A global leader in chemical manufacturing wanted a reliable solution to monitor moisture levels in propylene oxide (PO). PO is a highly hazardous and flammable substance used in producing essential chemicals. This application required precision and safety, pushing the limits of traditional measurement techniques.
Pioneers in process analysis
We installed our first online process analyzer back in 1978 at Dow Chemical.
Since then, we have come a long way and installed more than 10,000 units worldwide. And since day one, we never shied away from a challenge: we have installed customized process analyzers in the desert, on boats, and in dangerous environments. Meeting the needs of our customers is our number one priority.
Who is Metrohm Process Analytics?
Metrohm Process Analytics is a specialized division of the Metrohm company, dedicated to developing innovative solutions for industrial processing. Metrohm Process Analytics focuses on providing customized solutions based on our extensive range of laboratory analytical techniques.
Under the Metrohm Process Analytics brand, we offer process analyzers for titration, Raman spectroscopy, near-infrared spectroscopy (NIRS), electrochemistry, photometry, x-ray fluorescence (XRF), ion chromatography (IC), and ion-selective measurements.
Our solutions offer both unparalleled flexibility and full analytic customization. The product range varies from single-parameter analyzers to the most advanced multiparameter, explosion-proof analyzers, specially made for hazardous environments.
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Learn more about our scope of expertise: from ammonia in saturated brine and fertilizers, to zinc mining and purification – we've done it all. Our Applications Book gives a broad overview of applications sold in the past 50+ years to the process industry. With more than 10,000 process analyzers installed globally, there is a solution to your every challenge.
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We love customers who challenge us
Propylene oxide production demands stringent moisture control to prevent side reactions. Traditional FT-IR analyzers previously used by the manufacturer required significant maintenance and frequent downtime. Moreover, the hazardous and hygroscopic nature of PO made offline laboratory analysis too slow and impractical for real-time adjustments during production. The company needed a robust, explosion-proof solution for accurate, continuous, and low-level moisture monitoring.
To address these challenges, a robust industrial near-infrared spectroscopy process analyzer was introduced. Designed for hazardous environments, this instrument provides real-time, precise moisture measurements, using an explosion-proof (ATEX-certified) housing and an advanced industrial-grade flow cell. Capable of analyzing up to nine sampling points simultaneously, the system delivers results every 30 seconds, to ensure rapid response to production variations.
Key advantages include:
- High precision: Moisture levels in the low ppm range are measured with ±4 ppm accuracy.
- Improved safety: Online analysis eliminates the risks associated with laboratory sampling of PO (hygroscopic and flammable substance).
- Enhanced reliability: The signal-to-noise ratio (S/N) outperformed the previous FT-IR system. This reduces downtime.
Additionally, Karl Fischer titration was used to validate results to ensure accuracy in real-world production environments. Expert input from Metrohm improved laboratory practices, adding value to the overall workflow.
Thanks to the explosion-proof analyzer, the manufacturer now monitors moisture at multiple points from distillation to the final product. This innovative solution improves product quality, reduces chemical treatment needs, and enhances safety – all while increasing operational efficiency.
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Application note: Inline process monitoring of the moisture content in propylene oxide
A crude refinery and chemical manufacturer, operating in a remote desert location, faced challenges in safely and efficiently monitoring Octane Number (ON) during reformate production. This high-value stream requires precise, real-time control to optimize product quality, meet ASTM standards, and ensure safety in a hazardous environment.
Reformate production involves catalytic reforming, a process that demands continuous monitoring to make chemical adjustments and maintain compliance with strict ASTM standards. Real-time analysis is essential to qualify the final product for market release.
The customer’s existing Fourier Transform Near-Infrared Spectroscopy (FT-NIRS) analyzer was unreliable, prone to errors, and required frequent maintenance. Additionally, a poorly designed sampling system led to inconsistent results, making it difficult to trust the data for process adjustments. The hazardous nature of the operation also required an explosion-proof system capable of delivering timely and accurate results.
Metrohm Process Analytics delivered a comprehensive solution tailored to the customer’s needs, including a high-performance process analyzer combined with an advanced preconditioning system.
Key features of the solution include:
- Precise sample delivery: Inline filtration devices and temperature-controlled flow cells ensure reproducible, accurate measurements.
- Compliance with ASTM standards: The system is designed to meet strict quality requirements for reformate production.
- Explosion-proof housing: Ensuring safe operation in hazardous zones.
- Validation sampling: A dedicated port allows for easy collection of reference samples.
Expert local support and training were provided to ensure safe and effective operation in this remote and challenging environment. Training included maintenance guidelines and data interpretation, empowering the customer’s team to optimize their processes confidently.
With this customized solution, the refinery now monitors reformate production safely and efficiently using an explosion-proof analyzer. Real-time online ON measurements enable quick responses to process variations, reducing downtime and optimizing production efficiency. From tailored analyzers and application method development to on-site training, Metrohm Process Analytics provides complete solutions for even the most demanding applications.
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Application note: Online process monitoring of octane number during catalytic reforming
A global leader in the chemical industry needed a reliable and compact solution to monitor the dosage of a hydrogen peroxide-based medication that treats fish for lice during seawater baths on active boats. This challenging application required accuracy, speed, and durability in a non-traditional environment.
The delousing process involves immersing fish in seawater baths containing carefully measured doses of hydrogen peroxide (H₂O₂) to eliminate parasites. Accurate dosing is crucial because:
- Underdosing leaves parasites attached, compromising product quality and potentially harming the fish.
- Overdosing can cause oxidative stress, skin damage, or even death.
Given the remote, on-boat location, the solution needed to withstand harsh conditions, including rocking and swaying motions, while occupying minimal space. Rapid analysis and response times were critical to ensure correct dosing and compliance with government standards.
Metrohm Process Analytics developed a robust and compact online process analyzer specifically for this unique application.
Key features of the solution include:
- Fast analysis times: Measurements are completed in just 60 seconds, enabling immediate adjustments.
- Compact and durable design: The analyzer is small enough to fit in the limited space on board, while being rugged enough to handle the unstable conditions of an active boat.
- Precise dosing and monitoring: Ensuring accurate medication levels and optimal water quality to protect fish health.
This tailored solution was designed in collaboration with Metrohm’s expert chemists. It is a showcase of their ability to adapt analytical technologies for unconventional and remote applications.
Thanks to Metrohm Process Analytics’ innovative and customized approach, the customer now has a dependable solution for one of their most challenging applications. Whether for industrial or remote process monitoring, Metrohm delivers more than just an analyzer; it provides integrated solutions tailored to the customer’s needs.
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Application note: Effectively monitoring hydrogen peroxide online in salmon farms
In the steel industry world, ArcelorMittal is a name that resonates. It is one of the world's largest steel producers and plays a crucial role in the construction of modern infrastructures. ArcelorMittal relies on a process analyzer from Metrohm Process Analytics to monitor the quality of phosphate treatment and improve the efficiency of the process overall.
Atline, inline, or online process analyzers?
Most laboratory work is usually performed offline. However, in industrial process environments, offline samples often fail to reflect real-time process conditions. This can lead to delays in necessary adjustments – potentially hours or even days after identifying an out-of-specification reading. These inefficiencies in process analytics and control can be costly.
Manual samples also increase the risk of overcompensation in chemical treatments, as they are collected much less frequently than online, inline, or atline measurements. This can lead to unnecessary adjustments and inefficiencies in process control analytics.
So, what are online, inline, and atline measurements, and how do they enhance process analytical technology (PAT)?
Atline analysis is automated and performed near the sampling point. While there is not as much need for intervention as with traditional offline methods, it still requires continuous supervision. These systems bridge the gap between manual laboratory testing and fully automated process analytical technology. It offers a more practical approach to process control and analytics.
Online analysis only requires little manpower, as the entire workflow – from sample preconditioning to analysis – is automated. These systems deliver rapid measurements through integration with closed-loop control, enabling quick adjustments to maintain process consistency.
Inline analysis is ideal for the most accurate and immediate representation of a process stream. These measurements occur directly within the process stream, eliminating the need for sample collection or processing waste. Inline process analyzers provide instant results. This allows for seamless, automatic adjustments. This real-time approach offers unparalleled efficiency, making it the highest class of process analytical technology.
Industries can achieve optimal performance, reduce costs, and minimize waste by using advanced process analytical technology and Metrohm Process Analyzers. These allow for seamless integration of predictive analytics into process control, leading to faster, more informed adjustments. Adopting online, inline, and atline measurement methods is essential for maintaining efficiency and staying competitive in the field of modern process analytics and control.
Get to know our products
Metrohm Process Analytics has over 50 years of experience with online process analysis.
Our family of Process Analyzers brings laboratory analysis online for continuous monitoring and control. From titration and XRF to Raman and near-infrared spectroscopy, our robust and reliable analyzers are tailored to meet the demands of various industrial applications.
We are here for you, around the clock, around the globe
Metrohm Quality Service provides more than just analyzer service.
From your first contact with a sales engineer, to consultation sessions and emergency services, Metrohm Process Analytics is there for you. Metrohm has offices in over 50 countries worldwide and is thus able to provide on-site service and training in your local language in the shortest time possible.
Precision Process Monitoring
With the 2060 platform analyzers, we offer an advanced software solution tailored to comprehensive process analysis and diagnostics. The IMPACT software is specifically engineered for 24/7 inline, online, and atline analysis of multiple parameters across your plant – from quality control to manufacturing – ensuring nothing in your process will go unnoticed.