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Real-time process analytical chemistry solutions

Automated measurement of critical chemical process parameters to boost plant performance

Laser-based measurement technologies like Raman spectroscopy and tunable diode laser absorption spectroscopy (TDLAS), continue to gain traction over alternative methods like gas chromatography or mass spectrometry. With no moving parts, and greatly reduced need for sampling, the used process analyzers are easier to maintain, and provide highly precise results within seconds. This enables smarter control of rapidly changing processes in real-time, without human exposure to hazardous chemicals.

How we can help

Our analytical solutions provide fast, real-time measurement of chemical compositions with minimal operating costs and safety risks. We are experts in the development of customized analytical solutions that overcome unique measurement challenges including the design of process-specific probes, analyzer racks, and shelters.

  • Complete application support from feasibility study through commissioning, maintenance contracts, and long-term chemometric modeling support

  • Process analytical chemistry solutions are engineered to meet industry standards worldwide

  • Global service and support network

Applications

Reaction endpoint detection and kinetics control

Emulsion polymerization produces a wide range of polymeric materials, including paints, adhesives and synthetic rubbers. This type of reaction is performed within an aqueous environment where the monomer species is maintained within a single phase with a suitable surfactant or emulsifier. One or more monomer species may be used, and the resultant polymer or copolymer is produced as a stable suspension, in the form of a latex.

Detect reaction endpoint with Raman spectroscopy
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Raman spectroscopy is well suited for monitoring these reactions insofar as it is sensitive to the measurement of specific double bonds, and it does not suffer with interference from the aqueous matrix.

  • Band ratios can compensate for variations in overall measured intensity of the reaction

  • Water does not interfere with measurement in aqueous solutions

  • Ability to measure through glass reactor walls or windows

  • Excellent correlation with chromatographic and gravimetric data

Real-time control of gas impurities

Costs of a plant shutdown due to off-spec gas can be very high especially for petrochemical processes.

Controling gas impurities in feed gas in real time to improve product quality
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TDLAS analyzers monitor the quality of feed gases by selectively measuring contaminants such as ammonia (NH3), moisture (H2O) or acetylene (C2H2). These measurements help improve process control, meet product specifications, prevent catalyst poisoning and minimize flaring. The analyzers provide reliable measurements within seconds, thus enabling quick actions. We provide complete analyzer solutions comprising of a sample extraction and conditioning system and suitable analyzer enclosures.

In-line monitoring of product properties and quality

Polymerization reactions are often done in semi-batch mode. This allows for careful control of product composition in order to create high-performance materials with finely tuned custom properties. During the reaction, strict control over the reactant concentrations is necessary to avoid unwanted properties in the end-product. Simply adding the reactants in the correct ratio is insufficient.

Raman analyzers can identify bands for specific functional groups common to polymerization monomers
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Our Kaiser Raman analyzers are sensitive to specific functional groups, such as the vinyl and alkyl moieties common to polymerization monomers. Our easy sample interface and its fiber optic coupling to the base unit allows for flexible placement of the base unit relative to the batch reactors or process lines.

  • Options available for non-contact optics allowing measurement through reactor windows

  • Measure up to four batch reactors or process streams with a single analyzer

  • Deliver consistency between batches with respect to average molecular weight and polydispersity

Increase process control with in-line analytical methods

Process map of acetylene hydrogenation ©Endress+Hauser

By using TDLAS analyzers to monitor the contaminants in the feed gas, the costs of off-spec gas and shutdowns of the chemical plant can be avoided.

Schematic diagram of process-control system for semi-batch polymerization ©Endress+Hauser

Schematic diagram of process-control system for semi-batch polymerization.

Lợi ích

Process analytical chemistry (PAC) is key when striving to control and optimize your chemical processes. With in-line analytical technology, such as TDLAS and Raman spectroscopy, you will gain enhanced process understanding and control in real time. Bring your chemical plant to its next level of performance by increasing yield, improving quality, and ensuring the safest possible workplace.

  • Over 25

    years of continued operation by earliest installed analyzers

  • >2000

    process Raman analyzers installed around the world

  • 100+

    patents in Raman and holographic technology

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