combustion engineering

LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Ceramic Gas Sensors for Optimisation of Combustion

Processes

Dr.-Ing Frank Hammer


Outline

› Overview of LAMTEC

› Sensor Technology

› Manufacturing Technology

› Combustion Optimisation

› Application

› Summary

› References


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. €


Overview of LAMTEC - Locations

Headquarter Walldorf LAMTEC EAST ASIA Ltd.Buchon, South Korea

LAMTEC LeipzigDevelopment of hard- and softwareManufacture of flame scanners

LAMTEC Neu AnspachDevelopment of electronics


Overview of LAMTEC - Products/Applications

LAMTECProducts/Applications

Customers

Electronic burnercontrol 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 manufacturerPlant manufacturerMeasurement device manufacturer

Burner manufacturer Industry

Applications:Power plant/waste combustionChemical industryIndustrial applicationMeasuring- and control technologyResearch facilities and development


Overview of LAMTEC - Sales Partner


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


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

TU

,

,

ln2


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)

AK

AKKadAad

K

AS

S

S

T

gg

F

TU

)1(

)1(lnln

2,,

S

ad

ad

T

g

CO eK

c (

1

1


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


Manufacturing Technology – Thick Film Technology

Screen process engineering:

› flexible

› cost-efficient

› reproducible

› mass producible

squegee

Screenjump

screentension

screensquegee

angle

pressedthick film

screen printing pastecarrier substrate


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

SolutionII

Solution III

Solution IV

printing

Medium

Solution V

paste

HOdestilled

2

Solution I

stir 400 U/min25 °C

400 U/min60 °C, 5 min

400 U/min25 °C, 2 min

400 U/min25 °C, 2 min

400 U/min25 °C, 2 min

400 U/min25 °C, 2 min

Cool down

500 U/min65 °C, 45 min

100 Umin25 °C, 60 min

Solution V

Binder I

Plasti-cisers

Dispergingagents

Binder II

Defoamer

Ceramicpowder

Moisturi-zers

screen

printingScreen

stir

stir

stir

stir

stir

stir


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 2Check/Testing

Drying

Printing heating oil

Drying

Printing YSZ-Ceramic

Presintering

Paste preparation

VentilationPortioningPositioning

Screen /SMD moulding

Cleaning of substancesMechanismPositioning

Carrier substrate

Cleaning of substancesDegreasingPositioning

Activation Electrode 2Preliminary testHard 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


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

Sen

sor

tem

pera

ture

Ts

in K


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


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


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!

Þ 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

, CH

nm

effi

cie

ncy

Em

issi

on

edg

e

Com

bust

ion

fuel

s


Application – Combustion Regulation

Combustion Control increases

› The operational range

› reliability of operation

› safety

Combustion Optimisation

› increases the efficiency

› lowers fuel consumption

› Minimises pollution

S2

S1Processo r

AirFuel

BurnerFlue gas channel

Exhaust air

ProbeElectronic control

Combustion chamber


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 fulfilledrequirements 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


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 atmospheresup 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



Electronics Status: series

Function around 1000 units in operation since Mai 2003

Development Feb. 2003: prototypeMai 2003: pre-seriesOct. 2003: redesign pre-seriesMarch 2004: zero series

Life time tests no blackout since Oct. 2003

Price 500 € per piece




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


References – Long Term Measurement

Endurance test over 11 months

› identical characteristics

› no identifiable deterioration

› sensitivity increases slightly


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°C100% condensation !

• directly in the combustion chamberTmax = 600° !!No condensation !

Sturzbrenner



Mounting position in the condensing flue gas channel

› 4 CarboSen1000, plugged in

› 4 CarboSen1000, hanging

› 1 Lambda probe, plugged in



Mounting position in the hot incinerator

› 1 CarboSen1000 immersion probe


CarboSen

27


CarboSen

Miniaturised Sensor for Detection of Non-burned (CO/H2) in Combustion Exhaust Gas

28


CarboSen

29


Measurement Principal of CarboSen1.000

30


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


CarboSen

Characteristic

0

20

40

60

80

100

120

140

3000 3010 3020 3030 3040 3050 3060 3070 3080 3090 3100

Zeit in s

Us

en

in m

V

0

50

100

150

200

250

300

350

400

450

500

CO

re

fere

nz

in p

pm

U Sen 01 in mVU Sen 02 in mVU Sen 03 in mVCO MRU in ppm

32


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


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


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


Thank you for your attention

Questions?


Contact:

Steven Craig – President, Hays Cleveland

Phone: (216) 398-4414

Fax: (216) 398-8558

E-Mail: [email protected]

combustion engineering

Government & Nonprofit

lamtecleipzig gmbh

lamtec poland lamtec

combustion engineering

ooo lamtec moscow

company profile lamtec

escube gmbh

walldorf lamtec east

s c c f t u