Periodic Reporting for period 2 - UBISpec (Ubiquitous in-line mass spectroscopy for industrial process monitoring and optimization with sustainable impacts)
Berichtszeitraum: 2023-04-01 bis 2024-03-31
Biogas producers are seeking innovative solutions to increase efficiency, while ensuring safety, and reducing environmental impact. They can greatly benefit from in-line process monitoring. Biogas and biomethane overall production is about 30% below the full potential. Sub-optimal biogas production is due to interruptions in the chemical process of converting biowaste in biogas as the fermentation tanks experiencing organic overloading. These process failures occur unexpectedly, sometimes as often as once a year lasting from 3-6 weeks to several months. Production consistency and increased yield are crucial to rise the viability of biogas/biomethane as a significant renewable energy source.
To solve that, we are introducing the first mass-spectrometer (MS) to be used for industrial process applications. Spectro Inlets’ (SI) liquid gas analyser (SI-LGA) enables industrial customers to measure in-line and real-time biochemical reactions robustly and continuously. The technology enabler is our patented microchip consisting of a membrane inlet system with a vacuum and gas-handling system integrated in a MS, and a software to convert the MS signal to quantified measurements. The microchip inlet is composed of hydrophobic pores, which avoid liquid transport through the inlet system and thereby avoids clogging and fouling. The microchip has a “micro-headspace” cavity to equilibrate gases in the liquid environment. The gases are transported through a microcapillary to the vacuum of the MS for analysis. The software calibrates the signal in real-time the concentration of the dissolved gases in the liquid environment, which is sent to process control systems at the facilities. The solution offers industry disruptive new possibilities of real-time insights.
SI will be able to offer the first online vacuum conditions necessary for in-line measurements for industrial process applications, such as biogas production, but also for other industries such as bio-manufacturing (biopharmaceuticals, fermentation, etc.). SI-LGA’s unique value proposition to industrial customers is based on the following elements: robust hardware and software design for long-term in-line measurements in any liquid media; fast (sub-second) real-time measurements; high sensitivity towards multiple gas compounds; accurate quantification; robust and self-cleaning sensor inlet tolerating a broad range of environments; -live data integration into SCADA industrial monitoring and process control software.
To solve that, we are introducing the first mass-spectrometer (MS) to be used for industrial process applications. Spectro Inlets’ (SI) liquid gas analyser (SI-LGA) enables industrial customers to measure in-line and real-time biochemical reactions robustly and continuously. The technology enabler is our patented microchip consisting of a membrane inlet system with a vacuum and gas-handling system integrated in a MS, and a software to convert the MS signal to quantified measurements. The microchip inlet is composed of hydrophobic pores, which avoid liquid transport through the inlet system and thereby avoids clogging and fouling. The microchip has a “micro-headspace” cavity to equilibrate gases in the liquid environment. The gases are transported through a microcapillary to the vacuum of the MS for analysis. The software calibrates the signal in real-time the concentration of the dissolved gases in the liquid environment, which is sent to process control systems at the facilities. The solution offers industry disruptive new possibilities of real-time insights.
SI will be able to offer the first online vacuum conditions necessary for in-line measurements for industrial process applications, such as biogas production, but also for other industries such as bio-manufacturing (biopharmaceuticals, fermentation, etc.). SI-LGA’s unique value proposition to industrial customers is based on the following elements: robust hardware and software design for long-term in-line measurements in any liquid media; fast (sub-second) real-time measurements; high sensitivity towards multiple gas compounds; accurate quantification; robust and self-cleaning sensor inlet tolerating a broad range of environments; -live data integration into SCADA industrial monitoring and process control software.
Prior to the UBISpec project, the technology was developed at DTU from 2008 onwards. The first years of SI were spent commercializing the inlet technology and subsequently development of a turnkey mass spectrometry analysis instrument for electrocatalysis research was achieved in early 2019. Since then, multiple academic and R&D institutions have purchased the equipment, validating the technology, and strengthening the company in its product development, production, quality control and support capabilities. Since 2019, SI has been testing their MS technology in real-world industrial environments - including early pilot projects with industry players such as E.ON Denmark and Frederica Wastewater - and invested considerable R&D efforts on developing an ‘advanced prototype’ of the SI-LGA sensor for demonstration in biogas facilities
During the first of the project, SI has been working on LGA biogas installation and demonstration of an in-line mass spectrometer that directly interfaces with biomass at an industrial biogas facility. Firstdemonstration was achieved at Sønderjysk Biogas located in Southern Denmark using an in-line MS prototype, which lead to a redesign and the development of a fully automated prototype of the SI-LGA sensor. The new prototype was able to couple directly to SCADA and demonstrated robust operation with an uptime of more than 90%. A framework was developed allowing for full calibration and stable data output on the six main compounds of interest for biogas processes: H2, CO2, CH4, N2, H2S and NH3. Accuracy and stability were evaluated to be well within 10% for all compounds and data was reproducibly with 10% across several months of operation. With this foundation a process change was conducted, which demonstrated up towards 15% biomethane increase at Sønderjysk Biogas facility. With this technology we can develop the sensor further (making it ubiquitous), and apply it to other non-biogas applications.
During the first of the project, SI has been working on LGA biogas installation and demonstration of an in-line mass spectrometer that directly interfaces with biomass at an industrial biogas facility. Firstdemonstration was achieved at Sønderjysk Biogas located in Southern Denmark using an in-line MS prototype, which lead to a redesign and the development of a fully automated prototype of the SI-LGA sensor. The new prototype was able to couple directly to SCADA and demonstrated robust operation with an uptime of more than 90%. A framework was developed allowing for full calibration and stable data output on the six main compounds of interest for biogas processes: H2, CO2, CH4, N2, H2S and NH3. Accuracy and stability were evaluated to be well within 10% for all compounds and data was reproducibly with 10% across several months of operation. With this foundation a process change was conducted, which demonstrated up towards 15% biomethane increase at Sønderjysk Biogas facility. With this technology we can develop the sensor further (making it ubiquitous), and apply it to other non-biogas applications.
SI’s technology needs to tackle the following key features to become ready for the market:
1) Low-cost and certified sensor solution: Certain development tasks, such as electronic redesign and software hardening, will naturally reduce costs. However, component alternatives needed to further drive down costs will have to be evaluated to ensure that they live up to requirements of the system. CE and other certifications will require mostly documentation, but may also require component redesign which will have to be developed in a way that doesn't compromise the system robustness. Furthermore, QC protocols will have to be developed and refined in order to ensure that support costs are minimized.
2) Accurate and stable quantified measurement data stream: A further refinement of the calibration code is required for this feature to be fully realized. In addition, the recalibration protocol must be verified to ensure that the measurements are stable for long-term measurements.
3) Real-time, in-line robust long-term operation in industrial environments: A commercial version of the LGA sensor needs to be developed for widespread deployment. This includes software developing the hardware such as the sensor enclosure for temperature and humidity resistance (weatherproofing), electronics, hardening the control software in terms of error messaging and recovery protocols.
4) State of the art measurements in harsh bio-active media, beating other sensor solutions in even well-established industries such as biopharmaceuticals.
1) Low-cost and certified sensor solution: Certain development tasks, such as electronic redesign and software hardening, will naturally reduce costs. However, component alternatives needed to further drive down costs will have to be evaluated to ensure that they live up to requirements of the system. CE and other certifications will require mostly documentation, but may also require component redesign which will have to be developed in a way that doesn't compromise the system robustness. Furthermore, QC protocols will have to be developed and refined in order to ensure that support costs are minimized.
2) Accurate and stable quantified measurement data stream: A further refinement of the calibration code is required for this feature to be fully realized. In addition, the recalibration protocol must be verified to ensure that the measurements are stable for long-term measurements.
3) Real-time, in-line robust long-term operation in industrial environments: A commercial version of the LGA sensor needs to be developed for widespread deployment. This includes software developing the hardware such as the sensor enclosure for temperature and humidity resistance (weatherproofing), electronics, hardening the control software in terms of error messaging and recovery protocols.
4) State of the art measurements in harsh bio-active media, beating other sensor solutions in even well-established industries such as biopharmaceuticals.