Process gas chromatograph analyzers – How to choose a PGC?
How to choose the right Process Gas Chromatograph analyzer (PGC) for your application? When selecting a PGC, you may not be sure which make, or model is the best for your process requirements. Process gas chromatograph analyzers are durable purpose-built gas analyzing devices which provide specific qualitative and quantitative data, regarding the composition of a gas stream or sample found in an industrial application.
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ASaP products and services for process gas chromatographs
Our comprehensive range of products and services for process gas chromatographs include offshore and onsite service, and an extensive selection of gas analysis instruments, sample conditioning, sample probes, and various cabinets and houses for your instruments, tailored to meet the unique requirements of various cryogenic, renewable, and petrochemical applications. We are dedicated to delivering innovative solutions that ensure accurate and efficient operations in the process industry.
What is Gas Chromatography (GC) in short?
In short Gas Chromatography (GC) is an analysis technique which is able to separate hundreds of different components while determining the composition qualitatively and quantitively. The principles of gas chromatography make a powerful tool to specifically analyze one or more gases. There are 4 steps to a chromatographic analysis:
- Sample collection
- Sample injection
- Sample separation
- Sample detection
A gas sample is collected and then it is introduced into an inert gas stream called a carrier gas. The carrier gas carries the gas sample through a column or series of columns where the gases in the sample are physically separated. Once the gases of interest have been separated by the column, they are directed to a detector which provides an output proportional to their concentration. GC columns are at the heart of the gas chromatograph and responsible for the separation process.
What is the expert take on Process Gas Chromatography (PGC)?
We asked process industry veteran and expert in the field of Process Gas Chromatographs (PGC) Dirk Horst * to do the impossible: To summarize process gas chromatography on two sheets of paper:
What is the role of gas chromatography in process control?
Many people are more or less familiar with analysis of materials as done by special laboratories but do not have a clear idea how the analysis of a big chemical production process is controlled.
For this control, the analysis results from a so called “on-line” analyzer are used and one of the most important types is the process gas chromatograph as manufactured by reputable suppliers.
Gas Chromatography is an analysis technique which is able to separate hundreds of different components while determining the composition qualitatively and quantitively. A PGC is generally applied ranging from the Petrochemical, Refining, Power Generation, Pharmaceutical, Environmental etc.
What are the advantages of a GC application?
- Requires only very small samples with little preparation
- Separates complex mixtures into components
- Results may be rapidly obtained in a few minutes
- High precision
- Very Low Detection Limits
- Only instrument with the sensitivity to detect volatile organic mixtures of very low concentrations,
- Equipment is not too complex, sophisticated oven with accurate temperature and flow control.
The main reason often mentioned as disadvantage for application of a PGC is because the analysis results are obtained batch-wise and depend on the time it takes for a complete analysis.
However, modern sophisticated analysis techniques and correct selection of the analysis configuration may reduce the analysis time, of heavier hydrocarbon mixtures up to C40, to within a few minutes or faster!
What chromatography analysis techniques are there?
The analysis technique was invented by the Russian botanist Mikhail Tswett in 1900 during his research on the separation of plant pigments. He used a glass column filled with calcium carbonate as adsorbent and petrol ether/ethanol mixtures as transfer solvent to separate chlorophylls and carotenoids.
Nowadays we distinguish several other chromatographic techniques, based on the so called “Mobile Phase”, which is the “Carrier” of the Sample and the type of “Stationary Phase” in the analytical column like the Gas to Liquid Chromatography (GLC).
While Tswett used Liquid to Solid Chromatography, Gas to Liquid Chromatography is mainly applied for on-line Process GC’s.
For the “Mobile Phase” gases like Nitrogen, Helium and Hydrogen are used as a “Carrier Gas” that ‘carries’ a small amount of the process sample mixture through an analytical column.
The analytical column is the heart of the system and contains the “Stationary Phase” which is in case of a GLC an amount of specific liquid that is fixed, by a special technique onto a packing of solid particles (Packed column) OR as a thin film onto the inner wall of an Open tubular / Capillary column, see picture.
The principle used for the separation of a mixture of components in a fluid, that should be a gas or a volatile vapor, is the dynamic concentration distribution of its components between the Mobile and Stationary Phase while travelling through the analytical column.
The injected small volume of sample is ‘carried’ through the column by the mobile phase while separation of the different components is based on the following ‘Retention’ phenomena; combined as “Affinity”:
- Adsorption – at a surface
- Absorption – into an immobilized liquid layer
- Polarity – electrostatic interaction between ions ….. OR by
- Molecular Sieves – Molecule Size-exclusion chromatography (SEC)
How to use gas chromatography to measure complex sample mixtures?
To obtain high efficient columns for the separation of very complex sample mixtures, the art is to combine the mentioned Retention phenomena and manufacturers have developed thousands of customized columns.
While the time in the Mobile Phase tm for each of the components is the same, the time that a component stays in the Stationary Phase may be different, caused by their different affinities, and so may cause different Retention times – tR. The total time from injection till a component leaves the analytical column is the sum of tm and tR , called the Elution time.
By plotting the signal from the Detector, a Chromatogram is produced showing all the eluted components.
The initial correctly obtained chromatogram is an ultimate tool for later troubleshooting!
Note that the retention is also highly depending on temperature and the linear velocity of the analysis column.
Depending on the type of components to be measured, the main types of detectors used for PGC are the Thermal Conductivity Detector (universal type), the Flame Ionization Detector (organic compounds) and the Flame Photometric Detector (specific for Sulphur and Phosphorus).
Although the shape of a component peak is normally symmetrical (normal distribution), the shape may be influenced by several parameters like:
- The time a peak travels through the column
- The linear velocity
- The type of Column: Packed; Micro-Packed; Open Tubular; Capillary, Column Efficiency, expressed in the HETP factor of the “Theoretical Plate Model” as developed by Mr. “van Deemter” consisting of several factors influencing the peak width.
The aim of every chromatographer is to achieve nice sharp, symmetrical peaks, meaning a high efficiency and small HETP factor, while the peaks are (preferably) baseline separated (Selectivity) as combined into the Peak Resolution R.
How to identify and quantify peaks in gas chromatography?
Since the Retention times of the injected components are different, their Identification is done using the retention times of the separated components.
The total area of all peaks is in fact representing the total number of molecules of all components that are injected onto the analytical column. Since each component may have a different Area Response, depending on the applied type of detector, a Response Factor is determined for each component by means of a certified Calibration Gas mixture (External Standard).
When the PGC is running online, this response factor is used for the quantification of the unknown component concentrations of the analyzed process sample.
Dirk’s first professional study was in Electronics which was successfully followed by a dedicated study in instrumentation and obtained several other specified certifications during his long a career in the Oil and Gas industry.
Dirk has more than 34 years of experience in QMI, including the Dutch Oil Company N.A.M. (owned by Royal Dutch Shell), Shell Global Solutions in Amsterdam, Shell Head Office in Hague, Reliance Petroleum Refinery Ltd. in India, Nigeria LNG. and Shell in Sakhalin, Russia.
Dirk is currently working as Freelance Trainer to transfer his long-term experience to young engineers and technicians joining the world of instrumentation.
Our recommendations to learn more about Continuous Emission Monitoring Systems
To achieve optimal performance through an understanding of operating principles, possible interference and practical knowledge, you can attend the training course Process Gas Chromatography & CEMS Systems by none other than Dirk Horst himself.
In addition, Process Gas Chromatographs by Tony Waters is a guide to the fundamentals of applied gas chromatography and the process gas chromatograph, with practical procedures for design and troubleshooting This comprehensive resource provides the theory that underpins a full understanding of the fundamental techniques of gas chromatography and the process analyzer.
Analytical Solutions and Products employees are trained by Tony Waters and are very familiar with his and the work of Dirk Horst.
Range of Process Gas Chromatograph (PGC) applications
Natural gas
Natural gas analysis of the industrial processes designed to purify raw natural gas by removing impurities, contaminants and higher molecular mass hydrocarbons to produce what is known as pipeline quality dry natural gas. Natural gas has to be processed in order to prepare it for final use and ensure that elimination of contaminants.
Custody transfer
Process Gas Chromatographs (PGCs) are used in natural gas custody transfer applications. They provide information on the gas quality and composition with components such as methane, ethane and heavier hydrocarbons, water vapor, carbon dioxide, nitrogen and hydrogen sulfide. These gas chromatographs are normally located on large gas stations with dedicated buyer use.
Total Sulfur, H2S and COS
Hydrogen sulfide (H2S) and other sulfur compounds exist naturally in natural gas fields. It is necessary to remove these sulfur compounds from the gas in order to preserve public safety, reduce corrosion in pipelines, meet contractual agreements and to control odor in the gas. Thus, the analysis of hydrogen sulfide and total sulfur in natural gas by PGCs is critical to the natural gas industry.
Flare gas monitoring
Gas flaring is a source of emission that pollute the environment. Flaring releases greenhouse gases into the environment and further contributes to the problem of climate change. Hence, national and local government bodies are increasingly requiring process plants to monitor, report, and reduce emissions from their stacks and flares.
ASTM D3710 gasoline
Standard method for boiling range distribution of gasoline and gasoline fractions by process gas chromatography. This test method covers the determination of the boiling range distribution of gasoline and gasoline components. This test method is applicable to petroleum products and fractions with a final boiling point of 500°F (260°C) or lower as measured by this test method.
ASTM D2887 diesel
Standard method for boiling range distribution of petroleum fractions by process gas chromatography. Standard method for boiling range distribution of gasoline and gasoline fractions by process gas chromatography. This test method covers the determination of the boiling range distribution of petroleum products. The test method is applicable to petroleum products and fractions having a final boiling point of 538 °C (1000 °F) or lower at atmospheric pressure as measured by this test method.
Catalytic reforming & refinery hydrotreating
Catalytic reforming is a major conversion process in petroleum refinery and petrochemical industries. The process converts low octane naphtha into higher octane reformate products for gasoline blending and aromatic rich reformate for aromatic production. Hydrotreating is an important step to remove unwanted sulfur from streams that are used as feeds to some refinery units.
Specialty & industrial gasses
The field of analytical application is extremely diverse. Whether they are used to monitor the quality of foodstuffs, test engines in the automotive industry, control processes in the chemical or pharmaceutical industries, or in medicine, metallurgy or environmental monitoring: analytical methods ensure process control, quality assurance and even compliance with statutory regulations everywhere.
Overview of our gas chromatography analyzer products
aSAP process gas chromatograph analyzer shelters
These PGC shelters are made to house any kind of process gas chromatograph analyzers.
ABB NGC8206 Natural gas chromatograph analyzer
Measurement technology with the highest levels of accuracy, selectivity and reliability.
Process gas chromatograph analyzer monitoring with AIM predictive maintenance
AIM can predict the moment to replace your gas chromatographs maintenance sensitive parts.
Maintenance for your emission analyzers
Professional rapid-response service for your emission analyzers and systems
ABB NGC8209 C9+ Natural gas chromatograph analyzer
The NGC8209 utilizes a scalable framework to integrate data from a third analysis train. The extra chromatographic information is
provided as NC6’s, NC7’s, NC8’s and C9+.
ABB PGC5000 series Process gas chromatographs
Modular PGC5000 oven design completes any analytical project; from simple routine applications to complex applications.
ABB PGC5009 Fast process gas chromatograph analyzer
The PGC5009 represents the best in process analytics for simulated distillation analysis using fast temperature programmed process chromatography.
ASaP will integrate the process gas chromatograph analyzer you need!
Our specialists support and can integrate multiple PGC makes and models. Amongst others: Yokogawa GC8000, Honeywell EnCal 3000, and Emerson Rosemount 370XA.
Our process gas chromatograph analyzer products
aSAP process gas chromatograph analyzer shelters
The process gas chromatographs can be built into ASaP’s Slim Analyzer Packages (aSAP). These PGC shelters are manufactured in our workshop. They are tailor made for housing any kind analyzers and sample conditioning systems.
The analyzers are mounted inside a coated steel insulated room closed by two doors. Here is the clever part; when opening the doors, they lock in the two sidewalls and a weather protected environment is created. A sample conditioning system can be mounted back-to-back and when required test bottles are mounted.
Flexibility and quality
Due to its design, we are flexible in sizing and area classification. We build our process gas chromatograph shelters with the highest quality materials and include certificates such as ATEX and DNV.
Key benefits
- Suitable for any kind of process gas chromatograph or analyzer and sample conditioning system.
- Flexible in sizing and area classification
- ATEX and DNV
- Versatility in flange mounting options, digital communications and data management
- Comfortable field maintenance
Applications
- Oil and gas exploration
- Outdoor air quality monitoring
- Fugitive emission detection and monitoring
- Specialty Gas supply
- Continuous Emissions Monitoring System (CEMS)
- Hazardous waste incinerators at chemical plants
- Other process gas chromatography analyzer applications
Markets
- Petrochemicals
- LNG
- Fine chemicals
- Process industries
- Natural gas
- Other process gas chromatography analyzer markets
ABB NGC8206 Natural gas chromatograph analyzer
The NGC8206 Natural Gas Chromatograph combines simplicity with low installation costs and unmatched performance, making it the ideal solution for natural gas custody transfer. It is a field mounted GC which sets a new standard for determining the heating value of natural gas.
NGC8206 makes measurement easy
The NGC8206 performs on-site gas analysis and heating value computation where current
chromatograph technology has been either impractical or unaffordable. This truly “transmitter-like” gas chromatograph takes up no more room on the pipeline than most multivariable transmitters. Its fast analysis cycle and automatic setup features make installation and maintenance remarkably easy.
The state-of-the-art built-in 32-bit digital controller, the dual electronic carrier pressure regulators, oven mounted sensors, and other low-noise electronics provide unparalleled sensitivity and months between calibrations
Key benefits
- New design, more compact, more reliable, more precise
- Custody transfer/metrology quality GC for heating value and composition
- Lower cost to purchase, install and operation
Applications
- Natural Gas
- Custody transfer
- Other process gas chromatography analyzer applications
Markets
- Natural gas and LNG industry
- Process industries
- Other process gas chromatography analyzer markets
Process gas chromatograph analyzer monitoring with AIM predictive maintenance
Maintenance departments use different software packages for maintenance activities, due to different types of gas analyzers in analyzer houses or shelters.
How is AIM applied?
On a plant or in an analyzer shelter, different types of gas analyzers and sample systems are in operation. Because the analyzer performance is also depending on the performance of the sampling systems, these parameters will also be acquired. There is a need for analyzer shelter performance monitoring and prediction of fouling of the sample system to prevent breakdown of the analyzers. Improvement of sample conditioning maintenance is necessary to increase uptime of the analyzers.
The result of PGC analyzer monitoring with AIM
By monitoring the external factors like temperature, flow rate and condition of the sample system, the uptime of the analyzer increased significantly. Using preventive scheduled maintenance, unexpected issues are reduced, which leads to less ad hoc maintenance. By monitoring the sample system and analyzer as one item, the frequency of interventions by maintenance personnel is reduced.
What is AIM predictive maintenance software?
AIM is easy to use predictive maintenance software and an analyzer data collection for operators and reliability engineers similar to AMADAS to get insight into their measurement and analyzer equipment. AIM supports any brand of process gas chromatography analyzers. Amongst others; ABB PGC and NGC, Yokogawa GC8000, Honeywell EnCal 3000, and Emerson Rosemount 370XA.
Key benefits
- Control and validate your analytical equipment
- Complete overview, with KPI’s, clear dashboards, live tiles, and in-depth reports
- Pre-configured for your analytical equipment
- High return on investment
- STM D-6299 compliant
Applications
- PGC analyzer monitoring
- Monitoring of other analyzers
- Monitoring of transmitters
- Emissions and compliance
- Source evaluation
- Process monitoring
- LNG sampling
- Other process gas chromatography analyzer applications
Markets
- Petrochemicals
- Process industry
- Natural gas industry
- Chemical industry
- Any process gas chromatography analyzer markets
ABB NGC8209 C9+ Natural gas chromatograph analyzer
The NGC8209, the C9+ natural gas chromatograph performs on-site natural gas analysis and heating value computation using an extended analysis.
NGC8206 makes measurement easy
On-line chromatograph techniques are used to provide N₂ through C6+ data while a third column train is used to separate the C6+ fraction. The NGC8209 utilizes the modular and scalable XSeries software framework to integrate data from a third analysis train into the
standard C6+ analysis of the Natural Gas. The extra chromatographic information is provided as NC6’s, NC7’s, NC8’s and C9+ to provide this “extended analysis”. Heating value (CV), Wobbe, Relative Density (SG) and other calculations are performed using the combined analysis data in a similar manner to the NGC8206 Hydrocarbon Dew Point (HCDP) and Speed of Sound (SOS) calculations are available options.
Unparalleled repeatability and sensitivity
A single computer controller seamlessly processes all this data for various outputs. It also handles the stream switching and the timing for the sample. Incorporating a state-of-the-art built-in 32-bit digital controller, three electronic carrier pressure regulators, oven-mounted sensors and advanced low-noise digital electronics, the NGC8209 performs with unparalleled repeatability and sensitivity. The NGC8209 provides custody transfer metrology quality chromatography for heating value and composition measurement. It provides the user with a GC that is lower in cost, easier to install and commission, and less costly to operate.
Key benefits
- New design, more compact, more reliable, more precise
- Custody transfer/metrology quality GC for heating value and composition
- Lower cost to purchase, install and operation
Applications
- Natural Gas
- Custody transfer
- Other process gas chromatography analyzer applications
Markets
- Natural gas and LNG industry
- Process industries
- Other process gas chromatography analyzer markets
ABB PGC5000 series Process gas chromatographs
Modular PGC5000 oven design completes any analytical project; from simple routine applications to complex applications.
Highest levels of accuracy, selectivity and reliability
The ABB PGC5000 Series process gas chromatograph is based on over 50 years of innovation in on-line process gas chromatographs. It simplifies gas chromatography and increases reliability. It provides everything you need to know about your GC – at your fingertips.
The PGC5000A Generation 2 Master Controller with new Graphical Driven HMI offers a fully functional touchscreen. Developing, editing and storing analysis methods are now easy. Programming is now a thing of the past. Just “point and click” is all that is required to access any of the analyzer functions. All of the major analyzer functions are identified on tabs making it easy to know where to go to access information when needed.
ABB PGC SMART module
The ABB SMART module has the connection to the PGC5000 Master Controller for control and data collection. With this device, the software has the following features: Digital SHS Valve control with Alarm Status; Sample Temperature, Sample Pressure, and Sample Flow Alarm Status; Filter Differential Pressure Alarm Status; and Analog Inputs. Using the ABB SMART module, all alarm indicators from the SHS are available at the master controller for OPC and/or MODBUS data to validate analyses from the PGC.
Key benefits
- Multiple oven configurations can be designed for parallel and simultaneous chromatography
- Alarms and chromatographic problems are isolated, and the application sequences can be viewed independently
- Multiple isothermal temperature zones allow the application engineer to select the best column(s) for separating
- Division 2 / Zone 2 by design base certification reduces cost
- Wide range of I/O solutions for complete integration
Applications
- Total Sulfur, H2S and COS
- Refinery hydrotreating
- Catalytic reforming
- Flare gas monitoring
- ASTM D3710 (Gasoline)
- ASTM D2887 (Diesel)
- Specialty and industrial gas monitoring
- Other process gas chromatography analyzer applications
Markets
- Petrochemical
- Natural gas
- Sulfur recovery/sulfuric acid
- Other process gas chromatography analyzer markets
ABB PGC5009 Fast process gas chromatograph analyzer
The PGC5009 represents the best in process analytics for simulated distillation analysis using fast temperature programmed process chromatography.
Highest levels of accuracy, selectivity and reliability
A relatively small shift in the cut point for any refinery product can cost refiners millions in profits. In the absence of fast, accurate and reproducible boiling point data, refinery product yields are not optimized and more importantly, profits are lost.
The best in process analytics for simulated distillation analysis
The PGC5009 represents the best in process analytics for simulated distillation analysis using fast temperature programmed process chromatography. With a patented resistively heated column design and rapid cooling system, the PGC5009 provides superior chromatography.
The results are proven: accurate and reproducible retention times and weight percentage measurements required for boiling point curve calculation enabling optimized refinery process control.
Key benefits
- Tight cut point control for product yield optimization can save millions in refinery profits
- Blending to pipeline versus costly storage
- Significant savings in analyzer technician time through remote system diagnostics capability and an analyzer designed for ease of maintenance
Applications
- ASTM D3710 (Gasoline) in less than 4 minutes
- ASTM D2887 (Diesel) in less than 5 minutes
- Refinery hydrotreating
- Catalytic reforming
- Other process gas chromatography analyzer applications
Markets
- Petrochemical
- Other process gas chromatography analyzer markets
ASaP will integrate the process gas chromatograph analyzer you need!
Our specialists support and can integrate multiple PGC makes and models. Amongst others: Yokogawa GC8000, Honeywell EnCal 3000, and Emerson Rosemount 370XA.
The process gas chromatographs can be built into ASaP’s Slim Analyzer Packages (aSAP) or any other analyzer house or cabinet. These PGC shelters are manufactured in our workshop. They are tailor made for housing any kind of analyzers and sample conditioning systems.
The analyzers are mounted inside a coated steel insulated room closed by two doors. Here is the clever part; when opening the doors, they lock in the two sidewalls and a weather protected environment is created. A sample conditioning system can be mounted back-to-back and when required test bottles are mounted.
Flexibility in size and classification
ASaP is flexible in sizing and area classification. We build our process gas chromatograph shelters with the highest quality materials and include certificates such as ATEX and DNV.
Contact Our process gas chromatographs specialist today
For personalized assistance and further process gas chromatographs inquiries, please contact our specialist at ASaP. We are here to help and provide the support you need.
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You can contact us is you have a question about process gas chromatographs when it suits you. See our specialist’s contact information below.
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