hach biotector toc analyzers

Introduction:
Hach BioTector TOC Analyzers
March 2010
1

Presentation Content/Structure
HACH BIOTECTOR TOC ANALYZERS
• History of Liquid Analysis
• The BioTector Solution
• What is Two-Stage Advanced Oxidation (TSAO)?
• How does TSAO compare with the competition?
CASE STUDIES
• BioTector Installations
• Dairy Plant Wastewater Case Study
• Chemical Plant Wastewater Case Study
• Cooling Water Case Study
• Other BioTector Applications
BIOTECTOR ACCESSORIES
• Enclosures
• Sampling Systems
• Oxygen Generators
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History of Liquid Analysis
• TOC, COD & BOD analyzers were first developed for the laboratory
• Analyzer manufacturers, therefore, developed the technology with the laboratory
environment in mind
• Range of analyzers developed was based on thermal, UV persulfate
and dichromate oxidation methods
3

History of Liquid Analysis
• Today, customers require on-line and continuous analysis for TOC, COD & BOD
• Unfortunately analyzer manufacturers built on-line analyzers using the same
technology used for lab analysis (Thermal, UV Persulfate, Dichromate)
• Failed to take into account vast differences between laboratory and on-line
environments
• Resulted in poor reputation for on-line TOC, COD & BOD analyzers
4

Laboratory
On-line
5

The BioTector Solution
First manufacturer to truly understand real requirements of on-line analysis
• Clear objective: Provide customers with a true on-line analyzer capable of providing
reliable and accurate results, even in most difficult applications
• Unique approach: Looked beyond limited conventional oxidation methods to find a
new oxidation method capable of objectives
• End product: Necessary to couple BioTectors patented oxidation method with internal
components designed and built to last in the harshest of environments
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BioTector Solution: B7000 TOC Analyzer
• Superior reliability – Typically 99.7% uptime
• High dependability – Patented Two-Stage Advanced
Oxidation (TSAO) technology handles even the most
challenging applications involving fats, oils, greases,
salts, sludge, and particulates
• Intelligent design – Self-cleaning technology and
oversized tubing eliminates filtration and prevents
clogging and sample contamination
• Minimal maintenance – No calibration or service
required between 6-month service intervals
• Low cost of ownership – Provides a quick pay back
with cost savings in customers’ chemical dosing,
waste reduction and optimized processes
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How Does BioTector Work?
• Sampling: A representative, unfiltered sample from the stream to be measured is pumped into
the analyzer. The sample injection valve automatically selects the appropriate sample volume
for the optimum measuring range.
• TIC Detection: Acid is added to lower the pH so that inorganic carbon is sparged off as CO2.
This is measured to ensure Total Inorganic Carbon (TIC) is not carried over into the TOC.
• Oxidation: BioTector’s patented oxidation method Two-Stage Advanced Oxidation (TSAO)
achieves total and complete oxidation of the sample, including organic carbon to CO2, nitrogen
compounds to nitrate and phosphorous compounds to phosphate. TSAO utilizes hydroxyl
radicals generated within the analyzer by combining oxygen, which passes through the ozone
generator, with sodium hydroxide.
• TOC Measurement: To remove CO2 from the oxidized sample, the pH of the sample is lowered
again. The CO2 is sparged and measured by the specially developed NDIR CO2 analyzer. The
result is displayed as Total Organic Carbon (TOC).
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N
C
H 2N
HO
C
O
N
P
C
OH
Lewis Structure
What is Two-Stage Advanced Oxidation?
O
C N
N
O
O
C
P
C
O
C
OH
C
O
P
O
C
Adenosine-5'-triphosphate
OH
OH
OH
Carbon, Nitrogen and Phosphorus Compound Oxidation:
3D Chemical Structure
Nitrogen, Carbon and Phosphorus bonds are broken down to form NO 3 , CO 2 , PO 4 and H 2 O.
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C 10 H 10 N 5
What is Two Stage Advanced Oxidation?
O 13 P 3
10 Hydroxyl
Radical
Carbon, Nitrogen and Phosphorus Compound Oxidation:
OH •
OH •
OH •
OH •
High pH and Ozone
Nitrogen, Carbon and Phosphorus bonds are broken down to form NO 3 , CO 2 , PO 4 and H 2 O.
10

What is Two-Stage Advanced Oxidation?
N
C
H 2N
HO
C
O
N
P
C
OH
O
C N
N
O
O
C
P
C
O
C
OH
C
O
P
O
C
OH
OH
OH
Adenosine-5'-triphosphate
C 10H 10N 5O 13P 3
Exact Mass: 500.95
Mol. Wt.: 501.13
C, 23.97; H, 2.01; N, 13.98; O, 41.50; P, 18.54
The oxidation forms
CO 2 = 10 moles uses 20 Oxygen atoms
H 2 O = 5 moles uses 5 Oxygen atoms
NO 3 = 15 moles uses 15 Oxygen atoms
PO 4 = 12 moles uses 12 Oxygen atoms
Total Oxygen required = 52 Oxygen atoms
13 Oxygen atoms present in the compound
Therefore, 39 Oxygen atoms scavenged from
the environment (river, stream, process
etc.)
TOC = 240 mgC/L
COD = 1245 mgO/L
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How does TSAO Compare to Other Methods?
Calcium and salt Causes no impact with chlorides
up to 30% and calcium up to 12%.
Algae growth Does not impact the analyzer due
to automatic self-cleaning feature.
Microfilters and pre-filter
systems
TSAO (BioTector) Thermal UV Persulfate
Eliminates the need for filtering
due to 3.2mm sample tubes which
handle up to 2 mm particulates.
Oils, fats and greases Self cleans in approximately 12-24
minutes.
Measurement drifts Allows a 6-month calibration
interval due to TSAO method and
high quality build.
Automatic self-cleaning
capability
Includes automatic self-cleaning of
the reactor and sample system
with every reaction.
Leads to analyzer failure due to
collection of un-oxidized
particulates in the furnace.
Collects in the sample system, leading to plugging.
Requires filtering to prevent
plugging of very small sample
tubes (0.5 mm) and microsyringes.
Must shut down analyzer to clean
and maintain regularly.
Requires calibration every 2 to 3
days due to furnace buildup and
IR bench contamination.
Reduces persulfate oxidation
potential with concentration as low
as 0.05%
Requires filtering to prevent
plugging of very small sample
tubes and micro-slider valves.
Loses measurement for
approximately 12-24 hours.
Requires calibration every 2 to 3
days due to UV light source
scaling that causes incomplete
oxidation and drift.
Not available. Requires analyzer to be offline for 1 hour for manual
cleaning.
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TOC
TN
TP
COD
BOD
TC
TIC
VOC
Multiple Parameter/Multiple Condition Suite
Total Organic Carbon
Total Nitrogen
Total Phosphorous
Chemical Oxygen Demand
Biological Oxygen Demand
Total Carbon
Total Inorganic Carbon
Volatile Organic Compounds
Available with multi-stream (up to 6) and Class 1 Div 2 Certifications
Patented
Technolog
y
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Milk Milk Processing Processing Plant Plant
Installation Installation
•TOC analyzers integral part of
•TOC analyzers integral part of
plant management system
plant management system
•Results part of weekly
•Results part of weekly
management reports
management reports
•Any exceptions reported and
•Any exceptions reported and
justified daily
justified daily
•Substantial savings after
•Substantial savings after
installation
installation
• Payback as low as 3 months
• Payback as low as 3 months
• Powder Plant had reduction of
• Powder Plant had reduction of
37% on loading discharged to
37% on loading discharged to
the WWTP
the WWTP
Benefits
Benefits
•WWTP loading always within
•WWTP loading always within
design specification
design specification
•Discharge of product as waste
•Discharge of product as waste
reduced and minimized
reduced and minimized
•Old odor problem eliminated from
•Old odor problem eliminated from
WWTP
WWTP
•Note: No filtering used on any
•Note: No filtering used on any
part of any sampling system
part of any sampling system
BioTector in Dairy Plants
Ireland
TOC
Dairy Industry
Milk Intake Butter Plant Cheese Plant Casinate Plant Whey Plant
TOC TOC TOC TOC
Pow der Plant Bottling Plant
Bio-tower
TOC TOC Waste Water
TOC Treatment Plant
TOC
Discharge Plant
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BioTector in Dairy Plants
•BioTector has been measuring TOC on this wastewater pond since 1997
•Provides a reliability of better than 99.7% up–time (per customer)
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BioTector in Dairy Plants
• Outside surface of sample tubing used in dairy plant covered with fatty
material
• Internal surface of the tubing is kept clean with the self-cleaning technology
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Multi-Process Chemical Production Plant
TOC, TC, VOC, TIC Monitoring—Freeport, TX
BioTector
BioTector
Replaces
Replaces
20+
20+
Thermal
Thermal
TOC
TOC
Analyzers
Analyzers
•Incentive
•Incentive
for
for
change:
change:
reliability
reliability
+
+
maintenance
maintenance
cost
cost
•TOC
•TOC
measurement
measurement
important
important
up-stream
up-stream
to
to
identify:
identify:
•
•
Irregularities
Irregularities
in
in
operation
operation
of
of
each
each
process
process
plant
plant
•
•
Protect
Protect
WWTP
WWTP
from
from
excessive
excessive
loading—possible
loading—possible
biological
biological
process
process
destruction
destruction
•
•
WWT
WWT
costs
costs
charged
charged
back
back
to
to
each
each
process
process
plant
plant
on
on
basis
basis
of
of
TOC
TOC
loading
loading
Process 3
Process 2
Typical Compounds:
•Ketones (VOC)
•Alcohols (VOC)
•Chlorinated solvents
•Compounds soluble and non-soluble in water
•Sludge
•Sewage
BioTector
BioTector
Process 1
BioTector
Process 4
BioTector BioTector
• Non-Purgeable Organic Carbon (NPOC)
• Purgeable Organic Carbon (VOC)
Wastewater
Treatment Plant
Process 5
BioTector
BioTector
Process 6
Discharge
BioTector
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Monitoring of River Water for Process Cooling
West Virginia
21+
21+
BioTector
BioTector
TOC
TOC
Analyzers
Analyzers
•
•
7
7
units
units
measure
measure
river
river
cooling
cooling
water
water
• Silt, sand and muck
• Silt, sand and muck
•
•
Replaced
Replaced
UV
UV
Persulfate
Persulfate
TOC
TOC
analyzers
analyzers
protected
protected
by
by
in-line
in-line
filters
filters
• Needed cleaning up to
• Needed cleaning up to
4 times/day
4 times/day
•
•
BioTectors
BioTectors
operate
operate
without
without
do
do
not
not
have
have
filtering
filtering
system,
system,
clogging,
clogging,
and
and
serviced
serviced
on
on
6-month
6-month
basis
basis
•
•
Remaining
Remaining
BioTectors
BioTectors
on
on
various
various
upupstream
stream
and
and
discharge
discharge
applications
applications
• Replaced several
• Replaced several
Thermal TOC
Thermal TOC
analyzers
analyzers
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Other BioTector Applications
Industries using Two-Stage Advanced Oxidation technology for 10+ years
(over 600 units installed worldwide to date 2009):
– Dairy processing plants: Effluents high in fats, sugar and protein
– Chemical plants and applications: Process streams high in salt and contain
volatile organics
– Refineries: Wastewaters contain oil, calcium and salts
– Municipal treatment plants: Wastewaters have high turbidity and particulates
– Airports: Surface water contains de-icing chemicals, particulates and salts
(extremely high organic loads)
– Pulp and paper industries: Wastewater contains fibrous materials and
particulates
– Pharmaceutical industries: Waste streams contain a wide variety of chemicals
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BioTector Summary
High reliability: 86,000 measurements per annum and over 99.7% on-line time
Complete oxidation of large (up to 10ml) sample with hydroxyl radicals
No interference from salts or calcium
Totally self-cleaning technology
Representative sample without any filtration (up to 2mm particulates). Including
fats, oils, salts, de-icing chemicals, particulates, fibrous materials
Low maintenance: 6-month service intervals
No calibration requirement between services
Automatic range selection and multi-streaming.
Programmable analysis modes: TOC, COD, BOD, TIC, TC, VOC, TN, TP
Designed with purpose for on-line analysis
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Hazardous area certified BioTector
• BioTector TUV Certification
– ATEX Ex II 3G Ex pz T4
BioTector Accessories
• BioTector ETL Certification
– Z-Purge, Class 1 Div 2, Groups A-D, T4
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Integrated Weather-proof BioTector
BioTector Accessories
• Built for outdoor locations in extreme
weather environments
– e.g. desert conditions, low temperatures,
high temperatures.
• Incorporating reagents, sampling systems etc.
• Eliminates system design or engineering cost
• Eliminates integration cost
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Integrated Weather-proof BioTector
BioTector Accessories
• Available for standard and hazardous areas
• Vented reagent storage area
• Access to change reagents without
requirement for permit
• Cooling by safe or hazardous area
air conditioner or vortex cooler
23

Venturi-Driven Vacuum Sampler
BioTector Accessories
• Self-contained, self-cleaning sampling system
• Developed for extremely dirty samples
(oil refineries, breweries etc.)
• Wash back by air and water micro bubbles every cycle
• Long, slender PFA sample chamber
• 10.5mm ID easily cleaned by air and micro bubbles
• Available for standard and hazardous areas
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BioTector Accessories
Vacuum Sampling System
• Designed to bring a sample over a distance
of 40 meters with a maximum lift of 6 meters
• Presents the sample to the BioTector TOC
analyzer or any other analyzer at ambient
pressure
25

Stand-alone Oxygen Generator
BioTector Accessories
• Integrated compressor for the production of
highly concentrated oxygen from ambient air
• Standard BioTector oxygen generator capable
of delivering enough oxygen flow to drive two
BioTector TOC analyzers
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Oxygen Concentrator
BioTector Accessories
• Uses instrument air to make concentrated
oxygen
• On-site oxygen producer, capable of producing
highly concentrated oxygen on-demand
• Uses Pressure Swing Adsorption (PSA)
technology to separate oxygen from its air
supply, and releases the nitrogen through the
waste gas silencer
• Also available integrated inside the BioTector
analyzer (requires large cabinet)
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BioTector Installation Requirements
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BioTector Installation Requirements
SPECIFICATIONS
TOC TOC + TN TOC + TP TOC + TN + TP
VOLTAGE (V) 230 or 115
FREQUENCY (Hz) 50 / 60
POWER (W) 300
WEIGHT (Kg) 90 115 115 120
INCOMING
OXYGEN
PRESSURE
O2 Cylinder 1,000 mbar
O2 Generator 750 mbar
O2
Concentrator
1,250 mbar
SAMPLE PRESSURE (max) +/- 500 mbar
CONSUMABLES
Acid 4 to 8 weeks (application dependent)
Base 4 to 8 weeks (application dependent)
DI Water 4 to 8 weeks (application dependent)
TN Cleaning
Solution
NA 10 to12 weeks NA 10 to 12 weeks
TP Reagent NA NA 18 – 20 weeks 18 to 20 weeks
SERVICE 6 -month intervals
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