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SiC based field effect sensors and sensor systems for combustion control applications

by Andersson, Mike

Abstract (Summary)
Increasing oil prices and concerns about global warming have reinforced the interest in biofuels for domestic and district heating, most commonly through combustion of solid biomass like wood logs, hog fuel and pellets. Combustion at non-optimal conditions can, however, lead to substantial emissions of noxious compounds like unburned hydrocarbons, carbon monoxide, and nitrogen oxides as well as the generation of soot.Depending on the rate of combustion more or less air is needed per unit time to completely oxidize the fuel; deficiency of air leading to emissions of unburned matter and too much of excess air to slow combustion kinetics and emissions of mainly carbon monoxide. The rate of combustion is influenced by parameters like fuel quality – moisture and ash content etc. – and in what phase the combustion takes place (in the gas phase through combustion of evaporated substances or on the surface of char coal particles), none of which is constant over time.The key to boiler operation, both from an environmental as well as a power to fuel economy point of view, is thus the careful adjustment of the air supply throughout the combustion process. So far, no control schemes have been applied to small-scale combustors, though, mainly due to the lack of cheap and simple means to measure basic flue gas parameters like oxygen, total hydrocarbon, and carbon monoxide concentrations.This thesis reports about investigations on and characterization of silicon carbide (SiC) based Metal Insulator Semiconductor (MIS) field effect gas sensors regarding their utility in emissions monitoring and combustion control applications as well as the final development of a sensor based control system for wood fired domestic heating systems.From the main sensitivity profiles of such sensor devices, with platinum (Pt) and iridium (Ir) as the catalytic metal contacts (providing the gas sensing ability), towards some typical flue gas constituents as well as ammonia (NH3), a system comprising four individual sensors operated at different temperatures was developed, which through the application of Partial Least Squares (PLS) regression, showed good performance regarding simultaneous monitoring of propene (a model hydrocarbon) and ammonia concentrations in synthetic flue gases of varying content. The sensitivity to CO was, however, negligible. The sensor system also performed well regarding ammonia slip monitoring when tested in real flue gases in a 5.6 MW boiler running SNCR (Selective Non-Catalytic reduction of nitrogen oxides with ammonia).When applied to a 200 kW wood pellet fuelled boiler a similar sensor system was, however, not able to follow the flue gas hydrocarbon concentration in all encountered situations. A PCA (Principal Components Analysis) based scheme for the manipulation of sensor and flue gas temperature data, enabling monitoring of the state of combustion (deficiency or too much of excess air), was however possible to develop. The discrepancy between laboratory and field test results was suspected and later on shown to depend on the larger variation in CO and oxygen concentrations in the flue gases as compared to the laboratory tests.Detailed studies of the CO response characteristics for Pt gate MISiC sensors revealed a highly non-linear sensitivity towards CO, a large response only encountered at high CO/O2 ratios or low temperatures. The response exhibits a sharp switch between a small and a large value when crossing a certain CO/O2 ratio at constant operating temperature, correlated to the transition from an oxygen dominated to an almost fully CO covered Pt surface, originating from the difference in adsorption kinetics between CO and O2. Indications were also given pointing towards an increased sensitivity to background hydrogen as being the mediator of at least part of the CO response. Some general characteristics regarding the response mechanism of field effect sensors with differently structured metal contacts were also indicated.The CO response mechanism of Pt metal MISiC sensors could also be utilized in developing a combustion control system based on two sensors and a thermocouple, which when tested in a 40 kW wood fired boiler exhibited a good performance for fuels with extremely low to normal moisture content, substantially decreasing emissions of unburned matter.
Bibliographical Information:

Advisor:

School:Linköpings universitet

School Location:Sweden

Source Type:Doctoral Dissertation

Keywords:NATURAL SCIENCES; Physics; Other physics; SiC; Field Effect Sensors; Combustion Control

ISBN:978-91-85715-56-5

Date of Publication:01/01/2007

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