Chemical Sensors for the New Sampling/Sensor Initiative

1. Chemical Sensors for the NewSampling/Sensor Initiative Nelson Lytle Honeywell International, Inc. January 11, 2005

2. 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

3. Bio Assay Chemical Composition Cleaning Validation Coating Consistency Mixing Efficiency Moisture Concentration Particle Sizing Vapor Characterization Viscosity/Rheology Waste Minimization The Ten NeedsChemical/Composition/Property Mel Koch, CPAC

4. Major Goals of NeSSI • 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 micro-analytical devices

5. P V NeSSI: Enabler for Micro Analytical(the “rail” concept) Standard “connectivity” Standard Electrical (Digital) Interface “Rail” SAM* Standard “hockey- puck PC” Anyone’s Actuator Anyone’s Sensor Standard Mechanical Interface “Rail” *Sensor/Actuator Manager

6. Desirable Properties Sensor Wish List • 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

7. Density Refractive Index Viscosity Optical Absorbance Dielectric Conductivity pH/ISE/ORP Turbidity Thermal Conductivity Ultrasonic Moisture Gas Specific Simple Sensors - The Dirty Dozen Characteristics: simple, dedicated, robust, commonly used.

8. 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.

9. Polymerization Control Monitor molecular weight via density, RI, and viscosity. Use density or RI for low Mw and viscosity for high Mw.

10. Unsaturation in Edible Oils NIR absorbance can be used to monitor unsaturation in edible oils. But so can density and RI.

11. Edible Oil Classification Simple sensors can monitor blending and determine quality of edible oils. Use density, RI, viscosity, optical absorbance to classify oils.

12. Boiler Water Conductivity pH pNa Waste water pH TOC O2 NeSSI Sensor Clusters Water Monitoring: Sensors include pH, ISE, ORP, conductivity, UV absorbance.

13. NeSSI Sensor Clusters Continuous Emission Monitors: • NOx • SOx • O2 • CO Use NeSSI advantages of P,T,F control and filtration. Potential sensors include specific gas sensors, UV-Vis, and IR.

14. NeSSI Sensor Clusters Jet Fuel Properties: • Density • Flash point • Freezing point • Fuel system icing inhibitor • Aromatics Sensors include density, RI, turbidity, NIR/IR absorbance.

15. 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

16. 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.

17. Everything is in place to make it happen. Come on in … the water’s fine.

18. FIN