Chemical Sensors for the New
Sampling/Sensor Initiative
Nelson Lytle
Honeywell International, Inc.
Objectives
• Illustrate sensor/composition/property
measurement concept with examples
• Discuss potential NeSSI sensor cluster
applications
• Invite sensor developers to participate
• Increase the applicability of NeSSI as a
sensor platform
• Get tools into chemist’s and engineer’s hands
The Ten Needs
Chemical/Composition/Property
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Bio Assay
Chemical Composition
Cleaning Validation
Coating Consistency
Mixing Efficiency
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Moisture Concentration
Particle Sizing
Vapor Characterization
Viscosity/Rheology
Waste Minimization
Mel Koch, CPAC
Major Goals of NeSSI
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Modular, miniature, smart sample system
Based on ISA SP76 standard
Field mounted
Open connectivity for communications
Integration of sample system with
physical/chemical sensors
• Technology bridge to process for microanalytical devices
NeSSI: Enabler for Micro Analytical
(the “rail” concept)
Standard
“connectivity”
Standard Electrical (Digital) Interface “Rail”
SAM*
Anyone’s Sensor
P
Anyone’s Actuator
V
Standard Mechanical Interface “Rail”
*Sensor/Actuator Manager
Standard
“hockey- puck
PC”
Desirable Properties
Sensor Wish List
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Global electrical (hazardous) certifications
Plug & Play (self-identifies)
Robust (> 99.9% uptime)
Self checking/calibrating/correcting
Low cost (<$5K)
Suitable for operating as a Functional Clusters
Gas and/or Liquid Service
Fast (continuous) Response (< 10 seconds)
Physically small in size
Low Power (for intrinsic safe operation)
Low/No Utility or Reagent Usage
Simple Sensors - The Dirty Dozen
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Density
Refractive Index
Viscosity
Optical Absorbance
Dielectric
Conductivity
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pH/ISE/ORP
Turbidity
Thermal Conductivity
Ultrasonic
Moisture
Gas Specific
Characteristics: simple, dedicated, robust, commonly used.
Deacon Reaction
2HCl + 1/2 O2 = Cl2 + H2O
Step 1: HCl(g) reacts with metal oxide (MO) catalyst to produce
MCl and H2O(g)
Step 2: O2(g) reacts with MCl to produce MO and Cl2(g)
Thermal Conductivity
He: 222.3
N2: 38.3
O2: 41.0
Cl2: 18.0
HCl: 24.0
H2O: 35.7
UV Absorbance: Cl2 @ 350 nm
This process can be controlled using thermal conductivity and a UV-Vis
absorbance sensor.
Polymerization Control
Monitor molecular weight via density, RI, and viscosity.
1.200
1.4050
1.000
1.4000
1.3950
0.800
1.3900
0.600
Mol Wt vs Viscosity
RI
1.3850
0.400
1.3800
0.200
1.3750
0.000
1.3700
0.0000 0.0010 0.0020 0.0030 0.0040 0.0050 0.0060 0.0070
1/Mw
120000
100000
Viscosity
Density (g/ml)
1/Mw vs Density, RI
80000
60000
40000
20000
0
0
50000
100000
Mol Wt
Use density or RI for low Mw and viscosity for high Mw.
150000
Unsaturation in Edible Oils
Iodine Value vs 889 and 930 nm Absorbance
.4
0.450
0.150
0.440
889 nm Abs
.3
.2
.1
0.140
0.430
0.420
0.130
0.410
0.120
0.400
0.110
0.390
0
750
800
850
900
950
1000
Counts / Nanometers
File # 1 = 1544D2
1050
0.380
1100
0.100
80
Overlay X-Zoom CURSOR
6/21/2004 7:20 PM Res=0
930 nm Abs
.5
90
100
110
120
130
140
150
Iodine Value
Iodine Value vs RI and Density
1.476
0.9220
0.9200
1.474
1.47
0.9140
RI
0.9160
Density
0.9180
1.472
0.9120
1.468
0.9100
1.466
0.9080
80
90
100
110
120
130
140
150
Iodine Value
NIR absorbance can be used to monitor unsaturation in edible oils. But so can density and
RI.
Edible Oil Classification
Simple sensors can monitor blending and determine quality of edible oils.
0.5
PC2
Scores
canola c
safflower
peanut
olive
soy/canola
sunflower
corn w
0
1.0
PC2
X-loadings
canola m
viscosity
0.8
soybean
corn/canola
olive ev
0.6
corn m
-0.5
-4
-3
pca eo 7-19-04, X-expl: 98%,2%
PC1
-2
-1
0
1
2
3
4
0.4
RI
0.2
density
iodine
889.92value
abs
0
930.98 abs
-0.2
-0.4
-0.3
pca eo 7-19-04, X-expl: 98%,2%
PC1
-0.2
-0.1
Use density, RI, viscosity, optical absorbance to classify oils.
0
0.1
0.2
0.3
0.4
NeSSI Sensor Clusters
Water Monitoring:
• Boiler Water
– Conductivity
– pH
– pNa
• Waste water
– pH
– TOC
– O2
Sensors include pH, ISE, ORP, conductivity, UV absorbance.
NeSSI Sensor Clusters
Continuous Emission Monitors:
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NOx
SOx
O2
CO
Use NeSSI advantages of P,T,F control and filtration.
Potential sensors include specific gas sensors, UV-Vis, and IR.
NeSSI Sensor Clusters
Jet Fuel Properties:
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Density
Flash point
Freezing point
Fuel system icing
inhibitor
• Aromatics
Sensors include density, RI, turbidity, NIR/IR absorbance.
What am I proposing?
• Simple sensors provide a way to
perform analyses that are useful for
process control and optimization
• These are measurements that are being
used today
• Simply adapt them to the NeSSI
standard
Conclusion
• I hope that I have made you aware of
the opportunity to use simple, robust
sensors to make chemical and property
measurements.
• I hope to motivate sensor developers to
make sensors available that meet the
NeSSI standard.
Everything is in place to make it happen.
Come on in … the water’s fine.