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COMBIMASS® Biogas Flowmeter & Analyzer Systems

Introduction BinderGroup

COMBIMASS® Flowmeter series Physical Principle Calibration General installation advices Application Biogas

COMBIMASS® Flow Conditioner & condensate traps

COMBIMASS® Gas Analyzer Portable Analyzer GA-m Docking station GA-s Modular GA-s Click!

COMBIMASS® Installation Examples

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Binder Group AG Finance Holding

BINDER GmbH Manufacturing Company for Gas Flowmeter, Gas Analyzer and Control Systems

with following makes: COMBIMASS® / VACOMASS® / CAMASS®

INSTRUM AG Manufacturing Company for Stainless Steel Pressure Regulators and Valves

Binder Engineering GmbH / Binder Instrumentation Sales & Service Companies in DE/ F/

CH/ NL/ B/ SE Asia / China

BETA B.V. Manufacturing Company for Pressure and Temperature Switches

Overview BinderGroup Ulm, Germany

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Product Line BinderGroup – COMBIMASS® Flow Meter

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without conditioning

with conditioning

Patented Gas Flow Conditioner

Ch

ann

el h

eigh

t C

han

nel

hei

ght

Distance

Distance

Product Line BinderGroup – COMBIMASS® Flow Conditioner

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CAMASS® Calibration Lab

Product Line BinderGroup – CAMASS® Calibration Lab

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Product Line BinderGroup – COMBIMASS® Analyzer

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Product Line BinderGroup - VACOMASS® Control System

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for protecting explosive, corrosive and sterile processes with inert gases for liquids and other corrosive media

Product Line BinderGroup - INSTRUM® Pressure Regulators

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Custom built, high quality, user friendly, explosion-proof switches, available in a wide variety with different certificates and approvals

Product Line BinderGroup – BETA Pressure & Temp. Switches

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Sewage Treatment (municipal,

industrial)

Green Energy - Biogas

Chemical Industry

Oil & Gas

Pulp & Paper

Power Generation

Pharma & Biotechnology

Food & Beverages

Textile industry

Automotive

In General:

chemical industry

safety relevant processes

automation & control

high end precision products

Main Markets for BinderGroup Products

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The principle:

Gas flows by a heated sensing element and causes cooling down of the element by the mass flow (molecules)

Temperature:

Measurement is based on a Pt 100, an additional non-heated sensor is used as a reference.

Amount of heat:

The amount is direct related to the mass flow.

Basics of Thermal Dispersion Technology

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COMBIMASS flow meter measure directly in dry gases the standard volumetric flow or the mass flow of the gas respectively according to DIN1343. No pressure and temperature compensation are necessary.

COMBIMASS® sensors for thermal gas flow measurement are designed for minimal pressure loss are rugged, corrosion-resistant require minimal maintenance have no mechanical moving parts

COMBIMASS® sensors are characterized by high-precision resistors minimal drift of the raw signal excellent long-term stability

all this even under harsh operating conditions and at high temperatures.

Basics of Thermal Dispersion Technology - Advantages

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There are 3 different types of biogas flow meters:

COMBIMASS ® eco-bio+ SS (HC)

COMBIMASS ® eco-bio + AL

COMBIMASS ® oem-bio L

with 2 sensor pins, 12 mm diameter, with compression fitting with hot tapping unit and quick sampling connection/ ball valve

COMBIMASS® Biogas Flow meter series

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biogas hat a high percentages of water vapour (at the top of the digester 100% relative humidity) and contains beside others H2S and NH3

the concentration of methane is changing in the biogas

outdoor installation – operation for years under the sky – rain, snow, direct sun light, ...

big plants – long distances between the measuring points

ignition potential of methane-air-mixture

biogas is highly corrosive

COMBIMASS® Biogas flow meter – R&D challenges

Source "Redaktion energie aus pflanzen"

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Gas is damp saturated – based on temperature

Installation places: directly after the digester/ directly after gas cooler

Type: integrated/ external sensor

Based on temperature of the biogas and assuming a relative humidity of 100% the water contents can be calculated by standard method. But gas temperature musn´t be increased due to blowers, direct sun light etc. In these cases temperature method will calculate a wrong (too high) waterdamp portion.

Gas is not damp saturated – based on dew-point

Installation places: after gas storage tank, in front of the CHP

Type: external sensor

Using a special probe, the relative humidity and so the water contents can be determined. The probe is sensitive against H2S, therefore it can be used only after the filter at very low H2S-concentrations.

COMBIMASS® Biogas flow meter – humidity correction

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Temperature in °C

Wat

er c

on

ten

ts in

g /

m³ W

ater con

tents in

Vo

l.-%

COMBIMASS® Biogas flow meter – humidity correction

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Methane concentration in the biogas is changing

Type: correction module/ COMBIMASS® analyzer station

Based on actual CH4-concentration and gas velocity a correction factor is calcu-lated and used for flow correction.

COMBIMASS® Biogas flow meter – flow correction CH4

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The master module has one analog input and one analog output, each 4-20 mA. The flow signal is put into the master module via RX/TX.

Module 1: Humidity correction (for -AL )

based on the 4-20 mA signal of a tempera-ture probe (which can be supplied by Bin-der too) the flow signal is read in and corrected. The analog output will transfer the dry gas flow at standard conditions.

COMBIMASS® Biogas flow meter – correction modules

Module 2: Correction of gas composition

based on the 4-20 mA signal of methane concentration (which is transferred from local gas analysis) the flow signal is read in and corrected. The analog output will transfer actual flow corrected by actual gas composition.

Both corrections cannot be done in one module only!

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no maintenance required

no recalibration required

can be easily cleaned with a brush

always very precise flow measurements,

even when site conditions change (within a specific range)

cost advantages because of modular system

attractive add-ons using gas analysis

rugged design in stainless steel, no moving parts

deposits have few to no influence on the measuring accuracy

the reference sensor measures in each case the process temperature

COMBIMASS® Biogas flow meter – Advantages

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water damp portion is measured too = wet gas flow, but not standard (0% rel. humidity required); if gas is saturated at the installation point, damp portion is only a function of gas temperature

Non-heated sensor is used for measurement of gas temperature, humidity correction is implemented directly in the electronics in the sensor head

sensors are corrosion-proof (SS316 type) & resistant against moisture and dirt

easy installation also in an existing plants, minimal pressure drop

in combination with Binder´s correction modules or gas analyzer station the changing gas composition can be corrected in time

hot tapping units for the sensors available for easy assembly / disassembly under pressure

flow range from 0.25 to 25 m/s at a standard accuracy of 2% of reading

real gas calibration in the CAMASS® Calibration Lab

COMBIMASS® Biogas flow meter – Features

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The COMBIMASS® flow meter can measure very precisely but detect the flow at one point only. Therefore following facts must be considered:

fully turbulent flow - regular flow profile - no flow pulsations no piping pulsations - static gas composition - sufficient straight inlet and outlet piping

Otherwise detected flow can have an error of more than 30%. Different types of COMBIMASS® Flow Conditioner and Condensate Traps can improve the installation situation and so the final accuracy.

COMBIMASS® flow meter – Requirements on the installation place

Total existing straight run

2/3 1/3

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To achieve standard accuracy the shown straight inlet and outlet pipe runs are sufficient. To achieve a better accuracy further please use pipe runs according DIN EN ISO 5167-1.

COMBIMASS® flow meter – Requirements on the installation place

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Preferred position in wet gases is in horizontal pipe sections from side and heated sensor upside

In vertical pipes with wet gases the gas flow should be upstream

Other positions possible, but you must take care that there is no condensate running over the sensor tip (this would cause a high deviation, because the heat capacity of condensated water is much higher than the capacity of the gas)

Vertical piping and downstream gas flow can also be used in diagonal pipe runs or using condensate traps

COMBIMASS® flow meter – Mounting of the sensor in wet gases

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Consequence:

The thermal principle is e.g. suitable also for the measurement of wet gases, like biogas or gas from digesters in sewage treatment plants or landfill gas

Heated sensor point is more warm than environmental gas

Water condensation takes place only at the piping wall

COMBIMASS® flow meter – Mounting of the sensor in wet gases

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Process parameters like temperature, pressure, installation details of piping and gas composition will be considered always to achieve a high accuracy of flow metering. Type 1: Standard-Calibration of the COMBIMASS® flow meter under actual operating conditions in our CAMASS® Calibration Lab. This standard calibration will be done under the assumption that sufficient inlet and outlet straight pipe runs are available for installation of the COMBIMASS®flow meter.

Type 2: Calibration of the COMBIMASS® multi flow meter under actual operating conditions in our CAMASS® Calibration Lab.

Type 3: Calibration of a COMBIMASS® flow meter including simu-lation of the actual piping isometry (scale 1:1).

Type 4: Calibration of a COMBIMASS® flow meter in combination with the COMBIMASS® flow conditioner as a complete unit.

COMBIMASS® Flow meter – Types of calibration

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Type 5: Calibration of a COMBIMASS® flow meter as a real gas calibration (calibration loop is filled with real gas).

Type 6: Calibration takes place in comparison with master calibra- tion devices (and according to contractual requirements) on an DAkkS (German accredited Institute) Calibration Lab using mea- suring equipment, which is regularly and traceable recalibrated by the PTB (Physikalisch Technische Bundesanstalt).

COMBIMASS® Flow meter – Types of calibration

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Flow profile irregularities – swirls & pulsations

Built-in devices

• valves

• butterfly valves • control devices • fans ...

Piping

• elbows

• reduction pieces • expansion pieces • T-pieces ...

Deviations/errors of 20% or even more!

COMBIMASS® flow conditioner

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COMBIMASS® SCS-Principle

S wirl reduction

C ross flow conditioning

S moothing /damping of pulsations 1

3 2

COMBIMASS® flow conditioner

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precise measuring results even at unfavourable installation position of the flow meter

flow conditioning after 3 – 7*D only

minimal pressure loss

rugged and unsensitive to dirt

Made in stainless steel – corrosion resistant

available for installation in pipes and rectangular air ducts

available as a flange version or for insertion only

... for excellence in accuracy and measuring certainity

COMBIMASS® flow conditioner

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COMBIMASS® condensate traps for vertical pipe runs

fully made in stainless steel

with integrated condensate removal

for installation in vertical pipe runs

reliable and rugged design

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COMBIMASS® GA-m – The instrument

Standard biogas configuration: 2xIR CH4 0-100%/ CO2 0-100% 2xEC O2 0-25%/ H2S 0-2,000 ppm

Additional gas cells: H2 0-1,000 ppm / CO 0-1,000 or 0-2,000 ppm

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optical infrared analysis

measurement of up to 7 gas components

high performance measuring gas pump

easily exchangeable measuring gas micro-filter

up to 5 sensors plug-in and calibrated

optionally CO and H2-cells available

upgrade to an automatic, stationary analyzer system with up to 13 gas sampling points plus 1 for test gas as well as integrated measurement of flow and data seizure

COMBIMASS® GA-m – Features of the portable instrument

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at different places applicable, data can be stored measuring point-specifically snap

simple operation

rugged technology, maintenance-poor,

simple maintenance

integration of other measurements like gas flow, gas temperature & pressure possible

correction of flow signal by actual gas composition integrated

measuring data recording, PC - evaluation

ATEX certified

COMBIMASS® GA-m – Features of the portable instrument

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data transmission cable and Siteman-software

temperature sensor measuring range: 0 – 100°C

portable COMBIMASS flow meter eco-bio+ (up to DN400 pipe, up to 12,000 Nm³/hr, with integrated humidity correction – gas quality compensation in

the GA-m)

hot tapping unit with quick coupling or small ball valve

pressure controller, if gas pressure is above 30 mbar

filter shall be used in case of water drops in the gas flow

temperature/flow in

gas out

gas in battery charger

COMBIMASS® GA-m – Acessories

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battery pack

external filter

internal filter

electrochemical cells

sampling hose

gas pump

plastic couplings

COMBIMASS® GA-m – Spares and wearing parts

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All analyzer equipment requires service: recalibration, replacement of electrochemical cells, filters, pumps, etc.

Binder offer maintenance contracts with replacement of all usual wearing parts

Binder offers furthermore a „Priority service“ for customers without maintenance contracts (with 12 months new manufacturer´s warranty, except wearing parts)

Binder offers a service case by case (ticketing system for booking in)

For the duration of service/repair Binder offers spare analyzer

COMBIMASS® GA-m – Service, Maintenance and Repair

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COMBIMASS® GA-s Dockingstation with GA-m/ GA-e

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The standardized Docking station contains:

cabinet 400x400 with SPC and display, 24 VDC

required valves etc. for 2 gas sampling points

4 analog inputs for 2x flow and 2x temperature/humidity

1 measuring gas pump on strip

1 flushing valve

1 test gas connectivity

1 cabinet exhaust

gas and rinsing air are feed into the environment

operation over touchscreen or using 6 keys

menus and manuals in several languages available

without analyzer instrument

COMBIMASS® GA-s – Standard configuration

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“2-in-1” solution for easy maintenance: customer gets a spare analyzer and sends the analyzer to Ulm – service at site can be done by a technician or electrician

for GA-m analyzer with CH4/ CO2/ O2/ H2S/ (H2) or GA-e analyzer CH4/ (CO2/) O2/ H2S

can be expanded up to 13 measuring points (in a bigger cabinet)

Furthermore up to 13 flow and temperature/ humidity signals can be read in via DIN-rail modules, flow signals will get compensated automatically by actual gas composition

24 VDC/230 VAC external power supply box

Communication: Ethernet Modbus TCP, Modbus RTU/ RS485, Profibus DP, Analog signals 4-20 mA

COMBIMASS® GA-s – Features

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Gas pre-treatment consisting of coalescence filter, flaming arrestor, pressure controller, gas cooler can be supplied on request

digital outputs for alarm transmission or allocation of the measuring points, if 4-20 mA is used (not for bus transfer)

Data storage alternatively on USB-stick

External gas sensor 0-100% CH4/0-100% LEL with alarms for room control can be implemented

Gas feedback into the process optionally possible (with an additional solenoid valve and if required an additional gas pump)

Implementation of further sensors like pH, rel. humidity (after H2S-filter)

COMBIMASS® GA-s – Features

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common alarm for leakages, over/falling below set points as well as ventilation fault

key to store and protect configuration data

climatized cabinet for outdoor- installation as an option (incl. air cooling/heating and LEL- control of the cabinet)

External access to the analyzer menus via direct Ethernet wiring, internet connection or GSM/GPRS

Additional hard- und software for control of filling level of gas storage tank as well as load-depending dosing of feedstock to the biogas plant (10% savings in feedstock can be expected)

COMBIMASS® GA-s – Features

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A Click! COMBIMASS® cabinet is a fully modular system to provide regular gas measurements from a gas source – with high level of flexibility regarding sampling sequences and frequences, different concentrations, several gas ways. So nearly every task can be solved

The Click! System is modular and is based around the basic cabinet components (PLC with graphic display, pump module, various valve modules, gas modules IR / EC/ WL, LEL, data transfer modules, …)

Each Click! cabinet is a customized unique system with unique software. A full description of the project is required to design the system and calculate a price.

The cabinet should always be installed in the safe zone. It can be inside the container with the CHP.

COMBIMASS® GA-s Click! – The System

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It can indoors or outdoors. They can be wall mounted or free standing.

Autocalibration Check / Autocalibration Function

Only a small part of the sampled gas is used for analysis. The excess gas is fed directly into the environment. So the wear of electrochemical cells becomes less.

All standard data transmission kinds are available: Profibus DP, Modbus RTU, Modbus TCP, 4-20 mA,…

There are 3 general types of gas modules: Infra red: CH4, CO2 Electrochemical cells: O2, H2S, (NH3), CO Heat conductivity: H2, CO (0-30 Vol.-% High Range)

COMBIMASS® GA-s Click! – The System

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All modules can be easily adjusted for the zero point and span by the installer/maintainer to ensure optimum accuracy.

Gas modules require at minimum an annual check/ refurbishment, pump and valve modules should be serviced according to Binder´s recommendations

ensure spare modules available at site, “old” modules can be refurbished at low costs

Remove connections (hoses and wires for Gas IN , Gas OUT, Power supply, AO) and click out old module - click in replacement module and reconnect hoses and wires

Binder will refurbish the module and send it back to you/your customer for stock

COMBIMASS® GA-s Click! – Service and maintenance

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The Click! system can measure for a long time usual concentrations of gas components very precise (using auto calibration check or function)

but still it is a “field” instrument

problem: precise measurements of very low concentrations

example biomethane: H2S 0-2 ppm, NH3 0-2 ppm

this task can be solved by gas chromatography only

COMBIMASS® GA-s Click! – Technical limits

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Installation Examples Biogas Flow Meter and Analyzer

Flow metering and Analysis of Biogas: Digester / Flare / H2S-Filter-Control / Control of gas quality in front of the CHP/ Gas2Grid – biomethane into natural gas grid

Flexible Solutions for co-fermentation plants, solid waste / composting plants

Anaerobic pre-treatment of industrial sewage

Flow metering and Analysis of digester gas from WWTP´s

Flow metering and Analysis of landfill gas

R&D projects

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Reduction of C-Load of industrial effluent

Production of process heat and energy

Reduction of energy costs for biological sewage treatment in the own plant / reduction of BOD-load in the effluent

Reduction of costs for sludge treatment and storage

combined gas flow metering and analysis

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Application Biogas Plant:

Typical installations: Gas flow metering and analysis of each single digester, in front of the flare, in front of the CHP, H2S-filter control

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Examples – Biogas Gas from anaerobic digestion of manure, crops etc., DE

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Examples – Biogas Gas from anaerobic digestion of manure, crops etc., DE, IT

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Control of gas quality and flow in front of CHP´s

Control of H2S-concentration/ Removal to reduce costs for wear and increase maintenance time cycles

Control of the CHP-efficiency factor

Reduction of costs for insurances

Typical installation: Gas flow metering and analysis with calibration function for gas cells with testgas

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Examples – Use of Biogas, Digester Gas or Landfill Gas, DE

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Gas-2-grid Installations – Feed of biomethane to the natural gas grid

Typical installation: gas flow metering and analysis to control each step of treatment (H2S-removal, CO2-Reduction, Removal of moisture, pressure increase)

Special requirements: high accuracy and repeatability (use of flow conditioners, special calibration of flow meter, (auto)calibration of gas cells)

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Examples – Upgrade of Biogas to Biomethane, DE

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Flexible Solutions for Co-Fermentation plants, solid waste treatment/ composting plants

- Use of the Click! system for advanced requirements for flexibility, availability and further special features

- Typical installations: Gas flowmetering and analysis with autocalibration check/function for gas cells with several test gases

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Examples – Various installations of GA-s Click! Systems, U.K.

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Hydro- lyse 1

Fer-menter

1

Hydro-lyse 2

Fer-menter

2

1 Cogene-

rator

2 3

4 5

GA-s Click !

Sampling Cycles: 1. Gas 1:CH4/ CO2/ O2/ H2S/ NH3 - every 120 minutes 2. Gas 2:CH4/ CO2/ O2/ H2S/ NH3 - every 12 hours 3. Gas 3:CH4/ CO2/ O2/ H2S/ NH3 - every 12 hours 4. Gas 4:CH4/ CO2/ O2/ H2S/ H2 0-30% - every 24 hours 5. Gas 5:CH4/ CO2/ O2/ H2S/ H2 0-30% - every 24 hours

Examples – Co-Fermentation plant (crops + old food), BE

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Examples – Co-Fermentation plant (crops + old food), BE

Gas Flow Scheme and Cabinet Layout

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12 Boxes for acidification and one further tank for methanezation 12 sampling points for the boxes and 3 further sampling points in collection pipes in front and after the methane reactor, after H2S-filter incl. 3 gas flow meter

Examples – 2-stage solid waste and composting plant, NL

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General data transfer: Profibus All Menues on the PC-Screen in the control room 12 Boxen shall be analyzed every 15 minutes “Quick sampling” every 5 minutes for actual open box Sampling points 13 to15 up to 150 m away from cabinet

Examples – 2-stage solid waste and composting plant, NL

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Examples – 2-stage solid waste and composting plant, NL

Gas Flow Scheme and Cabinet Layout

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Examples – 2-stage solid waste and composting plant, NL

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Examples – Solid waste digestion plants, DE

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Typical installations: Food indsutry like breweries. Juice production, dayries, cheese production, production of raw materials for food industry, …

Cheese production France

Examples – Anaerobic Pre-Treatment of industrial sewage, FR

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Examples – Anaerobic Pre-Treatment of palm oil effluent, MY

Place of installation: Malaysia Official governmental test plant

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Examples – Anaerobic Pre-Treatment of palm oil effluent, IN

Place of installation: Indonesia Customer: Palm Oil Manufacturer

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Gas from SP “1, 2 and 3” are situated directly after the digester (raw biogas), “4” is gas coming from hydrolysate tank, “5” is gas sampled after the H2S-removal and “6” after the gas storage tank in front of the cogenerator. H2S-level in the raw gas can be up to 3,000ppm, but “5 and 6” may be expected to have H2S up to 100ppm. In order to be able to measure each level of gas precisely, each gas stream would need to be measured with a different range of H2S module.

air

Desul-phuri zation

Gas storage tank

Cogeneration

SP1 SP2 SP3 Flow 1 Flow 2 Flow 3

SP5

SP4 Flow 4

SP6 Flow 5

Hydrolys. Digester 1 Digester 2 Digester 3 Tank post f.

Examples – Anaerobic Pre-Treatment of palm oil effluent, IN

Measuring sequences:

1. Sampling point 1-5: CH4/ CO2/ O2/ H2S - every 60 minutes

2. Sampling point 6: CH4/ CO2/ O2/ H2S - every 30 minutes

3. Calibration gas 1: 60% CH4/ 40% CO2/ 3,000 ppm H2S every 72 hours autocalibration

4. Calibration gas 2: 100 ppm H2S/ 100% N2 every 24 hours autocalibration

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Examples – Anaerobic Pre-Treatment of palm oil effluent, IN

Gas Flow Scheme and Cabinet Layout

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Application Wastewater Treatment Plant - Digester

Reduction of external supply of electrical energy due to digesting and incineration of sludge

Installation of gas flow meter and analyzer closed to the digester, in front of the CHP, in front of the flare, control of gas treatment (H2S-filter)

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Examples – Digester Gas from sewage treatment plants, DE

Typical installation places are: directly after the digester in front of the flare in front and after the H2S-filter in front of the CHP

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Examples – Digester Gas from sewage treatment plants, DE

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Application Landfill

Gas flow metering and analysis of single boreholes and in collection pipes

energy and heat production reduces operations costs

typical installation: portable flow meter and handheld analyzer for boreholes and fields, Dockingstation „2-in-1“ for analysis of gas in collection pipes

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Examples – Gas from a landfill, DE

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Application R&D Projects

Gas flow metering and analysis to achieve highest accuracy and repeatability

Investigation of gas production of various feed stocks etc.

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Combination of gas flow metering and analysis for best accuracy (gas com position unknown and changes in time)

Examples – R&D project „hygienization“, DE

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Thank you for your attention! Any Questions? Manuela Charatjan Manager Process Engineering Binder GmbH 89187 Ulm Buchbrunnenweg 18 Germany manuela.charatjan@bindergroup.info www.bindergroup.info