PHASE II
PHASE I
Task
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Q9
Q10
Q11
Q12
Laser Sensor Upgrade Temperature Monitoring Simultaneous Multi-species Testing Test Furnace Upgrade Fabricate Industrial Sensor Pilot Testing Industrial Host-site Testing Long-term Industrial Demo
Planned Completed Extended Shifted
RESEARCH AND DEVELOPMENT
Chicago Research Center
Project Budget Status
Total Budget
$1,400,000 $1,200,000
Planned
$1,000,000
Actual
$800,000 $600,000 $400,000
Delay in Prototype
$200,000 $0 0
1
2
3
4
5
6
7
8
9
10
11
12
Project Quarter
RESEARCH AND DEVELOPMENT
