Customer\r\n

Our customer is considered one of the largest chemical manufacturers in the world and is a long-time user of Metrohm process analyzers. The existing relationship with this company for both Metrohm laboratory instrumentation as well as our line of process analyzers meant they knew exactly who to turn to with quite a challenging application request: Metrohm Process Analytics. Among the myriad products they produce globally is propylene oxide (C₃H₆O, PO), a highly hazardous, hygroscopic, and flammable substance used in the production of various important chemicals.

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Challenge

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One of the main issues in PO production is to keep moisture content to a low level to avoid side reactions. Our customer came to us with an immense challenge which no other vendor could approach: reliable measurement of low moisture level in PO. Their previous system of measuring moisture relied upon a set of FT-IR analyzers, which required much maintenance, subsequently leading to a lot of downtime. The hazardous and hygroscopic nature of PO necessitates online analysis for the most precise measurement of moisture content and short response times. Performing laboratory analysis is slow and requires difficult sample treatment for accurate results. The low moisture levels present in PO need "real-time" monitoring, due to the high production throughput which necessitates short response times in case of process variations.

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Solution

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Considering the hazardous, flammable properties of PO, a robust explosion-proof (ATEX) process instrument was offered by Metrohm Process Analytics to fulfill the customer requirements. The NIRS XDS has a build-in ATEX housing and it can measure up to 9 independent sampling points. The measurements were made online thanks to an industrial grade flow cell, which allows to precisely monitor low levels of moisture (a few tens of ppm at a precision of ±4 ppm). Results are communicated in real-time (every 30 seconds) through 4-20 mA to customer PLC.

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After performing a feasibility study with our instrument at the customer’s laboratory, a direct comparison was made between the results from IR and NIR in the process environment. The signal to noise ratio (S/N) for our NIRS instrumentation is much better than their previous IR, which is an added benefit for such low-level moisture determination. Metrohm also provides Karl Fischer titration as a reference analysis to ensure the spectroscopic results are accurate. Customer laboratory practice was also improved with valuable input given by Metrohm titration experts. This industrial process analyzer is now monitoring several different sampling points from the distillation tower to the final product (finisher).

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Conclusion

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Our customer had a really challenging problem and now they can safely monitor in real-time the low water content in PO. The combination of a single, explosion-proof online process analyzer enables the end-user to reduce chemical treatment, improve product quality, and increase profits.

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客户

我们的客户被认为是世界上最大的化学品制造商之一，是Metrohm过程分析仪的长期用户。与这家公司现有的关系，包括Metrohm实验室仪器以及我们的过程分析仪系列，意味着他们确切地知道谁可以解决相当具有挑战性的应用请求:Metrohm过程分析。他们在全球生产的无数产品中包括环氧丙烷(C_3.H₆O, PO)，一种高度危险、吸湿和易燃的物质，用于生产各种重要的化学品。

挑战

PO生产中的一个主要问题是保持较低的水分含量，以避免副反应。我们的客户向我们提出了其他供应商无法解决的巨大挑战:可靠地测量PO中的低水分水平。他们之前测量水分的系统依赖于一套FT-IR分析仪，这需要大量的维护，随后导致了大量的停机时间。PO的危险和吸湿特性需要在线分析，以最精确地测量水分含量，并缩短响应时间。进行实验室分析是缓慢的，需要困难的样品处理准确的结果。由于生产产量高，在工艺变化的情况下需要较短的响应时间，因此PO中存在的低水分水平需要“实时”监测。

解决方案

考虑到PO的危险、易燃特性，Metrohm process Analytics公司提供了一种坚固的防爆(ATEX)工艺仪表，以满足客户的要求。NIRS XDS有一个内置ATEX外壳，它可以测量多达9个独立的采样点。多亏了一个工业级的流式细胞，测量是在线进行的，它可以精确地监测低水平的水分(几十ppm，精度为±4ppm)。结果通过4-20 mA实时(每30秒)传达给客户PLC。

在客户实验室使用我们的仪器进行可行性研究后，在工艺环境中对红外和近红外的结果进行了直接比较。我们NIRS仪器的信噪比(S/N)比以前的IR要好得多，这是低水平水分测定的额外好处。Metrohm还提供Karl Fischer滴定法作为参考分析，以确保光谱结果的准确性。客户实验室实践也得到了Metrohm滴定专家提供的有价值的输入。该工业过程分析仪现在监测从蒸馏塔到最终产品(整理器)的几个不同采样点。

结论

我们的客户遇到了一个非常具有挑战性的问题，现在他们可以安全地实时监测PO的低含水量。单一防爆在线过程分析仪的组合，使最终用户减少化学处理，提高产品质量，增加利润。

Customer\r\n

Our customer, located remotely in the desert, is a major crude refinery and chemical manufacturer which produces various products ranging from gasoline to fine chemicals. Gasoline production is a highly hazardous operation requiring strict adherence to safety standards (IECEx) and constant monitoring of key process parameters such as Octane Number (ON). Providing dependable process data in a timely manner means that downstream process units (catalytic reformer) can be optimized quickly, increasing profits while reducing operational costs.

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Challenge

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In the refining process, reformate is considered to be a high value stream, as it has a high octane number. During catalytic reforming, the process has to be constantly controlled to perform chemical adjustments which optimize the quality of the reformate. Prior to shipping and selling this product, strict compliance to the “American Society for Testing Materials” (ASTM) standards is required to qualify the reformate end product for release on the market. Therefore, precision is highly important for “real-time” monitoring of the process. Additionally, this process is carried out in a hazardous zone which requires a robust, explosion-proof solution, with short analysis times (“real-time” analysis) to provide enough accurate data to monitor any process changes. The current process analyzer at this customer site was a Fourier Transform Near-Infrared Spectroscopy analyzer (FT-NIRS), which was not reliable, requiring a high degree of maintenance and troubleshooting. Also, due to a poorly designed sampling system, the analyzer was producing erroneous results that could not be trusted for normal operation.

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Solution

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Metrohm Process Analytics can provide a full solution for almost any application. For this customer, an analyzer in combination with a high-performance preconditioning system was needed to ensure reproducible sample delivery to the process near-infrared (NIR) analyzer. The preconditioning system consists of several inline filtration devices and temperature-controlled flow cells enabling consistent measurements continuously with high accuracies. The preconditioning system also guarantees the correct sample take-off point as well as providing a port for validation sample collection. This complete package makes it possible to fulfill all of the ASTM requirements. Other requirements for industrial analysis, such as robust online flow cells for long time operation as well as an explosion-proof (ATEX) housing, were also integrated into this challenging process monitoring solution. Expert local support and trainings from Metrohm sales organizations were given the top priority in this remote location to ensure proper operation in such a dangerous process environment, covering maintenance guidelines and interpretation of the data provided by the online process analyzer.

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Conclusion

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Our customer can now safely control the production of reformate via online process monitoring using a turn-key solution developed specially by Metrohm Process Analytics for their challenging needs. Online measurements in a hazardous area using a remotely controlled explosion-proof analyzer makes the working environment safer for everyone. A quick response to any process upsets minimizes downtime and optimizes production efficiency. From the customized process analyzer to application method development and together with on-site trainings by our experts, we are your partner for any challenge.

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客户

我们的客户位于沙漠的偏远地区，是一家主要的原油炼油厂和化学品制造商，生产从汽油到精细化学品的各种产品。汽油生产是一项高度危险的作业，需要严格遵守安全标准(IECEx)，并不断监测关键工艺参数，如辛烷值(ON)。及时提供可靠的工艺数据意味着可以快速优化下游工艺单元(催化重整器)，在降低运营成本的同时增加利润。

挑战

在精炼过程中，重整油被认为是一种高价值流，因为它具有高辛烷值。在催化重整过程中，必须不断控制该过程，以进行化学调整，以优化重整的质量。在运输和销售此产品之前，必须严格遵守“美国材料测试协会”(ASTM)标准，以使改造最终产品有资格在市场上发布。因此，精度对于过程的“实时”监控是非常重要的。此外，该过程在危险区域进行，需要可靠的防爆解决方案，分析时间短(“实时”分析)，以提供足够准确的数据来监测任何工艺变化。目前该客户现场的工艺分析仪为傅立叶变换近红外光谱分析仪(FT-NIRS)，可靠性不高，对维护和故障排除的要求较高。此外，由于采样系统设计不佳，分析仪产生的错误结果不能用于正常操作。

解决方案

Metrohm Process Analytics可以为几乎任何应用提供完整的解决方案。对于该客户来说，需要一台与高性能预处理系统相结合的分析仪，以确保近红外(NIR)分析仪的样品可重复性。预处理系统由几个内联过滤装置和温控流池组成，可实现高精度连续一致测量。预处理系统还保证了正确的样品起飞点，并提供了一个用于验证样品收集的端口。这个完整的包使它能够满足所有的ASTM要求。工业分析的其他需求，如长时间运行的坚固在线流池以及防爆(ATEX)外壳，也被集成到这一具有挑战性的过程监控解决方案中。来自Metrohm销售机构的本地专家支持和培训在这个偏远的地方被赋予了最高的优先级，以确保在如此危险的过程环境中正常运行，包括维护指南和在线过程分析仪提供的数据解释。

结论

我们的客户现在可以通过在线过程监控，使用Metrohm process Analytics专门为其具有挑战性的需求开发的交钥匙解决方案，安全地控制重整液的生产。使用远程控制防爆分析仪在危险区域进行在线测量，使每个人的工作环境更安全。对任何工艺故障的快速响应可最大限度地减少停机时间并优化生产效率。从定制过程分析仪到应用方法开发，再加上我们专家的现场培训，我们是您应对任何挑战的合作伙伴。

Customer\r\n

Our customer, who is a major global player in the chemical industry, has a long-standing relationship with Metrohm Process Analytics and knows who to trust for their challenging non-traditional application requests. In this situation, they needed to find a robust solution to accurately measure a medication which treats fish for lice (delousing agent) in a seawater bath on an actively working boat. Simple.

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Challenge

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Ensuring correct dosage of the medication as well as monitoring the water quality and waste is essential for compliance with government standards. Fish are introduced to seawater baths containing precise amounts of hydrogen peroxide (H₂O₂) medication for short periods of time for delousing. This removes any attached parasites, which can then be filtered from the water. Underdosing the bath would leave parasites still attached to the fish, resulting in a low-quality product or even leading to death of the animal. However, overdosing can cause oxidative stress in the fish, the bleaching of skin/scales, and death as well. Therefore, a quick analysis and response time is needed for accurate treatment. The fact that this analysis must be carried out on an active boat in remote areas meant that our online process analyzer must be rugged enough to withstand everyday usage with unstable footing and rocking, swaying motions. The limited space on board meant that a small footprint was absolutely necessary. Process control in this situation can mean the difference between life and death of the animals.

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Solution

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A rugged solution, custom-fitted for fast analysis on the ship was proposed to this customer by Metrohm Process Analytics – certainly not a typical industrial application nor location! Furthermore, our team of expert chemists were able to develop an online analysis method now reduced to merely 60 seconds between measurements.

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Conclusion

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Currently, our customer is able to save more money through several improvements: less medication used due to more accurate dosing, less product loss from inaccurate medication, and overall improved practices owing to the fast analysis times we provide. Our long-standing relationship with this customer allowed us to present a custom-built solution that any other vendor would say no to. From industrial analysis to remote process monitoring, we offer an integrated process solution, not just an analyzer.

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客户

我们的客户是全球化工行业的主要参与者，与Metrohm Process Analytics有着长期的合作关系，并且知道谁可以信任他们具有挑战性的非传统应用请求。在这种情况下，他们需要找到一个强大的解决方案来准确测量一种药物，这种药物在活跃的工作船上的海水浴中治疗鱼的虱子(除虱剂)。简单。

挑战

确保正确的药物剂量以及监测水质和废物是符合政府标准的关键。鱼被引入含有精确量的过氧化氢(H₂O₂)短期用药除虱。这样可以去除附着在水中的寄生虫，然后将其从水中过滤掉。剂量不足会使寄生虫仍然附着在鱼身上，导致产品质量低，甚至导致动物死亡。然而，过量会导致鱼的氧化应激，皮肤/鳞片漂白，以及死亡。因此，准确的治疗需要快速的分析和响应时间。事实上，这种分析必须在偏远地区的活跃船只上进行，这意味着我们的在线过程分析仪必须足够坚固，以承受不稳定的基础和摇摆的日常使用。有限的空间意味着小的足迹是绝对必要的。在这种情况下，过程控制可能意味着动物的生与死的区别。

解决方案

metrhm Process Analytics为该客户提供了一种坚固耐用的解决方案，可用于船舶上的快速分析-当然不是典型的工业应用或位置!此外，我们的专家化学家团队能够开发一种在线分析方法，现在将测量间隔缩短到仅60秒。

结论

目前，我们的客户能够通过以下几个改进来节省更多的资金:由于更准确的剂量而减少药物使用，由于不准确的用药而减少产品损失，以及由于我们提供的快速分析时间而全面改进的实践。我们与该客户的长期合作关系使我们能够提供任何其他供应商都会拒绝的定制解决方案。从工业分析到远程过程监控，我们提供集成的过程解决方案，而不仅仅是一个分析仪。