Frequently Asked Questions — ETI Online Industrial Process Analyzers

Question 1

What is "Online Analysis"?

Accepted Answer

Online analysis is the measurement of material characteristics in real-time. ETI's analyzer products are online and non-destructive, providing continuous data without interrupting the production process.

Question 2

How will an online analyzer help my process?

Accepted Answer

ETI online analyzers provide near-real-time elemental and quality feedback, allowing process control decisions to be made as material moves through the plant. Whether you're monitoring ash content in coal, raw mix composition in cement, or mass flow on a conveyor belt, continuous data enables immediate corrective actions and optimizes overall process efficiency — replacing slow, infrequent grab-sample laboratory analysis.

Question 3

What is SGA, DGA, and PGNAA?

Accepted Answer

These are the three core measurement technologies ETI uses across its analyzer product line. SGA (Single Gamma Analyzer) uses a single gamma source to measure bulk density and mass flow — the basis of the Model 500 Nuclear Belt Scale. DGA (Dual Gamma Analyzer) uses two gamma sources at different energy levels to measure ash content, heating value, or slurry density — used in the Model 410 Ash Analyzer, Model 510 BTU Meter, and Model 520 Slurry Analyzer. PGNAA (Prompt Gamma Neutron Activation Analysis) bombards material with neutrons and measures the resulting gamma spectrum to determine full elemental composition in real time — the technology behind the Model 730 FSEA.

Question 4

What analyzer do I need?

Accepted Answer

A guide to equipment selection is available in our Analyzer Capabilities document, which compares the Model 730 FSEA (PGNAA, full elemental analysis), Model 410 Ash Analyzer (DGA, ash and heating value), Model 500 Nuclear Belt Scale (SGA, mass flow), Model 510 BTU Meter (DGA, heating value in pipe), and Model 520 Slurry Analyzer (DGA, slurry density and ash). Contact us for a personalized recommendation based on your material and process requirements.

Question 5

How does flow rate affect analysis?

Accepted Answer

Flow rate has no effect on analysis. The analysis process begins with the bombardment of the material on the belt with thermal neutrons and/or gamma rays, making it independent of material flow speed.

Question 6

How are ETI analyzers calibrated?

Accepted Answer

ETI analyzers are calibrated using static bulk material samples before and after installation, and validated through dynamic comparisons against laboratory analysis after commissioning. For PGNAA instruments like the Model 730 FSEA, calibration accounts for full elemental composition. For dual gamma instruments (Models 410, 510, 520), calibration is performed against the specific parameter being measured — ash content, BTU, or slurry density. Recalibration is performed after source replenishments and detector replacements.

Question 7

What should I do if no data is displayed in DataView?

Accepted Answer

Work through these checks in order: (1) Verify there is material on the belt and the belt is moving. (2) Confirm the DataView application is running. (3) Check that the detector spectrum is visible in the DataView interface. (4) If the spectrum is visible but appears as noise, verify the source shutter is in the ON position. If none of these steps resolve the issue, contact ETI support for assistance with your Model 730 FSEA or dual gamma analyzer.

Question 8

How do I safely shut down the analyzer?

Accepted Answer

Always shut down all running applications before powering off the analyzer computer. Never remove power from a running computer. The correct shutdown sequence for all ETI analyzers is: close all DataView and other applications, shut down the operating system, then remove power from the DAU (Data Acquisition Unit).

Question 9

What industries use ETI analyzers?

Accepted Answer

ETI online analyzers are used across industries where continuous bulk material quality monitoring is critical. Primary markets include coal-fired power generation (ash content, BTU, sulfur, mercury), coal mining and preparation plants, cement and aggregate production (raw mix elemental analysis), biomass energy, metals and minerals processing, plastics recycling (mass flow measurement), and rare-earth extraction. The Model 730 FSEA, Model 410 Ash Analyzer, Model 500 Nuclear Belt Scale, Model 510 BTU Meter, and Model 520 Slurry Analyzer each serve specific measurement needs within these industries.

Question 10

What output formats and communication protocols are supported?

Accepted Answer

ETI analyzers support a variety of integration options including Modbus TCP/IP, direct SQL database connection, and analog outputs (4–20 mA). Digital I/O channels are also available for direct integration with DCS, SCADA, and other process control systems. Analysis data is stored minute-by-minute in a SQL database and is viewable in ETI's DataView software.

Question 11

How long does installation and commissioning typically take?

Accepted Answer

Installation and commissioning time varies by analyzer type and site conditions, but most systems can be installed and commissioned within one to three days. ETI engineers handle the full process, including mechanical installation, electrical connections, calibration, and operator training.

Question 12

Does the Model 730 FSEA require a radioactive materials license?

Accepted Answer

Yes. Government regulations require the plant to obtain a radioactive materials license to receive the Californium-252 (Cf-252) neutron sources used in the Model 730 FSEA. The analyzer itself contains no radioactive material during shipment, so no license is required to receive the unit. ETI will assist with the NRC or Agreement State licensing process.

Question 13

Are there any conveyor belt restrictions for the Model 730 FSEA?

Accepted Answer

Yes. The Model 730 FSEA may be adversely affected by conveyor belts made of PVC or certain configurations of steel-reinforced belting, because these materials interfere with the PGNAA neutron measurement. Belt specifications must be reviewed prior to installation. The Type-A housing is designed for a standard 35° belt angle, while the Type-B housing accommodates a 45° belt angle.

Question 14

How often do the neutron sources need to be replaced?

Accepted Answer

The Californium-252 (Cf-252) neutron sources used in the Model 730 FSEA have a half-life of 2.646 years. At approximately the 30-month mark, two new Cf-252 sources are added alongside the original sources to maintain PGNAA measurement performance. ETI handles all source transportation, installation, and licensed disposal — the customer is not responsible for source logistics.

Question 15

What routine maintenance does the Model 730 FSEA require?

Accepted Answer

The FSEA requires minimal maintenance. Weekly tasks include visual inspection of the belt-mounted unit for damage, checking belt alignment, and verifying there is no dust buildup in the tunnel. Monthly tasks include checking the tachometer and measuring slider bed wear plate thickness. Every six months, ETI performs a mandatory radioactive source leak test and general inspection.

Question 16

How is data from the Model 730 FSEA accessed and integrated with plant systems?

Accepted Answer

PGNAA analysis data from the Model 730 FSEA is stored in a SQL database on a minute-by-minute basis and is viewable in ETI's DataView application. Data can be retrieved by a Plant Information (PI) system via direct database connection or Modbus TCP/IP. The system also provides 4 analog output channels (4–20 mA) and 4 digital output channels for direct integration with DCS, SCADA, or process control systems.

Question 17

What materials can the Model 730 analyze?

Accepted Answer

The Model 730 FSEA is capable of analyzing a wide range of bulk materials on a conveyor belt using PGNAA. Beyond coal — where it measures ash, sulfur, mercury, BTU, and base-to-acid ratio — it can be calibrated for cement raw mix and clinker (calcium, silicon, aluminum, iron, magnesium), biomass feedstocks, metals and mineral ores, plastics, and rare-earth materials. Because PGNAA measures full elemental composition in real time, the Model 730 can be configured for virtually any material where elemental content is relevant to process control.

Question 18

Can the Model 730 FSEA operate in dusty or harsh environments?

Accepted Answer

Yes. The Model 730 FSEA is designed for demanding industrial conveyor environments. The instrument is housed in a rugged enclosure suitable for dusty, wet, and outdoor conditions. The tunnel design shields the PGNAA detector from ambient interference, and the system is built to operate continuously in coal plants, cement quarries, mining operations, and other harsh bulk material processing environments.

Question 19

What is the difference between the Model 410, 500, 510, and 520?

Accepted Answer

The Model 410M is our most popular configuration — it combines dual-gamma (DGA) ash measurement with a density-based moisture correlation module, giving you ash content, moisture, and heating value simultaneously from a single belt-mounted unit. The base Model 410 uses the same dual-gamma platform without the moisture module, measuring ash content and heating value in coal. The Model 500 Nuclear Belt Scale uses single-gamma (SGA) attenuation for non-contact mass flow and belt weight measurement. The Model 510 BTU Meter uses dual-gamma attenuation to measure heating value directly in a feeder pipe. The Model 520 Multi-Gamma Slurry Analyzer uses dual-gamma attenuation for ash content and density measurement in slurry pipelines.

Question 20

Do the dual gamma analyzers require a radioactive materials license?

Accepted Answer

Yes. The Model 410 Ash Analyzer, Model 500 Nuclear Belt Scale, Model 510 BTU Meter, and Model 520 Slurry Analyzer are licensed radioisotope-based gauges containing sealed radioactive sources — Am-241 (Americium-241) and Cs-137 (Cesium-137). In the United States, possession and use of these sealed sources requires a radioactive materials license issued by the Nuclear Regulatory Commission (NRC) or an Agreement State.

Question 21

What calibration samples are required?

Accepted Answer

Before factory testing begins, the customer must supply bulk material calibration samples representing the Low, Mid, and High ranges of the parameter being measured — 25 kg of each range. For the Model 410 Ash Analyzer and Model 510 BTU Meter, this means coal samples spanning the expected ash or BTU range. ETI sends these samples to an independent laboratory for certified analysis, which forms the basis of the instrument calibration.

Question 22

What is the source shutter and when should it be used?

Accepted Answer

The source shutter is a mechanical block inside the source holder assembly of the dual gamma analyzer that stops the Am-241 or Cs-137 radiation beam from being emitted. The area inside the frame of the Belt-Mounted Unit (BMU) is considered a radiation area — the shutter must be moved to the OFF position any time maintenance is being performed on or near the BMU, including belt repairs, conveyor work, or detector servicing.

Question 23

What routine maintenance do the dual gamma analyzers require?

Accepted Answer

The Model 410 Ash Analyzer, Model 500 Nuclear Belt Scale, Model 510 BTU Meter, and Model 520 Slurry Analyzer have a simple mechanical and electronic design that requires minimal maintenance. Weekly tasks include visually checking the Belt-Mounted Unit (BMU) for cracks or physical damage, and ensuring there is no dust buildup on the source lens or detector surface that could affect gamma transmission accuracy.

Question 24

How often do the gamma sources need to be replaced?

Accepted Answer

Cs-137 (Cesium-137) has a half-life of 30.04 years and Am-241 (Americium-241) has a half-life of 432.6 years. Neither sealed source used in ETI's dual gamma analyzers — the Model 410, 500, 510, or 520 — is expected to require replacement during the normal service life of the instrument.

Question 25

Can the analyzers handle varying belt speeds or material depths?

Accepted Answer

Yes. ETI's dual gamma analyzers — the Model 410 Ash Analyzer, Model 500 Nuclear Belt Scale, Model 510 BTU Meter, and Model 520 Slurry Analyzer — are not affected by changes in belt speed. Variations in material depth (loading) on the belt are compensated through the dual-gamma measurement technique, which uses two gamma energy levels to account for differences in material thickness and maintain accurate ash, BTU, density, or mass flow readings.

Question 26

What happens to measurements during an empty belt condition?

Accepted Answer

During an empty belt, the analyzer will detect the absence of material and the readings will reflect that condition. ETI's DataView software is configured to flag or exclude these periods from process data, ensuring that empty belt events do not corrupt historical averages or process control outputs.

Question 27

How are sealed radioactive sources disposed of at end of life?

Accepted Answer

ETI manages the full lifecycle of sealed radioactive sources used in its analyzers — including the Cf-252 neutron sources in the Model 730 FSEA and the Am-241 and Cs-137 sources in the dual gamma product line. When sources reach the end of their useful life, ETI coordinates return shipment to a licensed disposal facility in compliance with NRC and Agreement State regulations. Customers are not responsible for source disposal logistics.

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