Chemical Perspectives in Liquid Process Analytics 19 News Oxygen Analysis Made Easy With Powerful In-line TDL Sensors INGOLD Leading Process Analytics When it comes to process safety for protecting the environment, people and assets, only the best equipment will do. METTLER TOLEDO s new O 2 solution combines the convenience and ease of use of an in-line sensor with the performance of a powerful gas analyzer. With the GPro 500, oxygen measurement is simpler and more reliable than ever before. Laser technology for interferencefree measurement An oxygen sensor that provides faster measurement and more accurate data is always going to be of interest to the chemical industry. If it also has a significantly lower cost of ownership compared with other systems, it makes it a very attractive proposition. METTLER TOLEDO s GPro 500 represents a leap forward in oxygen sensors. Packed with state-of-the-art technology it offers exceptional measuring performance and easy installation, and requires little or no maintenance. Tunable Diode Laser (TDL) gas analyzers are a significant improvement over extractive analysis systems. Firstly, no sample extraction or conditioning is necessary. Secondly, they are immune to interference from moisture, dust or background gases. And thirdly, drift is extremely low. The best of both worlds METTLER TOLEDO has combined TDL technology with our expertise in industrial application analytical instrument design, to create a probe that delivers the convenience of an in-line sensor and the level of measurement confidence of a topline analyzer. Other TDL gas solutions are of a crossstack design, meaning that the receiver must be positioned directly opposite the laser source. This causes installation difficulties and requires regular, troublesome realignment. The GPro 500 incorporates
a probe that reflects the laser beam back to the receiver in the sensor head, therefore alignment is never required. And because the laser beam travels twice through the gas stream, the optical path length is doubled, resulting in more accurate O 2 measurement. Built-in intelligence METTLER TOLEDO s Intelligent Sensor Management (ISM) technology adds to the features of the GPro 500 by incorporating predictive diagnostics that continually assess the optical path quality and indicate when cleaning is required, before measurements are affected. Laser diode with built-in reference Other than yearly verification and occasional cleaning of the optics, no other maintenance is required. The GPro 500 can be left to provide real-time, continuous, accurate O 2 measurements, assuring you of operational safety at all times. The GPro 500 is the ideal choice for oxygen monitoring in process and safety applications. Discover more about the GPro 500, at: c www.mt.com/o2-gas Laser and detectors in one sensor head Applications Safety control Refineries Flares Oxychlorination in VCM and EDC plants Vapor recovery systems Combustion boilers FCC units Benefits Low installation costs Minimal maintenance No sample extraction or conditioning required Measurements unaffected by dust, moisture or background gases High reliability Predictive diagnostics for proactive maintenance planning Modular process adaptions Folded optical path for enhanced accuracy Publisher / Production Mettler-Toledo AG Process Analytics Im Hackacker 15 CH-8902 Urdorf Switzerland Illustrations Mettler-Toledo AG Uhde GmbH Aremac, Tinoni, Jianghongyan, Jgroup Dreamstime.com Purge nozzle Rugged probe design for in-situ use GPro 500 sensor showing key features Subject to technical changes. Mettler-Toledo AG 01/12 Printed in Switzerland. 2 METTLER TOLEDO Chemical News 19
M400 Transmitter Sensor Diagnostics Over HART New 2-Wire ISM Transmitter The M400 2-wire, multi-parameter ISM transmitter provides the highest reliability and easiest handling in hazardous area applications. Advanced sensor diagnostic tools available over HART or via the transmitter s second analog output, lead to reduced operating costs and help improve productivity. Outstanding reliability With its rugged design and approvals for hazardous area use, the new M400 2-wire transmitter series provides operating assurance even in the most challenging conditions. In combination with METTLER TOLEDO s advanced Intelligent Sensor Management (ISM) technology, this means the M400 2-wire unit offers greater process reliability in chemical, pharmaceutical and gas phase applications. Fits to your process The M400 transmitter is a single-channel unit for ph / ORP, oxygen and conductivity sensors. Its multi-parameter ability ensures the new series suitability for a wide variety of applications. Thanks to the mixed-mode input, which accepts analog or ISM sensors, the M400 offers a unique and smooth technology transition from conventional to digital sensors and provides a future oriented investment in your plant. Quick and simplified sensor handling With the advanced ISM functionality implemented in the M400, the transmitter series provides additional valuable benefits. Using METTLER TOLEDO s isense Asset Suite software, sensors can be very accurately pre-calibrated in a convenient location such as a workshop and stored for later use. When a pre-calibrated probe is M400 transmitter connected to the M400, the calibration data is automatically uploaded to the transmitter and the system is ready to measure in a few moments. This Plug and Measure feature minimizes the risk of installation troubles and simplifies sensor commissioning and replacement. Improved process control at lower cost Measurement data and sensor diagnostics tools such as the Dynamic Lifetime Indicator (DLI), Adaptive Calibration Timer (ACT) and Time to Maintenance (TTM) can be output to the process control system via two 4 to 20 ma analog output signals. Together with the M400 s HART communication capability, system integration is easily achieved, enabling more efficient maintenance of the measurement system. Unplanned shutdowns due to unforeseen sensor failure no longer occur, and the resulting increase in process availability and reduced maintenance lead to improved productivity and lower operating costs. Find out more at: c www.mt.com/m400-2wire METTLER TOLEDO Chemical News 19 3
InPro 4850 i ph Electrode Increase Your Chlorine Production With a New, Highly Durable ph Sensor Reliably measuring ph levels during chlorine production is very difficult to achieve consistently. For the first time, a new METTLER TOLEDO sensor has removed the barriers to precise, long-term ph determination. Chemical group Solvay has noticed a dramatic improvement in ph measurement. Widely used element Chlorine is one of the most commonly used chemical elements, with uses ranging from water treatment to synthesis of PVC to silicon chip manufacture. Production can be achieved through a number of methods, but the membrane cell process, during which brine is electrolyzed in large cells, is becoming most common for environmental reasons. Harsh conditions for ph probes The ph level throughout the chlor-alkali process is crucial to maximizing yield and minimizing damage to the expensive membranes that are used in the electrolysis cells. The combination of chlorine in the electrolyzed brine, crystallized salt, precipitated impurities and elevated temperatures is very demanding on standard ph electrodes. To maintain reliable ph measurements requires regular cleaning and calibrating of electrodes, and even then sensors typically have a short lifetime. Sodium reference solves one issue but creates another A more reliable alternative to conventional ph electrodes is probes with a hermetically sealed sodium (pna) reference system. Because the brine concentration in the chlor-alkali process remains fairly static, these pna / ph electrodes use the brine it- self as a reference. And because the reference system is sealed from the process, there is no possibility of sensor poisoning from chlorine, or diaphragm clogging from salt or impurities. Unfortunately, there is a drawback to this design: pna / ph electrodes output a very high impedance signal that is easily altered by surrounding electrical equipment. Additionally, the cable between sensor and transmitter acts like a radio antenna, which also affects the signal received at the transmitter and limits the length of cable that can be used. METTLER TOLEDO s new InPro 4850 i sensor has solved this issue. No more measurement concerns The InPro 4850 i is a high-quality pna / ph electrode that is uniquely different to other probes for chlor-alkali use, because the InPro 4850 i outputs a digital signal. The electrode is one of METTLER TOLEDO s expanding portfolio of Intelligent Sensor Management (ISM) instruments. ISM significantly improves sensor handling, reduces the maintenance requirement for measurement systems and increases process availability, leading to greater productivity. Central to the way ISM sensors operate is a microprocessor in the sensor head. This digitizes the analog measurement signal which it then exchanges with the transmitter. Because the signal is digital, it is unaffected by electrical interference and remains unchanged, even over very long cable runs. 4 METTLER TOLEDO Chemical News 19
By combining a sealed reference system with Intelligent Sensor Management s digitized signal along with ISM s other significant advantages, the InPro 4850 i provides unequalled measuring performance, requires little maintenance and is exceptionally durable. InPro 4850 i ph electrode Dramatic improvement, says Solvay With 17,000 employees and revenue of over 7 billion Euros in 2010, Solvay is one of the world s major chemical companies. At their plant in Jemeppe, Belgium, Solvay produce chlorine through the membrane cell process. Technicians were frustrated with the performance of their ph measurement equipment and were eager to try the InPro 4850 i electrode. Systems were installed at a number of cells where the anolyte exits. ph measurement is particularly problematic here as the brine still contains some chlorine which enters and poisons the reference system of conventional ph electrodes. After a few weeks it was obvious to Solvay technicians that they had found the answer to their ph measurement difficulties. The InPro 4850 i sensors were operating flawlessly in the process and the digital ISM signals were unaffected by interference from surrounding equipment. Neil Breton, Process Analytical Technologies Engineer at the facility is delighted with the electrodes performance, Changing to the InPro 4850 i has dramatically improved the reliability of our ph measurements. In the past, we were recalibrating some probes every week and changing them every two months. We are now simply checking them every two weeks. To this day, we have never suffered from probe failure. If you need durable ph measurement systems at your chlor-alkali facility, go to: c www.mt.com/pro-chlor-alkali METTLER TOLEDO Chemical News 19 5
InPro 4260 i SG ph Electrode Combatting Corrosion and Scale in Water Treatment Facilities Controlling corrosion and scale are significant issues in cooling towers and water treatment plants. Minimizing both relies on maintaining ideal ph levels. Brazilian chemicals producer Braskem has selected intelligent ph measurement systems from METTLER TOLEDO. Now, they have greater confidence in their water treatment processes, and have less downtime. America s largest resins producer Headquartered in São Paulo, Brazil, Braskem S.A is the largest producer of thermoplastic resins in the Americas and the eighth-largest in the world. It has the capacity to annually produce 15 million metric tons of thermoplastic resins and other chemical products. Braskem controls the two largest petrochemical complexes in Brazil. Company engineers were eager to reduce corrosion and scale affecting cooling towers and a water treatment plant. Production downtime associated with the effects of corrosion is widely recognized. The influence of scale on process efficiency is less acknowledged but is of no less importance. Just 3mm of scale can reduce the efficiency of a cooling tower heat exchanger by 30 %. Durable ph measurement system For these applications METTLER TOLEDO suggested the InPro 4260 i SG ph electrode and M420 transmitter. Unlike most ph electrodes, the InPro 4260 i SG probe does not contain a liquid reference electrolyte, nor does it have a diaphragm. Instead, it features a solid polymer electrolyte, Xerolyt Extra, that is highly resistant to poisoning substances and significantly extends sensor lifetime. An open junction, which eliminates clogging from particles, provides the contact between the measuring medium and electrolyte. The SG in the product name indicates that the sensor contains a solution ground coating that eliminates the risk of electrostatic interference and makes a parallel redox measurement possible. The M420 is an ATEX approved, 2-wire transmitter that has been designed to provide excellent durability in difficult operating conditions. On-board intelligence This ph measurement system includes METTLER TOLEDO s Intelligent Sensor Management (ISM) technology. ISM sensors have an on-board microprocessor that allows a number of valuable features that are not possible with non-ism probes. Plug and Measure: Using METTLER TOLEDO s isense Asset Suite software running on a PC or laptop, or an ISM transmitter such as the M420, sensors can be pre-calibrated in a convenient location and stored until they are needed. When InPro 4260 i SG ph electrode M420 transmitter 6 METTLER TOLEDO Chemical News 19
sensor exchange is required it is a simple matter of attaching a pre-calibrated probe. Calibration data is automatically uploaded to the transmitter and the system is ready to measure in a few moments. Predictive diagnostics: The Dynamic Lifetime Indicator (DLI) is a sophisticated algorithm that uses current and past process conditions to accurately forecast a sensor s remaining lifetime. The DLI prevents a sensor that needs replaced from being used in the process. By continuously monitoring reference impedance, temperature exposure and glass impedance, the Adaptive Calibration Timer predicts when calibration is next required in order to maintain measurement reliability. The predictive diagnostics tools are shown on the M420 transmitter and can be transmitted to the plant control system. Digital signal: Unlike conventional analog measurement systems where the process measurement is calculated by the connected transmitter, ISM sensors calculate the measurement in the sensor head and send this information digitally to the transmitter. Digital signals are unaffected by electrical interference or degradation caused by long cable runs; therefore, the signal that leaves the sensor arrives at the transmitter unchanged. Consequently, measurement stability is extremely high. Improved process confidence Braskem engineers are very pleased with the performance of the ph measurement system. They report that the InPro 4260 i SG sensor operates very reliably and that the M420 transmitter is simple to install and use. But it is the ISM technology that they are most satisfied with. Plug and Measure means system start up is quick and error-free, and sensor maintenance can be performed proactively rather than as corrective action. ISM has increased measurement system uptime and reduced time spent on maintenance. Thanks to METTLER TOLEDO s highperformance ph measurement solutions with ISM technology, Braskem engineers now have greater confidence in the quality of their water treatment processes. Their on-going struggle to combat corrosion and scale has become significantly easier. If you want higher confidence in processes at your facility, go to: c www.mt.com/inpro4260 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: c www.mt.com/ism METTLER TOLEDO Chemical News 19 7
Quantos Dosing Solutions Fast and Reliable Sample Preparation With Automated Dosing The pressure is on to achieve more with less. With the reduction of Out-of-Specification (OoS) results being one more issue to deal with, how can today s chemical companies make ends meet? Bringing automation into the laboratory The answer is to automate the tedious, repetitive laboratory processes in order to generate better results and, therefore, free up precious time for chemists and analysts so that they can concentrate on higher value tasks. Weighing remains a manual activity in many laboratories leaving the improvement of safety, speed and saving unresolved. The trend of recent years has shown that automated analysis systems are getting faster, safer and more precise. With the advent of faster analytical methods, such as UHPLC, plus rapid data processing software developments, attention is once again focusing on sample preparation as the bottleneck in the process. Reducing Out-of-Specification results Groups from method development, stability testing, formulation and quality control all identify the manual preparation of samples and standards as the most time consuming and error prone part of their process. The preparation of a solution is very time consuming and challenging. Imprecise sample preparations lead to OoS results, which can literally bring lab production to a halt, as any ongoing work must stop until the error source is discovered. The impact upon production environments is catastrophic but what if we could remove the main error contributor, i.e. sample preparation, from this expensive equation? The three main error sources leading to OoS are imprecise powder weighing, incorrect volumetric flask use and incorrect documentation. Thanks to the introduction of Gravimetric Liquid Weighing, Quantos now solves all three problems. A new way to weigh The new QLB liquid dispensing module now makes it possible to prepare each final concentration for calibration / analysis directly into HPLC injectable vials. The QLB doses the correct amount of liquid gravimetrically and is, therefore, more precise and safer than volumetric dosing. Errors that can occur during manual solid dispenses can even be corrected with the instrument using only the minimum amount of solvent and powder substances necessary. Gravimetric dosing eliminates the larger and more error prone steps, including the tedious volume solution preparation and dilution. Implementing automated powder and liquid dosing into the sample preparation workflow introduces massive gains in speed, safety and savings. The amount of time and money spent on Out-of-Speci fication investigations and inconclusive results can be significantly reduced by eliminating weighing and sample preparation errors. c www.mt.com/quantos QLB liquid dispensing module 8 METTLER TOLEDO Chemical News 19
Comprehensive Website The Information You Want is at www.mt.com/pro The METTLER TOLEDO Process Analytics website contains a vast amount of up-to-date information on all our chemical industry related 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 Register for free webinars j Request further information on products and services j Obtain a quote quickly and easily j Download our latest white papers j Read case studies relevant to your industry j Access buffer and electrolyte solution certificates j and more... Oxygen analytics competence center full of the latest information on monitoring O 2 for safety and process control. c www.mt.com/o2-gas 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 Chemical News 19 9
EasyClean 400 Greater Process Reliability and Sensor Life Extended up to 30 % Maintaining sensors at peak condition is important for performance reasons, and therefore process assurance. An automatic sensor cleaning and calibration unit frees maintenance staff for more important tasks. It can also significantly increase sensor life. Keeping sensors in prime condition can extend their lifetime by 30 % and provides greater assurance of process reliability. Conditions in the chemical industry mean the time spent on measurement point maintenance can be extensive. With the EasyClean 400, thorough sensor cleaning and accurate calibration are completely automated. Allowing the EasyClean 400 to dependably clean and calibrate ph electrodes frees maintenance staff to concentrate on more important and skill-intensive tasks. Find out how EasyClean systems can help your operations go to: c www.mt.com/easyclean Your benefits Completely unattended maintenance Automatic cleaning and calibration of ph measurement points. Greater production efficiency Eliminates downtimes caused by insufficiently maintained sensors. Configurable to your requirements Time of calibration, and time and duration of cleaning are fully programmable. 10 METTLER TOLEDO Chemical News 19
EasyClean 400 automatic sensor cleaning and calibration unit METTLER TOLEDO Chemical News 19 11
Get in-line with METTLER TOLEDO Don t leave it to chance! Heads I use the sensor again, tails I don t. ISM True Predictive Diagnostics No more guessing if a sensor will survive through the next production run. Intelligent Sensor Management s predictive diagnostics analyze process conditions and sensor health to provide you with accurate information on when sensor replacement will be needed. c www.mt.com/ism Intelligent Sensor Management from METTLER TOLEDO Mettler-Toledo AG Process Analytics Im Hackacker 15 CH-8902 Urdorf Switzerland www.mt.com/pro Visit for more information