Combustion Engineering

LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG
Ceramic Gas Sensors for
Optimisation of Combustion
Processes
Dr.-Ing Frank Hammer

Outline
› Overview of LAMTEC
› Sensor Technology
› Manufacturing Technology
› Combustion Optimisation
› Application
› Summary
› References

Overview of LAMTEC - Company Profile
› LAMTEC Sensors and Systems for Combustion Engineering (LAMTEC
Meß- und Regeltechnik für Feuerungen GmbH & Co. KG)
Wiesenstraße 6, 69190 Walldorf, Germany
› Established: 1st Juli 1995 as MBO from ABB
› Shareholders: Dipl.-Ing. Hans-Jürgen Altendorf, Dipl.-Ing. Bernd Jülg, Dipl.-
Ing. Harald Weber, Olaf Winne
› Subsidaries/ Associated Companies:
• LAMTEC-Leipzig GmbH & Co. KG, Germany (100%)
• LAMTEC EA Buchon EA Buchon South Korea (80%) Jan. 2006
• LAMTEC Poland
• LAMTEC SEA Ltd. Kuching Malaysia (2010)
• OOO LAMTEC Moscow (2012),
• Escube GmbH & Co. KG Stuttgart, Germany (100%)
› Employees: 100 (2 trainees)
› Turnover 2013: 14.3 Mio. €

Overview of LAMTEC - Locations
Headquarter Walldorf LAMTEC EAST ASIA Ltd.
Buchon, South Korea
LAMTEC Leipzig
Development of hard- and software
Manufacture of flame scanners
LAMTEC Neu Anspach
Development of electronics

Overview of LAMTEC - Products/Applications
LAMTEC
Products/Applications
Customers
Electronic burner
control system
Fuel-/air ratio control
IR/UV
Flame monitoring
system
Process and fault
indicator system
O2 measurement devices
Option:
Detection of non-burned
CO/H2
Boiler manufacturer
Plant manufacturer
Measurement device
manufacturer
Burner
manufacturer
Industry
Applications:
Power plant/waste combustion
Chemical industry
Industrial application
Measuring- and control technology
Research facilities and development

Overview of LAMTEC - Sales Partner

Overview of LAMTEC - Product Range
Burner Control
Electronic Fuel-/Air Ratio Control
Volume Flow Measurement
Flame Detection
O2 Optimization
O2 Measurement
CO/O2 Monitoring
Process and Fault Indicator System
Product Range

Sensor Technology – Non-Nernst Principle
Design of a CO measurement cell
Non-Nernst Sensor Voltage
cathode
Ad. phase:
Gas phase: pO2=21%, pCO=1%, (Rest N2)
O2,ad= 99%, COad= 1%O2,ad= 90%, COad= 10%
US
Solid Electrolysis









Aad
Kad
CO
CO
S
C
C
F
T
U
,
,
ln
2

Sensor Technology – The Sensor Voltage
› Langmuir adsorption isotherm
• monomolecular adsorption layer
• ads./des. in stationary state condition (SS)
› US is a function the coverage of anode and cathode  A,  K
• KA=KK :identical reaction kinetics SS-constants through
identical reactions (TE=TK=TS, one measurement
element)
• Dg ad,A  Dg ad,K :Comparison of Gibbs enthalpies through similar
adsorbents/adsorbate binding strength (identical basic
materials of electrodes on three phase boundary, alloy of
two phase layer for modification of adsorption on the
anode)


















DD











AK
AKKadAad
K
A
S
S
S
T
gg
F
T
U
)1(
)1(
lnln
2
,,

D








 S
ad
ad
T
g
CO e
K
c (
1
1

Sensor Technology – The CO Sensor
Characteristics of
Sensor
› planar
› multi-layer
› miniaturised
Functions of Sensor
› Solid electrolyte
› Non-Nernst principle
› electrocatalytic
electrode
Carrier substrate
3,5
20
t=0,6
Contact
point
Zirkonia
Heating coil
Glass cover
Electrode 1 Electrode 2

Manufacturing Technology – Thick Film Technology
Screen process
engineering:
› flexible
› cost-efficient
› reproducible
› mass producible
squegee
Screen
jump
screen
tension
screen
squegee
angle
pressed
thick film
screen printing pastecarrier substrate

Manufacturing Technology – Raw Materials
Sensor materials
› Al2O3-carrier substrate
› YSZ-functional ceramics
› Pt-heating coil
› Pt cathode/Pt-alloy anode
› Special glass cover
Innovative aspects
› laser technology
› hybrid layer technology
› sub- and nano-powder
› ceramic printing pastes
Solution
II
Solution
III
Solution
IV
printing
Medium
Solution
V
paste
HO
destilled
2
Solution
I
stir 400 U/min
25 °C
400 U/min
60 °C, 5 min
400 U/min
25 °C, 2 min
400 U/min
25 °C, 2 min
400 U/min
25 °C, 2 min
400 U/min
25 °C, 2 min
Cool down
500 U/min
65 °C, 45 min
100 Umin
25 °C, 60 min
Solution
V
Binder I
Plasti-
cisers
Disperging
agents
Binder II
Defoamer
Ceramic
powder
Moisturi-
zers
screen
printing
Screen
stir
stir
stir
stir
stir
stir

Manufacturing Technology – Process Optimisation
Simplification of the
production steps through
› Co-firing which is used in
the multi-layer process of
the manufactured
sensors
A decrease in
› Production steps
› Production time
› Tempering processes
› Sintering time
› Energy costs
› Manufacturing costs
Production chains with integrated process controls
co-firing
Printing Electrode 1
Drying
Printing Electrode 2
Check/Testing
Drying
Printing heating oil
Drying
Printing YSZ-Ceramic
Presintering
Paste preparation
Ventilation
Portioning
Positioning
Screen /SMD moulding
Cleaning of substances
Mechanism
Positioning
Carrier substrate
Cleaning of substances
Degreasing
Positioning
Activation Electrode 2
Preliminary test
Hard machining
Final testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing
Check/Testing Check/Testing Check/Testing

Manufacturing Technology – Sensor Optimisation
Thermal analysis
› instationary heating performance
› stationary temperature distribution
› stationary voltage distribution
 optimal sensor geometry
Thermography measurement
› comparison between theory and practice
› calculation of the sensor temperature TS
from the electrical operating data Rh
 optimal operating temperature
500
600
700
800
900
13 15 17 19 21 23 25
y = 0.7673x2
+17.139x+ 76.959
R2
= 0.997
c)
Heating resistor Rn in Ω
SensortemperatureTsinK

Application – The Sensor System
Sensors / Housing
› small (< 3W)
› robust (> 3 Jahre)
› temperature stability (< 200°C / 500°C)
› cost efficient (< 15€)
› fast (< 1s)
Elektronics (exaple)
› supply unit 14-20 V
› temperature control
› signal processing
› analogue outputs 0-10 V or 0/4-20mA
› relay outputs

Application: Combustion Technology
Today: Combustion Systems
› Fossil fuels
• Limited resources
(coal, gas, oil)
› Pollutant emission
• CO, NOx, CO2 etc.
› Danger: Global warming
Monitoring and Control of
Combustion Systems
Tommorow: Fuel Cells
› Chemical reacting agents
• Unlimited resources
(H2+ atmospheric oxygen)
› Pollutant emission
• No
› Potential for damage: H2
Safety Monitoring of
fuel cells and hydrogen
infrastructure

Application – Combustion Characteristic
Pollutant makers
› Traffic
› Industry
› Household and small-sized
burners
Existing sensor systems
› Automobile:  probe
› Industry:  / flue-gas probe
› Small-sized burners:
not available!
 Development of
miniaturised CO-Sensors
for combustion optimisation
CO
CHnmRuß
0.1 0.2 0.4 0.6 0.8 1 2 4 6 8
1,911,301.031.005
Incomplete
combustion
Flue gas
heat loss

Ruß,CO,CHnm
efficiency
Emissionedge
Combustionfuels

Application – Combustion Regulation
Combustion Control
increases
› The operational range
› reliability of operation
› safety
Combustion Optimisation
› increases the efficiency
› lowers fuel consumption
› Minimises pollution
S2
S1
Processor
Air
Fuel
Burner
Flue gas
channel
Exhaust air
Probe
Electronic control
Combustion
chamber

Sensor element Status: series
Function tested in oil, gas and solid fuel firings since 1999
Production more than 20.000 pieces since 2002
Reproducibility
Heater side
Sensor side
9±1, requirements are fulfilled
requirements are fulfilled for combustion optimisation
Field tests no blackouts of the sensor element since March 2002
Life time tests tests in oil and gas since Mai 2003, two peripheral blackouts,
tests go on
Price now: 250€ per piece; goal: 5-10€ per 100.000 piece
Summary – State of the Art

Housing: Status: „series“
Function around 2000 housings in operation (three different types)
Production
Integration
standard
high temp.
experiences with series:
without problems
up to 200°C, condensing atmospheres
up to 450°C, condensing atmospheres
Life time tests tests in gas and oil since Mai 2003, two blackouts, problems
solved, tests go on
Price now: 250€ per piece; goal 3-6€ per 100.000 pieces

Electronics Status: series
Function around 1000 units in operation since Mai 2003
Development Feb. 2003: prototype
Mai 2003: pre-series
Oct. 2003: redesign pre-series
March 2004: zero series
Life time tests no blackout since Oct. 2003
Price 500 € per piece

Field tests (excerpt)
electronics
Status: „ pre-series with demonstrator
Burner Boiler Testing site Testing time
Oil, blue flame Buderus LAMTEC/Odenheim since Sept.
2002
Oil, blue flame Viessmann VITO/Belgium Jan.-Feb. 2002
Oil, blue flame Rotex HLK/Stuttgart Jan. 2003
Gas, atmospheric Senertec VITO/Belgium Jan.-Feb. 2002
Gas, atmospheric Klöckner LAMTEC/Walldorf since Dec.1999
Gas, condensing Bosch Junkers HLK/Stuttgart Feb. 2003
Gas, condensing Buderus LAMTEC/Reisen since Aug. 2002
Gas, condensing Buderus LAMTEC/Östringen March 2004
Bio mass Hoval CSEM/Switzerland Feb.-March
2001
Bio mass Brunner FH Karlsruhe/KarlsruheSept. 2003

References – Long Term Measurement
Endurance test over 11 months
› identical
characteristics
› no identifiable
deterioration
› sensitivity increases
slightly

References – Sensors in Application (1)
Front view of a dual boiler 50-1.000kW
› 16 CarboSen1000 sensors
were tested:
• in condensing flue gas
Tmax = 80°C
100% condensation !
• directly in the combustion
chamber
Tmax = 600° !!
No condensation !
Sturzbrenner

Mounting position in the condensing flue gas channel
› 4 CarboSen1000, plugged in
› 4 CarboSen1000, hanging
› 1 Lambda probe, plugged in

Mounting position in the hot incinerator
› 1 CarboSen1000
immersion probe

CarboSen
27

CarboSen
Miniaturised Sensor for Detection of Non-burned (CO/H2)
in Combustion Exhaust Gas
28

CarboSen
29

Measurement Principal of CarboSen1.000
30

CarboSen
Sensor Assembling
› 11 layers incl. carrier
› Measure: 20mm x 3,5mm x 0,7mm
› Material: ceramics, glas, platinum, gold
• Thermally and chemical robust
› Production in thick and thin film process
• Cost-effective, suitable for mass market
31

CarboSen
Characteristic
0
20
40
60
80
100
120
140
3000 3010 3020 3030 3040 3050 3060 3070 3080 3090 3100
Zeit in s
UseninmV
0
50
100
150
200
250
300
350
400
450
500
COreferenzinppm
U Sen 01 in mV
U Sen 02 in mV
U Sen 03 in mV
CO MRU in ppm
32

Test Plant of Oil-Blue Burner
Qualification or reference measurement in
pipe of oil-blue burner
4 CarboSen1.000 in flue gas pipe
Reference
System (KS1D)
33

CarboSen1.000ST
34
Characteristics:
› Measurement of COe directly in humid flue gas up to 150°C, also condensing
› No reference air necessary
› Protection class IP67
Applications:
› Natural gas, fuel oil EL

CarboSen1.000
35
Characteristics:
› Measurement of COe directly in humid flue gas up to 400°C
› Elektronic is integrated in sensor head
› No reference air necessary
› Protection class IP67
Applications:
› Natural gas, fuel oil EL, pellet, piece wood

Thank you for your attention
Questions?

Contact:
Steven Craig – President, Hays Cleveland
Phone: (216) 398-4414
Fax: (216) 398-8558
E-Mail: scraig@unicontrolinc.com

Combustion Engineering

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