AMETEK Biofuel Application Notes

AMETEK CORPORATIONWe’ve taken technologythat we developed forone industry and modifiedit for application inrelated industries.WE ARE A GLOBAL LEADERAMETEK, Inc. is a leading diversified manufacturer of electronic instrumentsand electromechanical devices. We have over 11,000 colleaguesat more than 80 plants across the United States and in 14 countriesaround the world. Supporting those operations are more than 80domestic and international direct sales and service locations in over 30countries worldwide.AMETEK consists of two business groups: Electronic Instrumentsand Electromechanical. We are a leader in advanced instruments forprocess, aerospace, power and industrial markets; a differentiatedsupplier of technical motors and motion control solutions, electricalinterconnects and specialty metals; and a global leader in floor careand specialty motors.PIBU LocationsOur business unit headquartersis in Pittsburgh, PA withmanufacturing, sales and serviceoperations in Pittsburgh, PA,Newark, DE and Calgary, Canada.PITTSBURGH, PANEWARK, DECALGARY,Among our greatest strengths is the ability to develop innovativenew products and bring them to market successfully. We enjoyan excellent reputation for technical innovation and productdevelopment know-how. We have acquired businesses withexcellent technical capabilities and made a significant investmentin new product development. The result has been a steady stream ofsuccessful new products.WE ARE A RESPONSIBLE CORPORATE CITIZENAMETEK is an ethically responsible company committedto the highest standards of business behavior. We encouragegood corporate citizenship among our colleagues andare sensitive to the needs of the communities in which weoperate. The AMETEK Foundation, which has served as theCompany’s charitable arms since 1960, lends support to educational,health, civic and social programs in communities inwhich we operate.Our BreadthOur sales are evenly divided between two business groups:Electromechanical Group (EMG) and Electronic InstrumentsGroup (EIG). Our EMG group provides motors used in industriessuch as aerospace, military, mass transit, business equipment,medical applications. We are also a leader in specialty metal powder,strip, wire, and bonded products and produce specialty clad metalalloys and powders used in electronic applications. Our EIG groupprovides equipment for process industries, analytical laboratories, theaerospace industry; wherever power instruments are needed, for virtuallyevery industrial market.We rank among the world leaders in process analyzers control instruments.

BioFuels & AMETEK Process InstrumentsWhat is Biofuel?Biofuel can be broadly defined as solid, liquid, or gasfuel derived from recently living biological material.This distinguishes it from fossil fuels, which arederived from long dead biological material. Biofuelcan be theoretically produced from any biologicalcarbon source, though the most common by far isphotosynthetic plants. Many different plants andplant-derived materials are used for biofuel manufacture. Biofuels are used globally,most commonly to power vehicles and for generating heat. Biofuel industries arerapidly expanding worldwide.There are two common strategies for producing biofuels. The first isto grow crops high in either sugars (sugar cane, sugar beet, and sweetsorghum) or starch, (mainly in the form of corn) and thenuse yeast fermentation to produce ethyl alcohol (ethanol).The second is to grow plants that contain high amounts ofvegetable oil, such as oil palm, soybean, algae, or jatropha.These oils are then processed using heat to reduce themolecular weight (lower the viscosity or thickness). Thefree fatty acids in these oils can be converted to estersin a continuous process by combining the esterificationand transesterification processes. The result is a fuel that can be burned directly ina diesel engine, or the oils can be chemically processed to produce fuels such asbiodiesel blends which are a mixture of biofuel and petroleum distillates. Wood andits byproducts can also be converted into biofuels such as woodgas, methanol orethanol fuel. It is also possible to make cellulosic ethanol from non-edible plant parts,but this can be difficult to accomplish economically. In addition to the approachesjust described, biofuels can be produced by the breakdown of waste materials. Themethane produced can be captured, purified and sold to natural gas producers.Biofuel production requires analytical process measurements at various stages of theproduction process. The AMETEK Process Instruments Group produces instrumentsthat can measure the chemical properties of liquid and gas streams using ultravioletand near infrared absorption using broadband andlaser sources, mass spectrometry, zirconium oxide forO 2and gas chromatography for low levels of hydrogen.The following pages describe some of the biofuelapplication solutions provided by AMETEK.

BioFuel Production Process ControlAUTOMATED PROCESS CONTROLWestern Research® Model IPS-4Integrated Process SpectrophotometerIPS-4IntegratedProcess SpectrophotometerThe IPS-4 can be used tomeasure the ethanol contentin liquids, methyl esters inbiofuel, transesterificationendpoint, VOC's in wastewaterand moisture in wastemethane, to name just a few.One of our most versatile analytical platforms is the Model IPS-4 UV-VIS and NIR process analyzer capable of detecting, quantifying, andcompensating for multiple chemicals and interfering species. AMETEKcan customize the sample handling and conditioning system to meetyour sample fluid and application requirements. The IPS-4 can be usedto analyze for ethanol content in gasohol, methyl esters in plant oilderivedfuels, ester content in biofuel/diesel mixtures, and many otherliquid and gas biofuel production applications.ProMaxion Process Mass SpectrometerProcess mass spectrometry provides real-time analysis of multicomponentstreams and is ideal for control of many complex industrialprocesses such as the manufacturing of biofuels. Theseinclude the compositional analysis of gases produced duringthe biodegradation of waste materials and the monitoring ofvolatile organic compounds (VOC) in waste water streams.Biofuel offgas analysisDepending on the feedstock used, gasification can produce significantamounts of the higher hydrocarbons. Knowing what theyProMaxionare and how much is there can lead to tighter process controland provide an early warning system for potentially damaging process upsets. Whenthe extracted landfill gas is to be reintroduced into the pipeline, O 2and CO 2levelsmust be within strict transmission guidelines. With 10 ppm baseline sensitivity (1 ppmwith optional electron multiplier detector), the ProLine can ensure continuing productquality.Maximizing the output of a syngas-producing bioreactor requires a differential measurementacross the reactor. A ProLine or ProMaxion analyzer, with a typical analysistime of less than 15 seconds/sample point, is able to provide a uniquely detailedpicture of the entire process. The Process 2000 software package, with its real-timeCalculation Editor, eliminates the need to port data into a separate package for postacquisitionmanipulation. Component ratios, input/output subtractions, and mergingof other process data are performed and displayed simultaneously with the raw dataacquisition.INDUSTRIAL GAS PRODUCTIONModel 3050 AM Moisture AnalyzerThe Model 3050 AM moisture analyzer is ideal for critical moisture measurementapplications including feed gas analysis in biofuel production and moisture levels inmethane produced from biodegration of organic waste. The Model 3050 AM moistureanalyzer uses AMETEK’s proprietary Quartz Crystal Microbalance (QCM) sensor technologyto provide an accurate and responsive moisture measurement. The Model3050 analyzer has a built-in NIST-traceable moisture source that periodically validatesthe sensor’s response, ensuring operator confidence.

ETHANOL & BIOGAS PRODUCTIONCONTROL OF FERMENTATIONProLine RQ Process Mass SpectrometerThe ProLine RQ process mass spectrometer can monitor multiple fermentationreactors simultaneously and measure all of the gases entering and exiting eachreactor. Most important are the O 2consumed, the CO 2produced, and the ethanolcontent in the vent gas. This provides a continuous, highly refined control signal tomaximize culture health and productivity.What is RQ?Fermentation is the processby which living organisms arecultured to produce a specificproduct. Fermentation reactionsmust be closely monitoredto gauge the health ofthe culture and to determinewhen it can be harvested. Thelevels of carbon dioxide andoxygen in the off-gases areused to follow the progressof fermentation. The ratio iscalled the respiratory quotient(RQ) and is the prime indicatorof culture health.Biogas AnalysisProLine RQStan Siegel, owner of Green GasEnergy, LLC :"The Ametek ProLine is a greatexample of a modern, on-line analyticaltool. High performance andreliability coupled with easy operationallows us to turn landfill gasinto a pipeline quality product. Thehigh speed analysis and multi pointsampling makes for fast processoptimization. And the low maintenanceoverhead of the instrumentguarantees we'll stay that way."Trash to Clean EnergyAs the population of our planetcontinues to grow, millions of tonsof waste accumulate in landfillsaround the world. Landfills releasegases, mostly methane gas, whichhas become an important contributorto global warming. But methanegas can be captured and used topower businesses and vehicles andheat homes and greenhouses.Ethanol ProductionEthanol offers a valuable energyalternative to fossil fuels,which are both nonrenewableand contribute significantly toatmospheric pollution. Ethanolis often referred to as a‘biofuel’ since it can be manufacturedby fermenting grains,plant biomass and otherorganic materials using microorganismssuch as yeast cells.Ethanol can be used as a fueldirectly, but most often it isblended with gasoline (at about5-10%) to yield gasohol.According to the EPA, 350 landfillsacross the U.S. are convertinglandfill gas to clean energy.In addition to the United States,15 other countries also plan torecover and process methane gasfrom landfills. Experts project thatthe environmental and economicbenefits of using landfill gas as analternate energy source will triplein the next few years.

Trace Gas AnalysisTRACE ANALYZERS5910Moisture AnalyzerCG1100-RTPOxygen AnalyzerTrace Moisture - Model 5910 and Model 5830AMETEK’s moisture analyzers are designed to help minimize process upsetscaused by excessive moisture in bulk atmospheric gases. The Model 5910 hasthe sensitivity and stability required to ensure that bulk feed gases possess therequired sub-1 PPBv moisture impurity level with its limit of detection of a mere150 PPTv. On-line verification functions allow users to validate both the sensor’szero-baseline and its accuracy calibration using a NIST-traceable moisturesource.Trace Oxygen - Clean Gas CG1100 and CG1100-RTPOxygen level monitoring is another important analysis in biofuel production. Our Clean GasModel CG1100 provides a PPMv measurement of the oxygen present in a feed or exhaust gasstream. Zirconia technology provides fast response from initial high percent levels of oxygento low PPMv levels with no loss of accuracy or sensorlife.Impurities in Bulk GasTrace Analytical ta7000 SeriesBiofuel energy, power made from organic materialssuch as plants and animal waste, representsthe classic win-win for farmers, electricityproducers and the public. Biomass ischeaper and cleaner than other energysources such as fossil fuels and is, of course, renewable.At the same time, manure-based fuels offerfarmers a simple, profitable way to manage farm waste and the accompanyingodors and environmental issues.In the last two years, eighteen Wisconsin State dairy farms have invested in methanedigesters that heat up cow manure to produce gases and fuels which in turnpower an engine and turbine unit. The resulting electricity can be enough to supply anywherefrom 500 to 1,200 homes on an annual basis.The Trace Analytical Reduction Gas Analyzer is ideally suited forthe determination of ppb-to-ppm levels of hydrogen and carbonmonoxide in methane evolved from bacteria in anabolicdigestors. In this analysis, the Reduction Gas Detector (RGD) isused to provide rapid and reproducible measurements.Trace Analytical ta7000 Series

COMBUSTION CONTROLOPTIMIZATION OF PROCESS HEATERSThermox® WDG-IVCFuel fired heaters are used extensively in the production of biofuels. They offer specialchallenges for optimization due to high temperatures, multiple burners and zones, aswell as widely varying fuel calorific values.The fast-response WDG-IVC series is designed for direct measurement of oxygen andcombustibles in the high temperature zones (up to 3000°F / 1649°C) and is used worldwidefor optimization of fired heaters. Benefits of optimization include substantial energysavings, 15-20% NOx reduction, increased product quality and throughput, improvedsafety, and longer heater and tube life.Efficient Control of Waste Fuel BurnersThermoxWDGIVC/IQ AnalyzerThermox® S A/F IQ Air Demand & Wobbé Index AnalyzerThe increased costs of traditional fuels and the uncertaintyof their supply has led to greater use of waste gas, biomassand off-gas to supplement or replace them. Such fuelshave widely varying energy content making it difficult tooperate the combustion process efficiently and safely. TheStoichiometric Air/Fuel Ratio Analyzer (S A/F IQ) continuouslymeasures a sample of the fuel gas and air supplied tothe burner. This result produces a control signal to set thecorrect air-to-fuel ratio. Fast response enables the efficientcombustion of waste and off-gases in a wide range of applications.S/A/F IQAir Demand AnalyzerCombustion processes play a major role in the biofuels industries, and fuel costsassociated with boilers, furnaces, kilns, and process heaters, often accountfor the majority of the cost of running a plant. Increasing fuel costs and morestringent emissions limits have focused attention on improving the combustionefficiency of industrial boilers and process heaters.THERMAL OXIDATION of biofuel production wasteThermox® WDG-HPII Flue Gas Oxygen AnalyzerThermal oxidation is widely used to dispose of the plant material wastes that are abyproduct of biofuel production. The high temperatures and high dust loading in suchprocesses demand a special analyzer. The WDG-HPII flue gas oxygen analyzer is designedfor such applications and facilitates reliable operation of these critical facilities.Thermox flue gas analyzers have been helping customers improve combustionefficiency for more than 40 years. Thermox offers a wide range of sensor stylesso you can select the right analyzer for even the toughest applications.

ENVIRONMENTALCONTINUOUS EMISSIONS & COMBUSTION EFFICIENCY MONITORINGLAND COMBUSTION FGA AnalyzersA CEM or AMS system in terms of number of gases measured and datareporting, can often be met by a single product from our product range. Thesolution does not need to be a systems integration exercise. However, whenyou are looking for a flexible approach to system design which may includecomponents from other suppliers, AMETEK can provide complete, integratedsystems - not just a series of components.VOCs in Ambient air (MIMS)ProMaxion Process Mass SpectrometerThe biofuel prouction process often produces toxic substances or use suchsubstances in their manufacturing process. As a result there is a requirementto monitor the environment in and around the plant to ensure that theconcentrations of known pollutants remain below the exposure limits. Equipped for Membrane Interface MassSpectroscopy (MIMS), the ProMaxion uses a dimethylsilicone membrane inlet coupled directly to its ion sourcealong with a multiport arrangement for multiple sample stream selection and the introduction of calibrationstandards. Thanks to its extremely fast response and high sensitivity, a single analyzer can be used to monitorup to 80 ambient air sample locations around a plant.Installed LAND FGACOMPLIANCE MONITORING FOR OPACITY AND DUSTLAND Model 4500 MkII +Dust is an element of air pollution regulated by regional and federal air pollutioncontrol agencies. Facilities must demonstrate compliance by implementinga dust control program. The 4500 MkII + is designed for complianceapplications. It uses patented "Flood LED" technology to achieve thehighest levels of stability and accuracy and is approved to the latestgovernment standards. Using RS232 or RS485 serial Modbus interface, itis easily integrated into your plant control system.Installed Model 4500 MkII +Typical Uncontrolled Emissions from Biomass Combustion in BoilersParticulates:12.5-15 (kg per ton biomass)Organic compounds: 1 (kg per ton biomass)Sulphur dioxide: < 1.5 (kg per ton biomass)Nitrogen oxides: 5 (kg per ton biomass)Carbon monoxide: 1 (kg per ton biomass)

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