News 1. Process. Protection from Gas Explosion Inertization During Centrifugation. Perspectives in Liquid Process Analytics INGOLD THORNTON

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1 Process Perspectives in Liquid Process Analytics News 1 Protection from Gas Explosion Inertization During Centrifugation INGOLD Leading Process Analytics THORNTON Leading Pure Water Analytics Comi Condor are one of the leading suppliers of vertical continuous and horizontal centrifuges for the fine chemicals industry. It has selected METTLER TOLEDO for oxygen measurement in the inertization control system of its products. The result is improved centrifuge productivity and performance through in-situ measurement, and less maintenance. Class-leading centrifuges The Italy-based Comi Condor company has supplied world-class filtering centrifuges for fine chemical and pharmaceutical ingredient production for over a century. It draws on decades of innovation and continuous improvement for developing the best separation techniques that fulfill the most stringent industry requirements for product quality and yield. Their products also comply with some of the world s most rigorous safety regulations. Founded in 1885, the company develops, manufactures and sells its centrifuges from two plants located in Milan and Pavia. It is the leader in robust and reliable centrifuges with particular emphasis on compliance and GMP fulfillment for the pharmaceutical industry. Highest inertization requirements Comi Condor has developed a monitoring and control system based on the continuous measurement of centrifuge overpressure and oxygen level. The system allows safe operation of purging, filling, processing and emptying of the centrifuge. The safety requirements for running centrifuges (next to the ones necessary for hazardous area certification) can vary from one country to another. Italy applies one of the most stringent concepts that can exist: overpressure and oxygen control must be present on each centrifuge control system. This is considered the safest method of operation compared to overpressure control only. Control of oxygen can ensure that that particular element of the explosion triangle is continuously kept

2 Publisher / Production Mettler-Toledo AG Process Analytics Im Hackacker 15 CH-8902 Urdorf Switzerland below a safe limit during all stages of the centrifugation process. How the application was originally handled Comi Condor has manufactured safe centrifuges using oxygen and overpressure control for the fine chemicals industry for decades. However, the company s customers often noted tedious and sometimes even unpredictable maintenance operations on the extractive oxygen systems as a significant drawback. Disturbed batch manufacturing schedules and yield loss were the result, thus impacting the overall performance of the centrifuge. In-situ oxygen measurement Comi Condor contacted METTLER TOLEDO for a more reliable and easier to maintain solution. They selected one of Illustrations MarCom-Archiv Comi Condor Siemens Water Technologies Fred11, Babar760, 350jb Dreamstime.com our amperometric systems based around the InPro TM 6800 G sensor to replace extractive installation in the control system of the centrifuges. Moreover, the InPro 6800 G can be mounted directly into the centrifuge, so the delicate gas sampling system they had been using could be removed, thereby increasing reliability and saving on costs. Accurate and fast After a successful test period, good practical experience was gained with the features of the new system. A comparison of both the extractive and the amperometric equipment showed that the simpler METTLER TOLEDO solution displayed excellent measurement accuracy and proved to be as fast as the extractive solution. Competitive advantage Comi Condor has gained a competitive edge by offering its customers more reliable centrifuges that reduce downtime and require minimal maintenance. For new centrifuges where both oxygen and overpressure control is required, Comi Condor now preferably chooses METTLER TOLEDO amperometric systems. Find out more at: c InPro 6800 G oxygen gas sensor Cost-effective: j Amperometric design means costly gas extraction and conditioning system is not required Reliable: j Unaffected by exposure to water, water vapor or most organic solvents Low maintenance: j Membrane body replacement takes just five minutes and can be conducted on site by the user Subject to technical changes. Mettler-Toledo AG 07 / 11 2 METTLER TOLEDO Process News 1

3 M800 Transmitter Reduce Maintenance with a New Transmitter! Lower your operating costs through proactive maintenance. With its unique imonitor feature, the new M800 transmitter provides all the information you need to prevent unnecessary and unanticipated maintenance of your process analytics sensors. One instrument When our customers speak, we listen. Two years of development work have gone in to making our latest transmitter not only the finest in our portfolio, but possibly the most user-friendly analyzer on the market. Advanced on-screen diagnostics provide real-time monitoring of sensor condition for proactive maintenance. Touchscreen technology and the intuitive user interface offer incomparable ease of use. And for the first time, you are able to use both METTLER TOLEDO Ingold and Thornton sensors on the same platform. All major parameters METTLER TOLEDO offers a highly versatile family of sensors for applications in process analytics and water treatment. The new M800 transmitter platform covers all major measurement parameters in one instrument: ph/orp, oxygen (amperometric and optical), ozone, conductivity and flow monitoring are all possible in conjunction with our Intelligent Sensor Management (ISM TM ) sensors, and other parameters will follow. Up to four analytical sensors plus two flow inputs can be connected to one M800. With this multi-channel multi-parameter ability, most applications in the chemical industry that are today covered by different transmitters can now be equipped with the same instrument platform. imonitor the key to efficient maintenance Most scheduled maintenance work is unnecessary. Proactive maintenance allows higher efficiency and hence cost savings in daily operations, by informing operators in advance as to when maintenance will be required. With the imonitor, the M800 transmitter provides a tool for optimizing your sensor maintenance tasks. At a glance, the current performance of each connected sensor can be ascertained. Color-coded bars for all ISM diagnostic data provide real-time determination of measuring result quality. Alerting operators proactively to maintenance requirements helps prevent unanticipated, costly process downtime and ensures easy and efficient maintenance management. Complete control at a touch The M800 s large, high-resolution, color touchscreen simplifies all transmitter operations. The freely programmable display of up to eight measurement values or diagnostics data provides all vital information on one screen, or up to eight screens, to suit your requirements. Fully tailorable wizard set-up allows you to reach any menu function in only three touches. This concept helps reduce training effort and configuration failures to an absolute minimum. M800 transmitter quick overview j Intelligent Sensor Management j Color touchscreen/imonitor j Measures ph/orp, conductivity, DO (amperometric and optical), DO 3, O 2 gas, flow j 2- and 4- channel versions j Logbook j User management Find out more about the M800, at: METTLER TOLEDO Process News 1 3

4 ph and DO Enhanced Process Safety with Digital Sensors The risk of human error for pharmaceutical manufacturers does not just apply to production. Inadequate measurement system documentation can be a significant headache. For a Chinese API producer, the advantages of digital sensors and asset management software were obvious time saved, simpler maintenance and documentation at the touch of a button. Chinese API producer Zhejiang Hisun Pharmaceutical Co. Ltd. was established in It is located in Taizhou, an emerging port city in the middle of China s south-east coast. Hisun produces a diverse range of products including anti-tumor, cardiovascular, anti-infection and immunosuppressant treatments. The company actively explores overseas markets and has established strategic cooperative relationships with Lily, Pfizer, Merck and Bayer among others. ph and DO measurement During the fermentation stages of pilot testing and production, Hisun pays particular attention to maintaining the correct ph and DO levels due to the considerable influence these parameters have on fermentation yield. For ph and DO measurement, Hisun has used in-line measurement systems from METTLER TOLEDO for many years. Over this period, Hisun purchased InPro 3253 ph electrodes, InPro 6800 DO sensors and the corresponding transmitters, and they were very satisfied with the performance of the systems. However, asset management of the sensors was problematic and calibration records were kept in notebooks which could easily be misplaced. Due to there being too many human factors it was impossible to understand in detail the use of each electrode and sensor. As a result, there was often no time to purchase spare parts when it came to replacement and the facility had no contingency in this regard. From analog to digital In 2009, Hisun began making the switch from METTLER TOLEDO s analog sensors to our digital Intelligent Sensor Management (ISM) sensors. The features of ISM were exactly what Hisun required. A microprocessor in the head of each ISM probe stores all relevant sensor and calibration data as well as the measurement values recorded during the process. The data is transmitted digitally to an ISM compatible transmitter that displays diagnostic information on the condition of the sensor. This allows engineers to quickly determine if a probe requires cleaning, calibration or has to be replaced before the next batch starts; significantly improving process safety and making maintenance planning and stock control much easier. isense Asset Suite Of even greater use to Hisun is the isense Asset Suite software for ISM sensors. With isense, a record of every sensor calibration as well as the entire history of each sensor used at the facility is stored in the software. With complete and reliable docu- 4 METTLER TOLEDO Process News 1

5 mentation for each sensor easily accessible, requirements of regulatory standards are simply met. Sensor documentation is not the only function of isense. The software performs accurate pre-calibration in the lab, which yields better sensor performance in the process and also means that pre-calibrated probes can be stored for quick exchange when required. Li Hui, Technology Center Measurement Supervisor at Hisun is pleased with the new system. In the past, operators conducted calibration using buffer solutions at site which was often polluted, and the calibration result was not particularly satisfactory. Now that calibration can be conducted using the isense software, we only need to bring the sensor to the workroom for calibration. The software is easy to operate and saves a great deal of time. As Hisun continues to make the switch from analog to digital in-line measurement sensors, they will benefit further from predictive maintenance and competent sensor asset management, and can put their calibration notebooks in the wastebasket. Discover more about intelligent sensors and isense, at: Best Practice Stay one step ahead of maintenance with ISM Intelligent Sensor Management (ISM) reduces the installation, maintenance and calibration effort for METTLER TOLEDO s digital sensors to a minimum. This considerably improves process reliability, productivity and system availability. Find out how ISM can help you, at: InPro 6850 i DO sensor InPro 3253 i ph electrode METTLER TOLEDO Process News 1 5

6 Thornton M300 Transmitter Exceptional Reliability is the Reason Siemens Chooses Thornton The benefits of ultrapure water production using CEDI modules rather than resin-based systems are clear: consistent water quality and no chemical regenerants. In CEDI module production, for ensuring the units meet resistivity and temperature requirements, Siemens Water Technologies trusts Thornton instrumentation for its performance and reliability. New CEDI technology Siemens Water Technologies has introduced an innovative new Continuous Electrodeionization (CEDI) platform for microelectronics, with their VNX E and EX modules. The modules are designed with new technology that allows for continuous production of ultrapure water to meet the demanding challenges of microelectronics polish and make-up water. The modular high flow components can be linked like building blocks to create highly effective pure water systems while reducing the overall water system footprint in a fabrication plant. Maintaining water quality Consistent product water quality using CEDI technology has a significant advantage over regenerable resin-based deionization. A regenerable batch DI process must be monitored for water quality degradation. Should degredation occur, additional DI vessels that have been properly regenerated and rinsed are then brought online. This leads to fluctuating water quality as can be seen with MBDI systems. CEDI-based systems, however, are continuously maintained using electrical current to drive ions, so water quality performance is highly regulated. Quality control Reliable performance is a requirement for CEDI modules in high performance microelectronics makeup water. Since 2000, Siemens has relied on Mettler-Toledo Thornton 770MAX multi-parameter, multi-channel transmitters to maintain the resistivity and temperature of ultrapure water for CEDI QC monitoring. The company s current platform of thick cell modules from low flow MX to high flow VNX are all tested using Mettler- Toledo Thornton monitors. Eight additional QC test stations were added in 2004 using Thornton 200CR transmitters and today the new Thornton M300 transmitter products are used for temperature and resistivity monitoring. According to Rahoul Bhagat, Quality Assurance Manager at Siemens Water Technologies Ionpure Products, "We have never had to replace or change a Thornton monitor on our QC test stands. The meters are very reliable. Other than an annual calibration, they never require any additional maintenance. Easy integration The recently released Siemens VNX E and EX modules operate at very high recovery to optimize water savings. With % recovery and no chemical regenerants, these highly efficient modules help Siemens lead the way to green energy efficiency and costs savings. 6 METTLER TOLEDO Process News 1

7 Patrick Buzzell, CEDI Product Manager describes the Siemens VNX E and EX Modules as simple enough to set and forget. Buzzell continues, After correctly setting the electrical current based on the feed water, the E and EX will consistently produce high purity water. Similarly, Thornton products from the 770MAX to the M300 have provided consistent long term performance for us. Simplifying the integration of our components for our OEMs is an important consideration for Siemens Ionpure products and one that is shared by Thornton. Find our how your pure water QC can benefit from Thornton instrumentation: Ionpure is a trademark of Siemens, its subsidiaries or affiliates. QC test station at Ionpure Products showing Thornton transmitters Trb 8300 turbidity transmitter METTLER TOLEDO Process News 1 7

8 InPro 8100 Turbidity Sensor Three Essentials in Biofuel Fermentation ph, DO and Turbidity Measurement A significant rise in demand for ethanol as an environmentally-friendly automotive fuel additive has led biofuel producers to investigate methods of improving their productivity. A Canadian producer has found that METTLER TOLEDO analytical measurement systems have helped it maximize cell fermentation yields. World leader in cellulosic ethanol Based in Ontario, Canada, Iogen is a manufacturer of industrial enzymes with a focus on products for use by the pulp and paper, textile and animal feed industries. They are also the world leader in technology for producing cellulosic ethanol, a fully renewable, advanced biofuel that does not rely on food products. Rather, the source of the cellulose is derived from bio-waste, the non-food portion of renewable feedstocks such as cereal straws (wheat and barley straws) and corn stover. Cellulosic ethanol is made from a unique process utilizing specially developed enzymes to convert plant fiber into sugars that are then fermented and distilled to make ethanol. Recently, following successful operation in their demonstration facility, Iogen applied for funding to build a full-scale commercial production plant. InPro 8100 turbidity sensor Analytical measurements for optimal cell growth In order to maximize the yield of fermentation products, it is critical to maintain the ph of the media at an ideal level for cell growth. Even narrow ph excursions can cause a significant drop in product yield due to its impact on the living broth. Further, as part of the cells respiratory cycle, dissolved oxygen in the medium is consumed; this constantly needs replenishing. Too low a DO level stresses the cells and reduces yield, while excess DO is simply a waste of energy used for running air compressors. Once ideal ph and DO levels are maintained, tracking the progress of the reaction is of next importance. Should unexpected development be observed using real-time cell monitoring, timely Trb 8300 turbidity transmitter corrective action can be taken, thereby optimizing process yield. Monitoring cell mass METTLER TOLEDO has a long history with Iogen in the use of a variety of ph and DO sensors and transmitters in fermentation applications. Iogen has always been impressed with the performance of our systems and level of after-sales service. The Senior Production Engineer at Iogen approached METTLER TOLEDO inquiring about a solution for cell mass monitoring; a process requirement that goes beyond the capabilities of ph and DO control. Turbidity is ideal for such measurements as the solution becomes cloudier as cell mass increases. When the application was discussed, the Iogen engineer said he was not satisfied with the installed system for cell monitoring which uses an absorption technique. He explained that as the fermentation progressed, the turbidity system produced very non-linear results, particularly towards the end of the run when accurate readings were most critical. High linearity of backscatter measurement Backscatter turbidity measurement is the recommended approach for such an application. Our engineers described the difference between backscatter and absorption technologies (see panel right) and indicated that a METTLER TOLEDO 8 METTLER TOLEDO Process News 1

9 backscatter system would be accurate and linear throughout the growth cycle. Iogen was receptive to the new approach and a demonstration was arranged. The test was performed using an InPro 8100 turbidity sensor and a Trb 8300 transmitter. Process samples were provided for a three-point calibration, and a number of grab samples for comparison with their off-line values as measured in the lab. Data from the METTLER TOLEDO system resulted in the expected linear results. Based on the high correlation with the grab samples and the consequent improvement in yield, Iogen installed the system and an order for a second system soon followed. Find the right turbidity sensors for your processes, at: c Backscatter vs. absorption turbidity measurement Two common means of measuring turbidity are the absorption and backscatter techniques. Absorption probes have a cut-out which serves as the optical sample path (Figure 1). Light from one side of the notch passes through the sample and is received at an optical detector located on the opposite side. The greater the solids concentration, the less light is received at the detector. A limitation of this methodology is its use at high solids levels. When turbidity is high, most of the light is absorbed by the solids and the sensor is no longer responsive. This causes a flattening of the response curve as shown in Figure 3. With the backscatter probe (Figure 2), light from a source in the transmitter passes down an optical fiber and into the liquid medium. When solids are present, light is reflected back up the fiber and is detected by the transmitter. The higher the concentration of solids, the more light is reflected. Since the backscatter signal actually increases with increasing turbidity, this technique is far more linear over a broader concentration range than the absorption technique (Figure 3). Comparison of turbidity methods Light source Detector Optical path length (OPL) Optical fiber Signal Backscatter probe Absorption probe Figure 1 Figure 2 Figure 3 Turbidity METTLER TOLEDO Process News 1 9

10 UniCond Resistivity Sensors Breakthrough Resistivity Sensors High Performance over Wide Range New cutting edge technology allows accurate conductivity / resistivity measurement over a vastly wider range. The same robust titanium sensor can now operate in all stages of water treatment, without compromising reliability or accuracy. Previous limitations With conventional conductivity measurement, two or more sensors with different cell constants are sometimes needed to cover the range from raw, reclaimed or recycled waters through the purification stages to pure water. This sometimes causes mix-ups in sensor types and locations and requires a greater variety and quantity of spare parts. Also with conventional sensors, the user must remember to manually enter the precise cell constant and temperature calibration data for each individual sensor into the transmitter s memory to achieve rated accuracy. In addition, installations typically locate the sensor directly in-line in the system at a considerable distance from the transmitter and control panel. Over the years, Thornton has optimized the wiring and signal handling to minimize cable capacitance and resistance effects so that accurate measurements are provided. Nevertheless, these effects do cause some measurement limitations. Unified, universal solution Based on Mettler-Toledo Thornton s technology-leading experience with conductivity / resistivity and recognizing the opportunity to make significant improvements, Thornton engineers developed a miniaturized measuring circuit that could be embedded in the top of the sensor and send a robust digital signal to the transmitter. This unified design reduced the effective wiring distance between the sensor and the measuring circuit to a couple of centimeters! Without the effects of long cable capacitance and resistance, more sophisticated measuring techniques became possible. Because leadwire effects became negligible, electrochemical factors affecting the measurement could be dealt with more directly to improve rangeability. Measurement from ultrapure water to brackish water up to 50,000 µs / cm can now be made with a single UniCond TM sensor with excellent accuracy. This remarkable rangeability provides a number of advantages. Covering the entire range of most water treatment systems, the UniCond sensor becomes universal and simplifies specification, documentation, installation, wiring, operation and ordering of spare parts now actually, one spare part. UniCond sensors utilize Intelligent Sensor Management (ISM) technology, which maintains precise factory calibration data, as well as sensor identification, serial number, etc. in an internal memory. This enables simple Plug and Measure startup, eliminating manual data entry and any chance of operator error. Superior accuracy and reliability The UniCond sensor is also more accurate because it is calibrated as a system, which includes the cell constant, the temperature sensor and the measuring circuits. With all of these components integrated for calibration, individual errors are no longer cumulative. There is no added error by combining separate sensors and transmitters, each with their own limits of error. The advantages with UniCond conductivity/resistivity sensors are significant: higher accuracy, wider rangeability for greater standardization, and easier, more foolproof startup. For more information, go to: UniCond TM resistivity sensor 10 METTLER TOLEDO Process News 1

11 Comprehensive Website The Information You Want is at The new look METTLER TOLEDO Process Analytics website contains a vast amount of up-to-date information on all our products and services. Content is localized for your country and tailored to suit your selections. Simple layout allows you to quickly find the information and features you are looking for. j Learn about our most recent product developments j Request further information on products and services j Obtain a quote quickly and easily j Read case studies relevant to your industry j Access buffer and electrolyte solution certificates j and more... j Read the latest product news j Access our newsletter archive j Find out when our next trade show or exhibition is in your area j Register for free webinars presented by our industry experts j Download our white papers METTLER TOLEDO Process News 1 11

12 Get in-line with METTLER TOLEDO Free Software for ISM sensors isenselight is a free software tool for Intelligent Sensor Management (ISM) sensors. isenselight provides easy calibration of ISM sensors for fast Plug and Measure installation, and predictive diagnostics for increased process uptime. The simple to use interface offers all important information on one screen. Download it from: c Mettler-Toledo AG Process Analytics Im Hackacker 15 CH-8902 Urdorf Switzerland Visit for more information