Proposal program - HVG-DGG

DRAFT SECOND ANNOUNCEMENT
& REGISTRATION
Advanced Sensors & Process Control
in High Temperature Processes
Glass, Cement, Steel and Ceramic Industries
4.-6. October 2010
Maastricht, The Netherlands
Crowne Plaza Hotel
GlassTrend in co-operation with the International Commission on Glass (ICG), Deutsche
Glastechnische Gesellschaft (DGG), Agentschap NL, TNO and the National Committee
Netherlands Glass industry (NCNG) will organize a 2-days workshop on development of
sensors and measuring systems for high temperature processes in Maastricht, the
Netherlands.
The first full day – Tuesday 5. October, addresses technical and scientific papers on
developments of sensors and process control systems for processes in glass, ceramics,
steel/metal and cement industry. Currently available sensors and control systems will be
presented and the application and benefits of such sensors and process controllers are
discussed.
Sensor applications in glass, ceramics, cement and steel industries and future needs for
sensors are addressed.
Sensor development for characterization of melts, flue gas and combustion sensors,
sensors for raw materials and process control will be discussed
The focus is on sensor application to improve:
Energy efficiency of the production processes in these industries;
Combustion processes with respect of minimizing NOx, CO and CO2 emissions;
Quality of the production process (glass quality, cement chemistry, metal/steel
purity, ceramic composition and quality)
Stability of the production process, e.g. to avoid conditions that jeopardize
furnace lifetimes.
Experts from sensor companies, universities, and process industries will be invited to
present papers (5. October), showing the state-of-the-art of available sensors and the
application of sensors in production processes.
The second day (Wednesday 6. October) of the workshop will address the future needs
and directions for development of new sensors and integration of sensors and
measuring systems for process control in high temperature processes. The outcome of
this day will be a priority list of sensors that should be developed to improve the level of
control in the process industry and to initiate process control strategies to be developed.
The conclusions may serve as a starting point for a roadmap on sensor and process
control development for high temperature processes in the coming period 2010-2020.
Please make reservations in your agenda for 4.-6. October 2010!!
This announcement includes the program for 4.-6. October, registration forms, and the
foreseen titles and authors of the presentations. Hotel room reservations should be
arranged by each participant individually. Hotel recommendations are given in this
announcement.
The registration fee is 300 EURO per person, registration includes reception, conference
dinner, lunches, participation in the seminar and panel discussion sessions on road
mapping of sensor & process control development, and registration will give you access
to all power point presentations. Registration deadline: 15. August 2010.
On Monday afternoon, the TC15 (Sensors & Advanced Control) of the International
Commission on Glass (ICG) meets prior to the conference: 13.30-15.15 o „clock.
The semi-annual GlassTrend council meeting takes place on Monday 4. October at
15.30 hours in the conference hotel. The agenda for the council meeting will become
available for GlassTrend members.
Info requests: [email protected]
Registration form SENSOR & PROCESS CONTROL SEMINAR, 4.-6. October 2010
at Crowne Plaza Hotel in Maastricht, the Netherlands
Please send completed form to: [email protected]
Conference Registration fee: 300 EURO per person
(Glass Trend members – 2 persons per company & Invited Speakers enjoy waived fees)
Name:…..…….……………………..………........................................................Mr./Mrs.
Company:………….………………………………………………………………………............
Address company: ………….…………………………… ……………………………………...
………….……………………………………………….............................................................
E-mail address:
…………………………….
Telephone number:……………………
VAT number of your company: ………………………………………………
Purchase Order number:…………………………………………………………………….
Is your company Glass Trend member: YES / NO (circle correct answer)
Indicate here the meetings that you want to attend:


4 – 10 - 2010
-annual GT council meeting
4 – 10 - 2010

5 & 6 -10 - 2010
Block reservations have been made in the following hotels, 4. – 6. October 2010.
We kindly request you to take care of your own hotel accommodation, but
mention the KEYWORD: “SENSOR SEMINAR” upon reservation:
Hotel option 1: CROWNE PLAZA (Conference hotel)
If you would like to make hotel reservations in the Crowne Plaza Hotel Maastricht
please use THE REGISTRATION FORM OF CROWNE PLAZA HOTEL (SEE ANNEX)
Hotel option 2: Hotel Van der Valk Maastricht (2-3 km from conference hotel):
One overnight stay for one person will cost EUR 102,50 inclusive breakfast.
Hotel Option 3: Golden Tulip Apple Park Maastricht (3 km from conference hotel):
One overnight stay for one person will cost EUR 108,50 inclusive breakfast.
Hotel option 4: NOVOTEL Maastricht (2-3 km from conference hotel):
One overnight stay for one person will cost EUR 92,00 inclusive breakfast.
* Special food wishes: ………………………………………………………………………
Please send this form back by email or by fax: +31 40 265 08 50
before 15. August 2010 [email protected]
Hotel information
Crowne Plaza Hotel Maastricht (conference
location)
De Ruiterij
6221 EW Maastricht
The Netherlands
Tel.no.: + 31 43 35057/59
Fax no.: + 31 43 3509194
www: crowneplazamaastricht.com
Hotel Van der Valk Maastricht
Nijverheidsweg 35
6227 AL Maastricht
Tel.no.: + 31 43 - 387 3500
Fax.no.: + 31 43 – 387 3515
www.hotelvandervalkmaastricht.nl
Hotel Van der Valk is located on approx. 2-3
km from the conference location.
Golden Tulip Apple Park Maastricht
Pierre de Coubertinweg 3
6225 XT Maastricht
Tel.no.: + 31 43 352 90 00
Fax.no.: + 31 43 352 90 01
www.applepark.nl
Hotel Golden Tulip Apple Park Maastricht is
located at approx. 3 km from the conference
location
NOVOTEL Maastricht
Sibemaweg 10
6227 AH Maastricht
Tel.no.: +31 43 3611811
Fax.no.: +31 43 361 6044
www.novotel.com
Novotel Maastricht is located at approx. 2-3
km from the conference hotel.
OPTION 1 HOTEL REGISTRATION CROWNE PLAZA
Provisional Program
Workshop & Seminar: Advanced Sensors & Process Control High Temperature Processes.
Monday, 4. October 2010, Maastricht NL (Crowne Plaza Hotel Maastricht)
Hotel Crowne Plaza Maastricht, De Ruiterij, 6221 EW Maastricht, The Netherlands
Time
13.30-15.15
ICG-TC15 meeting, chair person Wilfried Linz (a simple lunch can be
provided to the TC15 attendees on request)
15.30-17.45
GlassTrend Council meeting, chair: Ruud Beerkens, program / agenda
will become available for Glass Trend members
18.30-20.15
Welcome Reception in Crowne Plaza Hotel Maastricht
Tuesday, 5. October 2010, Maastricht NL (Crowne Plaza Hotel Maastricht)– first draft,
see provisional program of papers on the next page
8.40-9.00
Welcome and Introduction
9.00-10.55
Session 1
10.55
Break
11.20-14.25
Session 2
12.45-14.00
Lunch
14.25-16.20
Session 3
15.25
Break
16.20-18.00
Session 4
19.00
Leave for conference dinner
19.30-23.00
Conference Dinner
Applications of Sensors in High Temperature Processes
(4 papers)
Sensors for Melts (4 papers)
Sensors for Combustion and Flue Gases (3 papers)
Other Sensors & Process Control (4 papers)
Wednesday, 6. October, Maastricht NL (Crowne Plaza Hotel Maastricht)
8.30-9.45
Summary and main conclusions sensor seminar
Presentation on future of Model-Based Predictive Control for Industrial
Processes, By Prof. Dr. Ir. Ton Backx,
Eindhoven University of Technology, Eindhoven, The Netherlands
9.45-11.00
Panel discussion – with moderator
11.00
Break
11.20-12.40
Future developments for sensors in High Temperature Processes
12.40-13.50
Lunch
14.00-14.45
Concluding remarks – roadmap for advanced sensors & process control
2010-2020
14.45-18.00
Option: Excursion
Tuesday 5, October 2010, Maastricht NL – first draft provisional program of papers
8.40-9.00
Welcome and Introduction
9.00-10.55
Session 1 Application of Sensors in High Temperature Processes
(chair: Ruud Beerkens)
Overview of needs for sensors in the glass industry
Wilfried Linz, Schott AG, Mainz, Germany
To be confirmed: Sensors in the steel industry, new developments & applications
Hans Pronk, CORUS, IJmuiden, The Netherlands
Inventory of sensors applied in industrial high temperature processes
Erwin Engelaar, Ruud Beerkens, TNO, Eindhoven, The Netherlands (NL)
Mobile Sensors for Process Parameters in Tunnel Kilns for Ceramic Product
Firing, Drs. ing J.C. Marks, Stichting Technisch Centrum voor de Keramisch
Industrie (Technical Centre Foundation Ceramics Industry), Velp, NL
9.00-9.25
9.25-9.55
9.55-10.25
10.25-10.55
10.55-10.20
COFFEE BREAK
11.20-14.25
11.20-11.45
Session 2 Sensors for melts (chair: Hayo Müller-Simon)
Ultrasonic sensors for high temperature melts (glass, metal, silicon)
AnneJans Faber, TNO, Eindhoven, The Netherlands
Electrochemical sensors for glass melts
Hayo Müller-Simon, HVG, Offenbach, Germany
On-line electrochemical sensors for the glass industry
Paul Laimböck, READ-OX, Valkenswaard, The Netherlands
11.45-12.15
12.15-12.45
12.45-14.00
LUNCH
14.00-14.25
LIBS based sensors to observe the glass production process
Bernhard Fleischmann, HVG, Offenbach, Germany
14.25-16.10
Session 3 Sensors for Combustion & Flue Gases
(chair AnneJans Faber)
Fiber optic sensors for process control
Wolfgang Schade, Fraunhofer Heinrich-Hertz-Institut + TU Clausthal,
Faseroptische Sensorsysteme, Goslar-Clausthal, Germany
Laser optic systems for in-situ analysis of gas species in process gases,
combustion spaces and flue gases & glass ceramics detection in cullet by hyper
spectra-imaging
Peter Kaspersen, NEO, Oslo, Norway
14.25-14.50
14.50-15.30
15.30-15.55
BREAK
15.55-16.20
Energy Savings by (Natural) Gas Chromatography,
Dr. Stefan Malcharek, Siemens Process Analytics, Product Marketing Gas
Chromatography, Siemens AG, Karlsruhe, Germany
16.20-18.00
Session 4
16.20-16.45
16.45-17.10
17.10-17.35
17.35-18.00
Other Sensors & Process Control
(chair: Wilfried Linz)
To be confirmed: Combustion control for high energy efficiency and Low NOx
emissions.
Peter Hemmann, SGT, Cottbus, Germany
Application of soft sensors and process control based on dynamic glass furnace
simulation models
Leo Huisman, Piet van Santen, TNO, Eindhoven, The Netherlands
Moisture measurement for raw materials in glass, cement and ceramic
industry
Mirande Wolvekamp, ACO Automation Components, The Netherlands
To be confirmed: Infrared sensing of furnace walls to control temperatures of
ovens & kilns
19.10
Leave for conference dinner from Crowne Plaza Hotel, Maastricht
19.30-23.00
CONFERENCE DINNER IN BONBONNIERE
Achter de Comedie 1 6211 GZ Maastricht
ABSTRACTS (not complete)
ADVANCED SENSORS & PROCESS CONTROL IN HUIGH TEMPERATURE
(INDUSTRIAL) PROCESSES
4.-6. October 2010
Maastricht
Mobile sensors for process parameters in tunnel kilns for ceramic product firing
Drs. Ing J.C. Marks
Stichting Technisch Centrum voor de Keramisch Industrie
(Technical Centre Foundation for the Ceramics Industry), Velp, the Netherlands
www.tcki.nl
In the ceramic industry, tunnel kilns are often used for the firing of green units (clay
based) to produce ceramic products (e.g. bricks, roof tiles etc.). These tunnel kilns are
between 5 m and 9 m wide, the length range is between 100 m and 200 m, and these
kilns have an internal height of between 0.5 m and 2.0 m. The products are moved
through the tunnel kiln on kiln cars covered with refractory material, whereby the total
time that the products remain inside the kiln varies from 50 hours to 150 hours. On its
way through the kiln, the temperature of the products rises from ambient temperature up
to 1250 °C in the middle of the kiln. After passing the hottest zone, they are cooled down
to approx. 50°C. The temperature beneath the kiln cars increases from ambient
temperature to a maximum of 150°C.
Until now, the temperatures of the kiln gases and in the piles of green units stapled on
the kiln cars have been measured by inserting long thermocouples upwards through the
kiln cars to the place where measurements need to be made. Beneath the kiln car, each
thermocouple is connected to a heat-resistant data acquisition system. These data
acquisition systems are fitted with heat-resistant electronics and batteries, in
combination with extensive insulation and a water-bath buffer, which slowly evaporates,
thereby cooling the instruments.
In addition to measuring the temperature profile in kiln gases and the product load, there
is also a need to be able to measure the air pressure and the atmospheric composition
along the length of the kiln. If modified appropriately, the same data acquisition system
may be able to register other basic signals (e.g. for CO, CO2 or O2).
In order to be able to measure air pressure profiles, we need to find pressure sensors
with a measurement range from -250 Pa to + 250 Pa, and which are sufficiently heatresistant and that can be fitted to a heat-resistant external battery supply with sufficiently
long operation time.
With regard to the measurement of atmospheric composition, the first need is to be able
to measure O2 (0-21%) and CO/CO2 (0-10 % / 0-20 %) in the kiln atmosphere when the
kiln cars travel through the kiln. CO measurements are needed to be able to identify
undesired (local) reducing conditions. In addition, when reducing conditions are
desirable, it will be possible to determine where and to what degree these conditions
occur. To accomplish this, the measurement system needs to be sufficiently heatresistant and to be fitted with a battery power source that lasts long enough to be able to
measure the entire firing curve.
Keywords: mobile sensing units, temperature sensoring, gas analysis, ceramics, kilns,
process control tunnel kilns
Electrochemical sensors for glass and metal melts
Hayo Müller-Simon
Research Association of the German Glass Industry (HVG)
Siemensstraße 45, 63071 Offenbach, Germany
Potentiometry and ampèrometry sensors can be used in order to measure
concentrations of some elements in glass and metal melts. Industrial applications of
such sensors in the glass production are the measurement of oxygen and sulfur in glass
melts as well as the measurement of oxygen in the tin bath of the float glass production.
A very recent development is a sulfur sensor for the tin bath of a float chamber. The
technical properties, control models and benefits of such sensors will be discussed.
Keywords: Oxygen, polyvalent ions, sulfur, in-situ analysis melts, glass, tin
On-line electrochemical sensors for the glass industry
Paul Laimböck, Read-Ox B.V., Valkenswaard, NL, [email protected]
A survey will be presented on the various on-line sensors which are, or have been
developed by Readox, or which are regarded as potentially interesting for future
development. These electrochemical sensors are all based on a potentiometric,
voltammetric or amperometric measuring principle. Design, application and merits will be
discussed.
The oxygen activity sensor for the glass melt is used for on-line redox control, especially
in industrial glass production furnaces melting a high share of recycling cullet or furnaces
producing a glass product with a very narrow color specification. Investigations in the
past showed that by adding an extra electrode to the glass melt redox sensor it may be
used to perform square wave voltammetry. With this voltammetric technique multivalent
elements such as sulfur, iron and chromium can be on-line measured in the glass melt in
the feeder channel.
The oxygen sensors for the tin bath are used to measure the oxygen content of the
molten tin and atmosphere in the tin bath in float glass production lines. Surface defects
such as bloom, tin pick up and tin dripping can be reduced by monitoring and control of
the oxygen activity. Moreover, the sensors can be used as a fast alarm for air leaks in
side wall sealing joints or leaking water-cooled devices. Presently, a combined oxygen
and hydrogen sensor is being developed for both the atmosphere and molten tin. With
this sensor, pO2, pH2 and pH2O (dew point) can be monitored simultaneously.
Drawback of potentiometric sensors is that their output signal is proportional to the
logarithmic of the concentration of the species to be measured. For this reason Readox
is developing amperometric oxygen and hydrogen sensors for the gas atmosphere.
These sensors have a linear output signal with the specie concentration, making them
more suitable to measure practical ranges such as 0.1 to 5% oxygen (combustion
spaces) or 0.5-10% hydrogen (tin bath atmosphere).
Keywords:
On-line
sensor,
oxygen
pressure,
oxidation
state,
potentiometry,
amperometry, voltammetry, water vapor, oxygen, hydrogen, sulfur, iron, glass melt, tin
bath, furnace atmosphere
Energy Savings by (Natural) Gas Chromatography
Dr. Stefan Malcharek
Siemens Process Analytic, Product Marketing Gas Chromatography
Siemens AG, Karlsruhe, Germany [email protected]
Summary: This paper explains the advantages of the determination of the Calorific
Value of natural gas and how to use this to improve the efficiency of glass furnaces.
Following questions will be answered in this paper:
Why to use online analytics?
Why do we need to know the Calorific Value of natural gas?
What are the customer benefits?
What is the expected Return on Investment?
Do you need specially trained people?
What is unique about the Siemens solution?
Where has this solution been applied?
Keywords: glass production, gas analytics, process analytics, gas chromatography,
energy savings, furnace optimization, natural gas quality
Product Briefing Outline: More than 50 years of experience and continuous\innovation
have led to SITRANS CV, a unique online Process Gas Chromatograph (GC) that can
be installed in the field to determine the Calorific Value of Natural Gas.
Problem: In general, around 75% of the energy for glass manufacturing is used in the
melting process and natural gas is commonly used as fuel to heat the furnace.
The quality of the natural gas will have an effect on the efficiency of the burners. Gas
suppliers guarantee the gas quality within specified limits, but even the fluctuations
within these limits have an impact on the burning efficiency.
Solution: By monitoring the natural gas quality online, the process control system can
adjust the burners accordingly and sorely reduce the gas consumption.
An important parameter in the analysis of natural gas is determination of the calorific
value from the chromatographic analysis, which is essential for monitoring the delivered
quantity of energy.
For this purpose, Siemens developed the SITRANS CV gas chromatograph. Siemens
can look back on 50 years of experience in process gas chromatography for the analysis
of different gas compositions and the SITRANS CV is the latest development. It is based
on the high performance Micro Electronical Mechnical System (MEMS) technology and
the unique multiple and inline analytical functions open up new possibilities and provide
shorter analysis times.
From the measured concentration of gas components, SITRANS CV calculates the
superior and inferior calorific values, standard density and Wobbe index according to
different standards like ISO, GOST and AGA 8 in a very accurate and fast way. The
calorific value is updated every 150 seconds and the burners are always supplied with
the exact amount of gas, significantly reducing the energy consumption and the gas bill.
In addition, the combustion process and the temperature become more stable and this
improves the life time of the furnace and the quality of the glass.
Advantages: Cost reduction is obviously the main driver for this solution, but in addition,
this solution offers additional advantages. Because of its rugged and compact design,
the analyzer can be installed in the field without a shelter, close to the sample point,
even in a demanding environment. Maintenance costs are kept to a minimum with the
maintenance free switching devices, onboard diagnostics, single point calibration and
easy to use operating software. The operation software CV Control has unique features
such as Method Optimization and is so user friendly that well trained chromatography
specialists are not required on site for standard operation and maintenance of the
SITRANS CV.
The analyzer saves the mean values of all components and the calorimetric values for a
period of up to 100 days. If required, Siemens can deliver the complete certified system
that provides a detailed comparison of the quality information of natural gas from the
user and the producer.
Application of soft sensors and process control based on dynamic glass furnace
simulation models
Leo Huisman; Piet van Santen
TNO Glass Group, Eindhoven, The Netherlands [email protected]
Glass melting process control is usually based on a small number of temperature
measurements. Temperature sensors are placed in the crown or bottom at locations
based on experience and availability. The relevant processes, however, take place in the
glass melt positions (e.g. hot spot, batch blanket) where the conditions are too harsh for
sensors to survive or to which sensors do not have access.
Knowledge of the behavior in the glass melt can be obtained through mathematical
model simulations. Computational Fluid Dynamics (CFD) models are used for several
decades to calculate the temperature, velocity and concentration fields in the glass melt
and from that residence time distributions. In CFD modeling, the glass melting furnace or
feeder is divided into a large number (~ 105) of grid cells and for each of these grid cells
conservation equations for mass, energy and momentum are solved in order to find the
temperature and velocity vector as functions of time in the corresponding grid cell.
Accurate simulations typically run as fast as the real glass melting process. For example
the simulation of a job change that takes a full day to stabilize, takes about the same
time of 1 day.
Since about 6 years, these models are also used for melter and feeder control. To this
end “model reduction” is applied to obtain lower complexity models that allow fast
prediction and optimization of dynamic behavior of the melting process. The reduced
models predict the effect of process changes on glass melt properties (temperature
changes, flows) about 3 to 4 orders of magnitude faster than the original CFD models.
These reduced models are used in a Model Predictive Controller (MPC). Models used in
MPC predict the future behavior of the temperatures and calculates optimal time
trajectories for the inputs, such as fuel input, batch composition and electrical boosting
power. Since the used model is based on a rigorous first principles model (the CFD
model), we call this application R-MPC. Main objective of these control applications is
stabilization of crown and bottom temperatures. So, the models are used to predict and
optimize measured temperatures only.
The reduced CFD models can also be used for prediction of other temperatures than the
measured ones and also flow patterns in the glass melt. However, if only model
simulations are used then there will be deviations between the model and reality, due to
disturbances. Known disturbances such as pull rate and cullet fraction in the batch can
be taken into account in the model predictions. For the effects of unknown disturbances,
the model has to be kept on track with the process via the available actual process
measurements. This is a kind of model re-calibration on a frequent basis. To this end, a
so-called observer is used that estimates the unknown disturbances that have caused
the deviation between model results and process measurements. Accordingly,
corrections are made to the variables in the model, without violating the applied physical
laws (model equations), in order to get the best possible estimate of the temperature and
velocity fields in the melter. Thus, the model estimates accurately changes in process
properties (temperatures, velocities, residence times, melting trajectories) in all positions
of the glass melting tank.
In this presentation results will be presented of some recent RMPC applications in glass
industries. Furthermore, results will be presented of a soft sensor application in the
container glass industry.
Keywords: CFD modeling, soft-sensor, Model Based Control, Process optimization
Moisture measurement for materials in glass, cement and ceramic industry
Mirande Wolvekamp
ACO Automation Components, The Netherlands [email protected]
Problems in the production processes mostly appear due to a late response on
changes in the process conditions. One of the largest influences on these
changes are changes in the process settings / input raw materials. For instance,
the consistency, formula reproducibility further processing and the consistent
high quality of the product are the result of controlling the water content of the
raw material or batch. The ability of measuring moisture in the input streams at
an early stage of the production or even in the different production stages can be
a judge benefit in the control of the complete production process. This is
important for instance in glass industries (humidity of cullet, sand), cement
industry, ceramic industries (moisture in clays). There are several systems of online moisture measurements on the market, but it will always be a compromise
concerning price, quality and deployability, which one to choose.
The ACO on-line moisture measurements have been on the market for quite
some time. The success of ACO has been achieved, thanks to a combination of
experience in practice, new developments in co-operation with industrial partners
applying these moisture sensors, and university studies.
ACO developed and supplies HFC (High Frequency Capacitive) moisture
measurement systems. These types of sensors enable on-line moisture
measurements for almost all applications. However, in practice, about 85% of the
failures in on-line moisture measurement are due to wrong installation, therefore
ACO creates new (mounting) tailor-made solutions, depending on the customers‟
requirements and the process circumstances.
Our motto: We don‟t want to sell just an on-line moisture measurement sensor,
we sell complete solutions.
The presentation will therefore look into the following topics:
Explanation of the HFC measuring principle
Selection of the right sensor for the right application (sensor comparison)
What is important for an accurate moisture measurement?
Application solutions of ACO
What can be expected from a moisture measuring system from ACO?
The results/benefits of using these sensors for glass and ceramics
production plants
Keywords: raw material, moisture, energy savings, process control, clays, cullet,
sand, moisture sensor