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NeSSI: An Enabling Technology for MicroAnalytical

Learn about NeSSI, an innovative platform and enabling technology for microAnalytical sensors that has the potential to revolutionize the process analytical chemistry industry.

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NeSSI: An Enabling Technology for MicroAnalytical

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  1. NeSSI*: An Platform and an Enabling Technology for MicroAnalytical *NeSSI = New Sampling/Sensor Initiative Frank Schweighardt - Air Products Don Nettles - Chevron Texaco “the best way to predict the future is to create it”

  2. Today we will not cover your “garden variety” analytical sensor... Courtesy of First Alert A Kidde Co.

  3. Presentation Outline • Process Analytical Chemistry 101 • [a quick look] • An End User’s vision of an ideal microAnalytical sensor • Enter NeSSI* • enabling technology for microAnalytical • a rapid path to the process

  4. What is Process Analytical Chemistry? • “The art and science of making [relatively] continuous analytical measurements in the chemical industry.” • “The real savings from process analyzers are to be realized in improved processes that produce less waste, consume fewer raw materials, and produce better products.” • [Hassell/Bowman. Applied Spectroscopy. Jan. 1988.]

  5. Economic Benefits of Process Analysis • Lab to Process Analysis Cost Comparison • Cost of Lab Sample: $25-$75/sample • Break Even Point = c. 300 samples/yr. • Process Analyzer Cost of Ownership • $15K per year +/- $5K • typically 10-15 year life span • 45% cost to build/55% cost to maintain • Modeling & Optimization Benefits Lab vs. Analyzer Cost data courtesy of PAPAC Presentation L. Melton

  6. Investment in Process Analyzers Companies surveyed were: Dow, Exxon, DuPont, Eastman; ICI Americas, UCC Reference: PAPAC Presentation (L. Melton)

  7. Chemicals, Plastics & Refining usually require hazardous area certification Industry Segmentation Source: PAI Report

  8. But may do up to 50 % of our analyses Analysis Types in the Marketplace Source: PAI Report * FTIR, NIR, MS, Raman, etc. \

  9. 6. Data Collected & Acted Upon 1. [Sample] Extraction (representative) 7. Validate 5. Return 2. Transport typ. Up to 300 ft. Class I. Extractive Analysis- Remote Analyzer House 3.Manipulate (Sample System) 4.Analyze Central Analyzer House

  10. Class I. Extractive Analysis- Remote Analyzer “House” Courtesy of Dow Chemical - Freeport, TX

  11. Probe type devices... - conductivity/pH - optical techniques - oxygen - Al2O3 moisture Challenges - validation - high development costs - no process “buffering” - fouling - technology constraints - may require withdrawal method AT Analogous to a thermocouple Class II - “In-Line”* Analysis…(perhaps) the ideal analytical system * a.k.a. in-situ, IN-alyzer

  12. ZrO2 Oxygen (Opt.) Aspirator Class IIIa - Extractive Analysis (Stack Analysis*) STACK - Aspirated/Convection - Hi-Temperature - Atmospheric Pressure - Low hydrocarbons (ZrO2) Analogous to a pressure transmitter * a.k.a. ex-situ, by-line

  13. SLIP-STREAM - Line pressure & temp. - Typ. high flows - Typ. a “Piped” System - Delta P required - Maintenance accessible P AT Analogous to a control valve station Class IIIb - Extractive Analysis (Slip-stream*) * aka side-stream; by-line

  14. Ethernet microClimate Enclosure SAM CANbus P F V P FL A Vent or Recycle T Substrate M Substrate Heater Auxiliary Heating/Cooling T Catalytic Oxidation Class IIIc - By-Line Extractive Analysis (NeSSI) Advantages: - Being by-line means only very low sampling volumes are required - Sample can be manipulated to meet the needs of the analytical sensor

  15. Type IIIc - By-Line Analysis Example Courtesy of Dow Chemical Freeport, TX

  16. Today’s Analytical System • Can be more of an “art” than a “science” • Custom assembly (typ) by an integrator • Large sample & utility usage • Skilled maintenance staff required • Semi-automated Courtesy of Dow Chemical Freeport, TX

  17. The Ideal microAnalytical Device • Global Hazardous Certifications • Multi-drop I.S. protocol (low power) • Plug & play (self-identifying) • Robust (> 99.9% uptime) • Smart/self-diagnostic • minimum or no moving parts • modular replacement (hot swap) • Low cost c. <$5K or <$1K “disposable”

  18. The Ideal microAnalytical Device • Analysis Type • Multi: GC, MS, spectrocopy • Single: O2, H2O, pH, conductivity • Functional Clusters • pH, DO2, Conductivity: “water package” • NOx, O2, CO: “CEMS package” • Gas and/or Liquid Service • “Configurable” rangeability • PPB, PPM, PERCENT

  19. The Ideal microAnalytical Device(conditioned sample) • Typ. Pressure: • (typical) vacuum to 150 psig • (higher) vacuum to 500 psig • Typ. Temperature: -20 to 80 C. • Flow (gas) • 3 to 200 cc/min and 3 to 2,000 cc/min • Flow (liquid) • 1 to 300 cc/min and 1 to 1,500 cc/min

  20. The Ideal microAnalytical Device • Fast Response (< 10 seconds) • Low Power (intrinsic safe operation) • High selectivity (normal and upset) • 316L SS (typ.) or process compatible • Self Correcting (drift compensation) • Ambient temp/pressure changes • Sample pressure/flow/temp changes • Low/No Utility or Reagent Usage

  21. NeSSI an Enabling Technology for microAnalytical • A Standard Mechanical Platform • ANSI/ISA SP76 mechanical “footprint” • standard form factor • component interoperability • Lego like component fabrication • A StandardConnectivity Interface(Intrinsically Safe DeviceNet/Ethernet) • A Standard Software Interface

  22. dcs CANbus V P A F SAM PDA Auxiliary Heating/Cooling Programmable Substrate Heater T T o&muser What will a NeSSI system look like? Ethernet LAN Analyzer Controller Substrate

  23. NeSSI: an Enabling TechnologyProvides a Safe microClimate for Sensors Intrinsically Safe electrical sensors & CANbus comm. bus allow “hot” plug & play capabilities in hazardous electrical locations - No Purge or Pressurization - Low utility req. - No need to S/D for maintenance (X-purge) AC Power Networked Heaters & Temperature Control: - Substrate & Enclosure MicroClimate Enclosure - no costly X-proof bolting or flame-proof enclosure - environmental protection AC Power

  24. NeSSI an Enabling Technology SAM* does the repetitive jobs • PDA Field Interface • - Graphical • - Wireless • -Bluetooth™ • - 802.11 Wi-Fi Gateway to an Ethernet LAN(DCS/maintenance systems) can use multiple com protocols - OPC/HTTP/FF, etc. Host to a… Sensor/Actuator Bus Software Applets for Sample System Repetitive Tasks (Appl-I) SAM *SAM = Sensor Actuator Mgr. Provides “Open” Development Space for Custom Software The Bluetooth and the Bluetooth trademark are owned by Bluetooth SIG, Inc.

  25. NeSSI an Enabling Technology for microAnalytical • Advantages... • lowers the entry barriers for micro Analytical developers • lowers infrastructure development costs and associated risk • faster to market • developer can concentrate on providing a premiere microAnalytical sensor

  26. dcs V A P F Auxiliary Heating/Cooling Programmable Substrate Heater T T o&muser NeSSI “Sandwich” concept Standard Connectivity Interface Ethernet LAN DevelopmentFocus can beon Sensors ! CANbus Analyzer Controller Standard Sampling Interface SAM Substrate PDA

  27. MicroAnalytical & Process Analytical Market Acceptance Lower Cost Ease of Design System Reliability • Technology Explosion! • Fast networks/computers • Robust/miniature electronics • Lab-on-a-chip; lasers; wireless • Open standards/interoperability • What does the Market Need? • Reliable, rugged, low cost & fast • What are the Critical Issues? • Component/System Availability • Cost & Acceptance in Industry By-Line/In-Line Analyzer House On the Post 1938 2000 Time

  28. Summary • Quick Overview of Process Analytical • Attributes of an ideal microAnalytical sensor described • NeSSI provides an enabling platform which will speed microAnalytical sensors to the process

  29. Acknowledgments & References • Lynn Melton (U of Texas - Dallas) • PAPAC presentation • Walt Henslee, Mike Walsh, Ron O’Reilly (Dow Chemical) • PAI Associates (S. Walton/T. McMahon) • CPAC Web Site: http://www.cpac.washington.edu/NeSSI/NeSSI.htm • Generation II Specification • Request for Proposals • Previous Presentations

  30. NeSSI*: Status Update *New Sampling/Sensor Initiative CPAC - Seattle, WA - May 4, 2003 Rob Dubois - Peter van Vuuren – Jim Tatera . Tatera & Assoc. “the best way to predict the future is to create it”

  31. “Everyone needs a vision of success…”

  32. NeSSI Vision of Success • We are able to… • Design... • Assemble... • Configure... • ...an analytical system on our workbench. • Lego Like Assembly • No special skills to assemble • plug and play/self-documenting • Fully Automated

  33. NeSSI Roadmap 02 04 06 Analytical & Wireless Gen. III Smart/”Electrified” Gen. II Mechanical Gen. I uAnalytical Field Installations Simple Analyzers(H2O, O2, pH, UV/VIS, etc.) Smart Field Installations Design /Prototype - Gen II Smart/Heating/SAM Mechanical Field Installations Mechanical Component Availability e.g. filters, valves, etc. NeSSI/CPAC Vision & Roadmap ANSI/ISA SP76 Standard Approved 05 03 2000 01 Time (years) Dow Rev. 2, July 2002

  34. NeSSI Generation Segmentation Wireless, Advanced Gas & Liq. Sensors & Platform for microAnalytical Value Gen III Electrical Transducers/IS CANbus Gen II Mechanical Components (mostly) Gen I

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