Report Submitted to the Research Experience for Undergraduates Program at the USF College of Engineering.

 

 

Title: Gas Dilution System

 

 

Name: Randolph Williams

Level: Senior

Number of semesters participated: 1

Date of submission:

 

Advisor: Dr. Venkat Bhethanabotla

Department: Chemical Engineering

 

 

 

 

 

 

This report has been approved:_________________________________Date:________

                                                            (Advisor signature)

 

Report can be published on the REU website: YES/NO

 

 

 

 

 

 

 

Abstract: This paper describes the equipment design needed to generate and detect low concentration organic vapors with sensors.  Sensor capababilities, such as sensitivity, selectivity, and response time, must be quantified.  The vapor dilution system provides a means of testing these parameters by introducing chemical vapors to the sensor. 

Introduction

 

Sensitive, selective and fast responding sensors were developed; however, these parameters need to tested and quantified for various organic vapors at low concentrations.  This requires some equipment that will generate vapors in known concentrations.  The equipment should be fully automated and capable of taking continuous recordings of temperature and concentration.  Additionally, it should automatically select one or more of the various organic liquid sources for vapor generation and testing. The former requirements specify a dynamic gas dilution system.

 

Theory

 

Procedures for production of mixtures of vapors at precise concentrations are much more difficult than for liquids.  Gasses, unlike liquids, cannot be easily weighed; gas volumes may change during handling, and temperature and pressure effects must be considered.  Two methods of preparing mixtures of gases can be classified as static or dynamic.  Static methods are used for small volumes, high concentrations, and tolerable losses of gases to wall containers.  Dynamic methods are used for continuous vapor flows, large volumes, and negligible losses to wall containers.  From the various dynamic methods available, the evaporative method is widely used.  Dynamic evaporative methods are sensitive to the depth, the vapor pressure, and the temperature of the liquid.  In the present design, there will be three streams: The carrier stream (Qs), and the dilutant streams (Q1 and Q2).  The following equations apply to the chosen evaporative method:

 

 

 

 

 

 

CONCENTRATION (Ci):                                                                    

1. Ci = (Yi*Qs)/(Qs+Q1+Q2)

MOLE FRACTION (Yi):

2. Yi=Pvp/PT                        

VAPOR PRESSURE (Pvp):

Antoine Equation:

3. ln(Pvp)=VPA-(VPB/(T+VPC))

OR

Wagner Equation:

4. ln(Pvp/Pc)=((1-x)^-1)*( VPA*x+VPB*x^1.5 +VPC*x^3+VPD*x^6)

Ci = Organic Concentration

Yi= Mole fraction

Qs= Carrier Gas Flow Stream (ccm)

Q1= Dilutant Flow Stream (ccm)

Q2= Dilutant Flow Stream (ccm)

Pvp= Organic Vapor Pressure (bars)

PT= Total Pressure (bars)

T= Temperature (K)

The above equations were used to calculate theoretical concentrations for various organic vapors. The results of these calculations are presented in Table 1 and Table 2 of the appendix. Equation one assumes that the mass of the vapor collected is negligible. Organic chemicals were chosen so that they will exist as liquids at operating temperature. Another set of equations were developed to account for the volume of the vapors generated. A Matlab program was developed to calculate the theoretical concentrations and ppm levels possible for five of the organic chemicals. The programs are given in the appendix.

System Design and Dilution Method

Figure 1 shows the gas dilution system design and method chosen.  Electrical connectivity and signal lines are omitted for clarity. The flow of the carrier gas starting at MFC 1 (mass flow controller) is described below:

Carrier gas (nitrogen or hydrogen) is delivered through ¼ ” stainless steel tubing to bubbler units containing organic liquids.  Due to the kinetic nature of the sensor response, gas flow control is very important; consequently, the gas flow rate is regulated with MKS mass flow controllers. The selection of the bubbler unit is controlled by solenoid valves, which in turn are controlled with a Labview program.  The carrier gas is bubbled through the organic liquid. At the outlet of the bubbler there is a teflon tube which carries the vapor through another solenoid valve to a T-junction.  The carrier gas is then further diluted to the desired concentrations and sent to a SAW. 

Figure 1: Dilution Apparatus

Figure 1: Inert carrier gas (Qs), from MFC 1, collects organic vapor from E1-E4. The carrier gas flow to the bubbler is regulated by solenoids (V1-V8), connected to a digital acquisition card.  By pass (P#) allows for flushing the lines. MFC 2 (Q2) and MFC 3 (Q3) regulate the dilutant streams.  Diluted gas goes to SAW sensor for testing. Temperature (T) and pressure (P) are maintained at desired values.

 

Different organic liquids are contained in E1 to E4.  If a single bubbler is chosen (E1), its corresponding solenoid valves (V1, V5) must be switched from normally closed to open.  At the same time the remaining valves (V2-V4, V6- V9) should remain closed to contain the other organic liquids.  The system must avoid intermixing components from different bubblers; however, intermixing is allowed if more than one bubbler is chosen.  This system design allows for the sensor to have a supply of either one low concentration component or a mixture of components.  To achieve this objective the solenoid valves are connected to Omega solid state relays.  This is connected to a National Instruments digital acquisition card and a PC with Labview software for continuous measurement and automatic control. The valve V-9 acts as a bypass to flush the system, and is activated prior to selecting a different organic vapor.  This allows the clean carrier gas to clean the entire system of any previously selected chemical.

The most important objective of the gas dilution system is to generate a stream containing low concentration organics.  To achieve this requires proper design of the bubbler units E1 to E4. Dynamic systems with appreciable vapor pressures can produce concentrations close to saturated vapor pressures by bubbling the carrier gas through the organic liquid.  For low boiling liquids, a single tube is sufficient.  A fritted disk is fitted to the end of the tube to aid in vapor generation. The temperature of the bubbler units is maintained by housing the bubblers in a water bath.

Pending Conclusion

The success of the above gas dilution system design is yet to be determined.

High frequency polymer coated quart crystal microbalances will be used as the test sensor for calibrating the equipment.

 

 

 

 

 

 

 

References

 

  1. J. W. Grate, David S. Ballantine Jr., Hank Wohltjen, An Automated Vapor Generation and Data Collection Instrument for the Evaluation of Chemical Microsensors. Sensors and Actuators, 11 (1987) 173-188.
  2. R. S. Barratt, The preparation of standard gas mixtures: a review, Analyst (London) 106 (1981) 817-849.
  3. J. W. Grate, Mark Klusty, Vapor Stream Dilution by Pulse Width Modulation, Naval Research Laboratory Memorandum Report 6762, Dec. 11, 1990.
  4. Michael Thompson, David C. Stone, Surface-Launched Acoustic Wave Sensors: Chemical Sensing and Thin Film Characterization. Chemical Analysis: A series of monographs on analytic chemistry and its applications. 144. New York: Wiley, 1997, 117-153.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

APPENDIX

 

 

TABLE 1: Theoretical Concentrations

 

 

 

 

 

 

 

Q1=90

Q1=80

Q1=70

Q1=60

Q1=50

ORGANIC

Name

P(mmHg)

Yi

Ci

Ci

Ci

Ci

Ci

BENZENE

A

182.44124

0.24005

0.0240054

0.025269

0.026673

0.028242

0.030007

CYCLOHEXANE

B

185.071729

0.24352

0.0243515

0.025633

0.027057

0.028649

0.030439

PENTANE

C

866.084717

1.13959

0.1139585

0.119956

0.126621

0.134069

0.142448

OCTANE

D

43.5588864

0.05731

0.0057314

0.006033

0.006368

0.006743

0.007164

HEXANE

E

279.38273

0.36761

0.0367609

0.038696

0.040845

0.043248

0.045951

ACETONE

F

424.953222

0.55915

0.0559149

0.058858

0.062128

0.065782

0.069894

ETHANONL

G

134.448854

0.17691

0.0176906

0.018622

0.019656

0.020813

0.022113

ETHYLBENZENE

H

21.5433506

0.02835

0.0028347

0.002984

0.00315

0.003335

0.003543

CHLOROBENZENE

I

26.0569397

0.03429

0.0034285

0.003609

0.003809

0.004034

0.004286

CYCLOPENTANE

J

553.702471

0.72856

0.0728556

0.07669

0.080951

0.085712

0.091069

N-DECANE

K

3.70803583

0.00488

0.0004879

0.000514

0.000542

0.000574

0.00061

N-HEPTANE

L

92.2720216

0.12141

0.0121411

0.01278

0.01349

0.014284

0.015176

METHANOL

M

266.178964

0.35024

0.0350235

0.036867

0.038915

0.041204

0.043779

ISOPROPYL ALCOHOL

N

104.855602

0.13797

0.0137968

0.014523

0.01533

0.016232

0.017246

PROPANOL

O

52.5791695

0.0776

0.0069183

0.007282

0.007687

0.008139

0.008648

TOULENE

P

58.9770618

0.06918

0.0077601

0.008169

0.008622

0.00913

0.0097

NPROPYL BENZENE

Q

8.40295772

0.01106

0.0011057

0.001164

0.001229

0.001301

0.001382

BENZALDEHYDE

R

3.1239658

0.00411

0.000411

0.000433

0.000457

0.000484

0.000514

ETHYLENE GLYCOL

S

0.41165456

0.00054

5.417E-05

5.7E-05

6.02E-05

6.37E-05

6.77E-05

GLYCEROL

T

0.0001658

2.2E-07

2.18E-08

2.30E-08

2.42E-08

2.57E-08

2.73E-08

METHYL ETHYL KETONE

U

176.845009

0.23269

0.0232691

0.024494

0.025855

0.027375

0.029086

 

 

OPERATING CONDITIONS

TOTAL PRESSURE (mmHg)

760

CARRIER GAS (CCM)

20

DILUTANT Q1 (CCM)

VARIANT

DILUTANT Q2 (CCM)

90

TEMPERATURE (K)

313.15

 

Table 1: The theoretical concentrations and vapor pressures were calculated from Equations 1 to 4 for twenty common organics.  The results show that very low concentrations will be produced with two dilutant streams and one carrier gas stream. The vapor pressure of Pentane, C, is above the total pressure, therefore, it will not be used to generate a vapor.  Also, note glycerol’s low vapor pressure.

 

 

 

 

 

 

TABLE 2: Theoretical Concentrations

 

 

 

Q2=80

Q2=70

Q2=60

Q2=50

Q2=40

Q2=30

ORGANIC

Name

P(mmHg)

Ci

Ci

Ci

Ci

Ci

Ci

BENZENE

A

182.44124

0.0480109

0.053345

0.060014

0.06859

0.080018088

0.096021705

CYCLOHEXANE

B

185.07173

0.0487031

0.054115

0.060879

0.06958

0.081171811

0.097406173

PENTANE

C

866.08472

0.227917

0.253241

0.284896

0.3256

0.379861718

0.455834062

OCTANE

D

43.558886

0.0114629

0.012737

0.014329

0.01638

0.019104775

0.02292573

HEXANE

E

279.38273

0.0735218

0.081691

0.091902

0.10503

0.122536285

0.147043542

ACETONE

F

424.95322

0.1118298

0.124255

0.139787

0.15976

0.186382992

0.223659591

ETHANONL

G

134.44885

0.0353813

0.039313

0.044227

0.05054

0.058968796

0.070762555

ETHYLBENZENE

H

21.543351

0.0056693

0.006299

0.007087

0.0081

0.009448838

0.011338606

CHLOROBENZENE

I

26.05694

0.0068571

0.007619

0.008571

0.0098

0.011428482

0.013714179

CYCLOPENTANE

J

553.70247

0.1457112

0.161901

0.182139

0.20816

0.242851961

0.291422353

N-DECANE

K

3.7080358

0.0009758

0.001084

0.00122

0.00139

0.001626332

0.001951598

N-HEPTANE

L

92.272022

0.0242821

0.02698

0.030353

0.03469

0.040470185

0.048564222

METHANOL

M

266.17896

0.0700471

0.07783

0.087559

0.10007

0.11674516

0.140094192

ISOPROPYL ALCOHOL

N

104.8556

0.0275936

0.03066

0.034492

0.03942

0.045989299

0.055187159

PROPANOL

O

52.57917

0.0138366

0.015374

0.017296

0.01977

0.023061039

0.027673247

TOULENE

P

58.977062

0.0155203

0.017245

0.0194

0.02217

0.025867132

0.031040559

NPROPYL BENZENE

Q

8.4029577

0.0022113

0.002457

0.002764

0.00316

0.003685508

0.004422609

BENZALDEHYDE

R

3.1239658

0.0008221

0.000913

0.001028

0.00117

0.00137016

0.001644193

ETHYLENE GLYCOL

S

0.4116546

0.0001083

0.00012

0.000135

0.00015

0.00018055

0.00021666

GLYCEROL

T

0.0001658

4.36E-08

4.85E-08

5.45E-08

6.23E- 08

7.27E-08

8.73E-08

METHYL ETHYL KETONE

U

176.84501

0.0465382

0.051709

0.058173

0.06648

0.0775636

0.09307632

 

 

OPERATING CONDITIONS

TOTAL PRESSURE (mmHg)

760

CARRIER GAS (CCM)

20

DILUTANT Q1 (CCM)

0

DILUTANT Q2 (CCM)

VARIANT

TEMPERATURE (K)

313.15

 

Table 2: The effect of using only dilutant is considered in this set of calculations. The results show that low concentrations can still be achieved with only one dilutant stream.  Antoine and Wagner equation constants were obtained from The Properties of Gases and Liquids, Fourth Ed.

 

 

 

PROGRAM 1: Used to calculate theoretical pmm levels possible for benzene, cyclohexane, n-hexane, toluene, and dichloromethane. Program accounts for volume of vapor generated in bubblers.

 

 

 

selection % Calls menu

if x==0

    disp('Program Terminated')

end

 

if x==1

%Benzene Constants

VPA=-6.96009;

VPB=1.31328;

VPC=-2.75683;

VPD=-2.45491;

Tc=553.5;   % K

Pc=40.7;    % bar

R=83.14;    % bar*cm^3*mol^-1*K^-1

MW=79.114;  % Molecular Wt.

 

T=input('Enter BubblerTemperature:  ')

PT=1.01325; %Operating Pressure, bar

%Antoine

%lnPvp_A=VPA-(VPB/(T+VPC))

%Pvp_A=exp(lnPvp_A)*760

%y=Pvp_A/PT

 

%Wagner

x=1-T/Tc;

Psat_sol=exp( ((1-x)^-1)*( VPA*x+VPB*x^1.5 +VPC*x^3+VPD*x^6 ) )*Pc; % bar

ys=Psat_sol/PT                                      % Fraction of undiluted vapor

 

Qc=input('Enter initial Carrier Gas, SCCM: ');       % Carrier Flow, SCCM

Q1=input('Enter Dilutant 1 flow, SCCM (Dilutant 2 = 2*Dilutant1): ');  % Dilutant 1, SCCM

Q2=2.*Q1;                                           % Dilutant 2, SCCM

 

Qs=(ys.*Qc)./(1-ys)             % Volume of Vapor generated from bubbler, cm^3/min

                                % by volumetric fraction equal to mole fraction

Qcs=Qc+Qs                       % volume of carrier gas and solvent vapor, cm^3/min

 

yds=Qs./(Qcs+Q1+Q2)             % Fraction of diluted vapor

                

Cmixt=Psat_sol./(R.*T*(1/100^3) )           % Mixture concentration, mol/m^3

Cds=yds.*Cmixt                              % Concentration of diluted mixture, mol/m^3

Cds_mg=Cds.*MW*1000                         % Concentration diluted mixture, mg/m^3

PPM_vv=(Qs./(Qcs+Q1+Q2))*(10^6)             % Parts per million, by volume

 

selection

 

end

 

if x==2

%Toulene Constants

 

VPA=-7.28607;

VPB=1.38091;

VPC=-2.83433;

VPD=-2.79168;

Tc=591.8;

Pc=41;

R=83.14;        % bar*cm^3*mol^-1*K^-1

MW=92.141;      % Molecular Wt.

Tfp=178;        % Freezing Pt, K

Tb=383.8;       % Boiling Pt, K

 

T=input('Enter BubblerTemperature:  ')

PT=1.01325; %Operating Pressure, bar

%Antoine

%lnPvp_A=VPA-(VPB/(T+VPC))

%Pvp_A=exp(lnPvp_A)*760

%y=Pvp_A/PT

 

%Wagner

x=1-T/Tc;

Psat_sol=exp( ((1-x)^-1)*( VPA*x+VPB*x^1.5 +VPC*x^3+VPD*x^6 ) )*Pc; % bar

ys=Psat_sol/PT                                      % Fraction of undiluted vapor

 

Qc=input('Enter initial Carrier Gas, SCCM: ');       % Carrier Flow, SCCM

Q1=input('Enter Dilutant 1 initial flow, SCCM: ');  % Dilutant 1, SCCM

Q2=2.*Q1;                                           % Dilutant 2, SCCM

 

Qs=(ys.*Qc)./(1-ys)             % Volume of Vapor generated from bubbler, cm^3/min

                                % by volumetric fraction equal to mole fraction

Qcs=Qc+Qs                       % volume of carrier gas and solvent vapor, cm^3/min

 

yds=Qs./(Qcs+Q1+Q2)             % Fraction of diluted vapor

                

Cmixt=Psat_sol./(R.*T*(1/100^3) )           % Mixture concentration, mol/m^3

Cds=yds.*Cmixt                              % Concentration of diluted mixture, mol/m^3

Cds_mg=Cds.*MW*1000                         % Concentration diluted mixture, mg/m^3

PPM_vv=(Qs./(Qcs+Q1+Q2))*(10^6)             % Parts per million, by volume

 

selection

 

end

 

if x==3

% Cyclohexane

VPA=-6.96009;

VPB=1.31328;

VPC=-2.75683;

VPD=-2.45491;

Tc=553.5;

Pc=40.7;

R=83.14;        % bar*cm^3*mol^-1*K^-1

MW=82.146;      % Molecular Wt.

Tfp=169.7;      % Freezing Pt, K

Tb=356.1;       % Boiling Pt, K

 

T=input('Enter BubblerTemperature:  ')

PT=1.01325; %Operating Pressure, bar

%Antoine

%lnPvp_A=VPA-(VPB/(T+VPC))

%Pvp_A=exp(lnPvp_A)*760

%y=Pvp_A/PT

 

%Wagner

x=1-T/Tc;

Psat_sol=exp( ((1-x)^-1)*( VPA*x+VPB*x^1.5 +VPC*x^3+VPD*x^6 ) )*Pc; % bar

ys=Psat_sol/PT                                      % Fraction of undiluted vapor

 

Qc=input('Enter initial Carrier Gas SCCM: ');       % Carrier Flow, SCCM

Q1=input('Enter Dilutant 1 initial flow, SCCM: ');  % Dilutant 1, SCCM

Q2=2.*Q1;                                           % Dilutant 2, SCCM

 

Qs=(ys.*Qc)./(1-ys)             % Volume of Vapor generated from bubbler, cm^3/min

                                % by volumetric fraction equal to mole fraction

Qcs=Qc+Qs                       % volume of carrier gas and solvent vapor, cm^3/min

 

yds=Qs./(Qcs+Q1+Q2)             % Fraction of diluted vapor

                

Cmixt=Psat_sol./(R.*T*(1/100^3) )           % Mixture concentration, mol/m^3

Cds=yds.*Cmixt                              % Concentration of diluted mixture, mol/m^3

Cds_mg=Cds.*MW*1000                         % Concentration diluted mixture, mg/m^3

PPM_vv=(Qs./(Qcs+Q1+Q2))*(10^6)             % Parts per million, by volume

 

selection

 

end

 

if x==4

%n-Hexane Constants

VPA=-7.46765;

VPB=1.44211;

VPC=-3.28222;

VPD=-2.50941;

Tc=507.5;

Pc=30.1;

R=83.14;    % bar*cm^3*mol^-1*K^-1

MW=86.178;  % Molecular Wt.

Tfp=177.8;  % Freezing Pt, K

Tb=341.9;   % Boiling Pt, K

 

T=input('Enter BubblerTemperature:  ')

PT=1.01325; %Operating Pressure, bar

%Antoine

%lnPvp_A=VPA-(VPB/(T+VPC))

%Pvp_A=exp(lnPvp_A)*760

%y=Pvp_A/PT

 

%Wagner

x=1-T/Tc;

Psat_sol=exp( ((1-x)^-1)*( VPA*x+VPB*x^1.5 +VPC*x^3+VPD*x^6 ) )*Pc; % bar

ys=Psat_sol/PT                                      % Fraction of undiluted vapor

 

Qc=input('Enter initial Carrier Gas SCCM: ');       % Carrier Flow, SCCM

Q1=input('Enter Dilutant 1 initial flow, SCCM: ');  % Dilutant 1, SCCM

Q2=2.*Q1;                                           % Dilutant 2, SCCM

 

Qs=(ys.*Qc)./(1-ys)             % Volume of Vapor generated from bubbler, cm^3/min

                                % by volumetric fraction equal to mole fraction

Qcs=Qc+Qs                       % volume of carrier gas and solvent vapor, cm^3/min

 

yds=Qs./(Qcs+Q1+Q2)             % Fraction of diluted vapor

                

Cmixt=Psat_sol./(R.*T*(1/100^3) )           % Mixture concentration, mol/m^3

Cds=yds.*Cmixt                              % Concentration of diluted mixture, mol/m^3

Cds_mg=Cds.*MW*1000                         % Concentration diluted mixture, mg/m^3

PPM_vv=(Qs./(Qcs+Q1+Q2))*(10^6)             % Parts per million, by volume

 

selection

end

 

if x==5

% dichloromethane Constants

VPA=-7.35739;

VPB=2.17546;

VPC=-4.07038;

VPD=3.50701;

Tc=510;

Pc=63;

R=83.14;        % bar*cm^3*mol^-1*K^-1

MW=84.933;      % Molecular Wt.

Tfp=178.1;      % Freezing Pt, K

Tb=313.0;       % Boiling Pt, K

%Operate (263 to 303 K, or -10 to 303 K)

T=input('Enter BubblerTemperature:  ')

PT=1.01325; %Operating Pressure, bar

%Antoine

%lnPvp_A=VPA-(VPB/(T+VPC))

%Pvp_A=exp(lnPvp_A)*760

%y=Pvp_A/PT

 

%Wagner

x=1-T/Tc;

Psat_sol=exp( ((1-x)^-1)*( VPA*x+VPB*x^1.5 +VPC*x^3+VPD*x^6 ) )*Pc; % bar

ys=Psat_sol/PT                                      % Fraction of undiluted vapor

 

Qc=input('Enter initial Carrier Gas SCCM: ');       % Carrier Flow, SCCM

Q1=input('Enter Dilutant 1 initial flow, SCCM: ');  % Dilutant 1, SCCM

Q2=2.*Q1;                                           % Dilutant 2, SCCM

 

Qs=(ys.*Qc)./(1-ys)             % Volume of Vapor generated from bubbler, cm^3/min

                                % by volumetric fraction equal to mole fraction

Qcs=Qc+Qs                       % volume of carrier gas and solvent vapor, cm^3/min

 

yds=Qs./(Qcs+Q1+Q2)             % Fraction of diluted vapor

                

Cmixt=Psat_sol./(R.*T*(1/100^3) )           % Mixture concentration, mol/m^3

Cds=yds.*Cmixt                              % Concentration of diluted mixture, mol/m^3

Cds_mg=Cds.*MW*1000                         % Concentration diluted mixture, mg/m^3

PPM_vv=(Qs./(Qcs+Q1+Q2))*(10^6)             % Parts per million, by volume

 

selection

end