1 Metrohm Process Analytics Solution provider for online, inline, and atline process analysis. 2 From the lab to online process analysis: The best analytical solution Process analyzers designed and manufactured by All these analysis techniques can be implemented in Metrohm Process Analytics are the preferred solution for different process environments. But how to bring these process monitoring in a wide range of industries. solutions to your process is another question. There are Whatever your project requirements and budget, four ways to implement analysis techniques in your Metrohm Process Analytics has the right solution for you. process, and depending on which one you implement, We offer analytical systems for electrochemistry, ion you get several benefits in return. chromatography, ion selective measurements, photometry, spectroscopy, and titration. DUCIBILITY UCTIVITY O D RP COST O E R R SS SAVINGS SAFETY P Y E C RELIABLEN EFFICIEN Tailored solutions in industrial plants with online, inline, atline, and offline analysis Offline measurements: 3 In this type of process analysis, samples are manually Features: retrieved and transported to a remote laboratory from Reproducibility the take-off point of the process and high experienced Cost Savings chemists are needed to perform the analysis. The proper-Efficiency Safety ties of the sample can vary between sampling and analysis, so direct process control is not possible, especially for unstable samples. Atline measurements: With atline analysis, samples are taken manually from a Features: take-off point to a process analyzer in proximity to the Reproducibility Cost Savings process. This method is ideal when multiple samples Efficiency have to be taken at several sampling points along the Safety process and across the production floor over long distances. However, continuous manpower is needed to collect samples and the frequency of analysis is not optimal. Online measurements: Automation is the key feature of the two following Features: analysis measurements. With online analysis, sample Reproducibility flow is directed from the process loop to the analyzer Cost Savings Efficiency automatically (by the use of a fast-loop system) so very Safety limited manpower is needed. This method permits automated sampling, registration, preconditioning, fast feed-back of results, and efficient process control. Inline measurements: For the most «real-time» analysis, inline analysis is the Features: perfect choice. With this technique, a sensor, fiber or Reproducibility probe is used to connect the analyzer directly in the Cost Savings process stream for continuous analysis. The closer your Efficiency Safety analysis techniques get to be «real-time», the more benefits you get ( e.g. higher safety, efficiency, cost savings, ...). The following pages give a direct comparison between offline and atline/online/inline analysis according to these four key qualities: reproducibility, cost savings, efficiency, and safety. High analysis frequency - High quality products 4 Manual sampling is one of the main disadvantages of offline analysis. It is time-consuming and the sample has to be taken to the nearest laboratory, which implies that Inline/Online the characteristics of the sample no longer represent the current process conditions (temperature, moisture Target content, and many more). This means that any necessary process adjustments take place hours or even days after Offline an out-of-specification reading, and reproducibility of results are not as efficient as with online and inline Target analysis Time Reduce giveaways by Time-consuming manual sampling and long distances to € 2.3 M/month the laboratory are eliminated by utilizing online, inline, or atline process analyzers. Samples are more representative by implementing inline analysis in a refinery @100,000 and reproducibility of results is increased as the barrels per day Petrochemistry measurements are performed exactly the same, every time. Reproducibility 5 Process improvement with online analyzers - Safeguard your company’s assets Unforeseen plant shutdowns involve higher expenses Regular control of process parameters is critical to main-and chemical analysis performed directly at the most tain product and process specifications and to achieve critical process points is crucial to reduce the potential for optimal product quality and consistency in any industry. unforeseen plant shutdowns. By providing data in «real-Deviation of these parameters from target can negatively time» to the industrial control system ( e.g. DCS or PLC), impact on product quality and lead to excessive operat-downtimes are reduced and costly company assets are ing costs, e.g: safeguarded. • Excess chemical consumption Many processes are controlled within tightly defined • Reduced throughput/fluctuations limits for many basic parameters (such as weight, tem- • Lower manpower/rework perature, and pH) or more unique parameters such as acid concentration in etching solutions, acid-end groups • Out of specification products/rejects in polymerizations, product moisture levels in drying • Lower yield processes, amine loading and amine concentration in CO scrubbers, and many more. 2 • Higher energy usage € 5.5M/year In savings when inline analysis is implemented on a spray dryer Cosmetics Cost Savings Accuracy is key - Increase company profits 6 In offline analysis, samples are taken much less frequently than online, inline, or atline measurements, making it 4% much more likely to overcompensate with chemical In extra revenues with inline analysis in fermentation treatments when not deemed necessary at all. Therefore, process increased analysis frequency and accuracy is key for Biofuels efficient process adjustment and optimization. Processes that rely on any analytical measurement will achieve the required accuracy depending on different aspects: • The analytical instrument employed (Standard Error of Prediction «SEP») ROI < 4 months* • Error of sampling from the process and sample by implementing online analyzer systems for liquor preparation quality analysis • Frequency of analysis Pulp&Paper • Process variation error Offline laboratory analysis can negatively impact on process accuracy by introducing manual sampling error. Also, offline analysis limits the analysis frequency due to manual limitations and differences between analysts. Throughput Operational costs Offline Atline Online Inline *Process and analyzer-dependent Efficiency Safety benefits of process analyzers - Avoid incidents with process automation 7 Offline process analysis implies multiple manual steps Introducing inline or online process analyzers reduces the and occupational hazards when exposed to toxic sampling error and increases the sampling frequency as chemicals and hazardous areas of operation. All of these well as improving the prediction error for the analysis. steps will be reduced or totally eliminated by using Improving all these steps leads to significant improvements online or inline process analyzers, which reduces in process accuracy narrowing the normal operating incidents, resulting in increased plant safety. window to ensure the process is operating at its highest efficiency and above all in the safest way. By limiting the manual handling steps, you eliminate any risk of exposure to hazardous chemicals. Furthermore, with automated sampling (online, or inline) you can: 80% of accidents • Detect dangerous sample composition in process environments are due to human errors. • Avoid hazardous sampling and laboratory analyses When online or inline sampling is implemented, • Analyze in hazardous zone (Ex-proof area) the origin of accidents is less likely due to human errors. • Monitor spillages • Reduce waste water streams • Detect of out-of-specification process streams Safety 8 www.metrohm.com witzerland G, CH-9100 Herisau S ohm A witzerland at Metr V., printed in S ohm Applikon B. a, Metreirerr ea F Subject to change without prior notice Layout by Andr 8.000.5340EN – 2020-04