Chemical manufacturing involves complex and hazardous processes that require strict control to ensure safe and efficient production. Process control is essential in chemical manufacturing to achieve consistent quality, increase productivity, reduce waste, and prevent accidents. 

Chemical processes involve the transformation of raw materials into finished products through various chemical reactions. These reactions are highly sensitive to variations in temperature, pressure, and other process variables. Even small deviations from the desired conditions can result in significant changes in the final product quality or yield.

Process control systems use sensors, controllers, and other monitoring devices to continuously measure and adjust process variables to maintain optimal conditions. By providing real-time feedback and control, these systems can detect and correct process variations before they affect the final product.

Our Fourier transform infrared (FTIR) and Fourier transform near-infrared (FT-NIR) process analyzer ANALECT™ PCM 1000™ provides process control by continuously monitoring the composition of liquids, solids, and gases in real-time during chemical manufacturing processes.  

Also our GUIDED WAVE™ Dual Beam Photometer ClearView db® provides process control in chemical manufacturing by continuously monitoring the concentration of chemical compounds in liquids and gases during production.  One of the key benefits of the ClearView db is its ability to provide real-time measurements, which enables operators to make quick adjustments to the process parameters and ensure consistent product quality. The analyzer is also designed for easy installation and maintenance, which minimizes downtime and reduces overall costs.

Sulfur is an impurity often found in petroleum products and feedstocks, typically it is removed during crude oil processing. Sulfur content is toxic and corrosive which may cause damage to refinery equipment.  Monitoring sulfur as an impurity in chemical manufacturing is important for several reasons. Sulfur is a common impurity in many chemical products and can have negative impacts on product quality, worker safety, and environmental compliance. Here are a few reasons why monitoring sulfur is important:

• Product quality: Sulfur can negatively impact the quality of chemical products. For example, sulfur can cause discoloration or odor issues in products such as plastics or polymers, reducing their value and marketability.
• Worker safety: Sulfur is a hazardous material and can pose a risk to worker safety if not handled properly. Exposure to high levels of sulfur can cause respiratory problems, eye irritation, and other health issues.
• Environmental compliance: Sulfur can contribute to air and water pollution if not properly managed. For example, sulfur dioxide emissions from chemical manufacturing processes can contribute to acid rain and other environmental issues.
• Regulatory compliance: Sulfur is subject to regulatory limits in many chemical products and manufacturing processes. Monitoring sulfur levels is necessary to ensure compliance with these regulations and avoid penalties and legal issues.

Our ATOM INSTRUMENT™ FGA-1000™ online process analyzer utilizes patented Excimer UV Fluorescence (EUVF) Technology to measure total sulfur in a variety of applications such as monitoring refinery flare gas and subsequent sulfur dioxide (SO₂) emissions as mandated by the EPA Rule 40 CFR 60, Subpart Ja.  

Safety and compliance are critical considerations in chemical manufacturing due to the potential risks associated with working with hazardous chemicals. There are several challenges in ensuring safety and compliance in chemical manufacturing, including:

• Complex regulations: Chemical manufacturing is subject to a wide range of regulations at the local, state, and federal levels. 
• Hazardous materials: Chemical manufacturing involves working with hazardous materials that can pose a risk to worker safety and the environment. 
• Equipment and infrastructure: Chemical manufacturing often requires specialized equipment and infrastructure, such as reactors, pipelines, and storage tanks. 
• Training and expertise: Workers in chemical manufacturing must be trained and experienced in handling hazardous materials and working with complex equipment.
• Environmental impact: Chemical manufacturing can have a significant impact on the environment, including air and water pollution. 
• Emergency preparedness: Chemical manufacturing facilities must be prepared to respond to emergencies, such as spills, leaks, and fires. 

Our EXTREL MAX300-RTG™ 2.0 mass spectrometer provides benzene fenceline monitoring compliance for OSHA requirements, USEPA Method 320, and the RSR by continuously monitoring the ambient air for benzene concentrations in real-time.  It operates by drawing in air samples through a sampling inlet and analyzing the air for benzene concentrations using mass spectrometry. The mass spectrometer separates and identifies the various compounds in the air sample and measures the concentration of benzene and other volatile organic compounds (VOCs) present.

New regulations on flare emissions require oil refineries and chemical plants to analyze the vent gas and quickly make appropriate adjustments as mandated. You need a complete analysis for compliance with regulations such as EMACT, MONMACT, RSR, Subpart Ja, Ontario Reg. 530/18, Korean Facility Management Standards to Reduce Fugitive Emissions, and HRVOC rules.  Chemical manufacturers need fast, reliable monitoring.  Real-time gas analyzers provide the speed and reliability needed for flare compliance, control, and monitoring of H₂S, Total Sulfur, Net Heating Value (NHV)/BTU, H₂, and full speciated composition.

Flare gas monitoring is an important practice for several reasons:

• Environmental protection: Flare gas monitoring helps to identify and measure the amount of gas that is being flared, which can contribute to air pollution and climate change. By monitoring and reducing flare gas emissions, industrial facilities can help protect the environment and minimize their impact on the surrounding community.
• Safety: Flares are used to safely burn off excess gas and prevent dangerous buildups of combustible gases. Flare gas monitoring can help ensure that flares are working effectively and safely, reducing the risk of accidents or explosions.
• Regulatory compliance: Flare gas monitoring is often required by environmental regulations, and failure to comply can result in fines or other penalties.
• Cost savings: Flare gas monitoring can help identify opportunities to reduce the amount of gas being flared, which can save money by reducing the need for additional gas processing or storage facilities.

Our ATOM INSTRUMENT™ FGA-1000™ flare gas analyzer has the highest dynamic measurement range of any commercially available analyzer, requiring only a single point calibration without the need for additional sample valves, calibration gases or system hardware. 

Fuel gas monitoring is the process of measuring and analyzing the composition and quality of fuel gas used in industrial processes. Fuel gas is commonly used in a variety of applications, such as furnaces, boilers, and turbines. Fuel gas monitoring is important because it helps ensure that the fuel gas being used is of the appropriate quality and composition for the intended application.  This involves the use of gas analyzers that measure the concentrations of various gases in the fuel gas, including methane, carbon monoxide, hydrogen, and other hydrocarbons.  Fuel gas monitoring is important for several reasons, including:

• Safety: Monitoring fuel gas ensures that it is not contaminated with harmful gases, which could create hazardous conditions during combustion or release toxic emissions.
• Efficiency: The quality and composition of fuel gas can impact the efficiency of industrial processes. Monitoring helps to ensure that the fuel gas is of the appropriate quality and composition to achieve optimal performance.
• Regulatory compliance: Regulations often mandate the monitoring of fuel gas to ensure that it meets specific quality and composition standards.
• Cost savings: Monitoring fuel gas can help identify opportunities to improve efficiency and reduce waste, which can result in cost savings for industrial facilities.

Our EXTREL MAX300-RTG™ 2.0 mass spectrometer delivers rapid response for optimized combustion efficiency and accurate H2 blending to reduce carbon emissions for 40 CFR Part 60, and HRVOC compliance by continuously monitoring the composition of gas streams in real-time.  It operates by drawing in gas samples through a sampling inlet and analyzing the gas for its composition using mass spectrometry. The mass spectrometer separates and identifies the various compounds in the gas sample, and measures the concentrations of different gases, such as H₂, CO, CO₂, O₂, and CH₄, among others.  And is capable of providing rapid response measurements with a response time of less than 100 milliseconds. This allows operators to quickly adjust combustion parameters, such as air/fuel ratios and burner settings, in real-time, to optimize combustion efficiency and reduce carbon emissions.

Steam methane reformers (SMRs) are used to produce hydrogen gas from natural gas through a process called steam reforming. Gas analyzers are used in SMRs to monitor and control the reaction process, ensuring that the process is efficient and safe.

Gas analyzers are typically used to measure the concentration of various gases throughout the SMR process, including methane, hydrogen, carbon monoxide, and carbon dioxide. The gas analyzer data is used to control the process and optimize the yield of hydrogen gas while minimizing the formation of unwanted byproducts, such as carbon monoxide.  There are several key steps in the SMR process where gas analyzers are commonly used, including:

• Pre-reforming: The natural gas feedstock is preheated and mixed with steam before entering the reformer. Gas analyzers are used to monitor the gas composition and ensure that the feedstock is properly mixed before entering the reformer.
• Primary reforming: The feedstock is heated to high temperatures and mixed with steam in the reformer to produce a synthesis gas containing hydrogen, carbon monoxide, carbon dioxide, and other gases. Gas analyzers are used to monitor the composition of the synthesis gas, ensuring that the process is running efficiently and safely.
• Secondary reforming: The synthesis gas is further heated and reacted with steam to produce additional hydrogen and carbon dioxide. Gas analyzers are used to monitor the composition of the gas and ensure that the reaction is proceeding as intended.

Our COSA XENTAUR™ 9800 CXi™ Calorimeter can monitor hydrocarbons, BTU, Wobbe, CARI, and density in chemical manufacturing by measuring the heating value of hydrocarbon gases and liquids in real-time.  It operates by injecting a small sample of the gas or liquid into a combustion chamber and measuring the amount of heat released during combustion. The heating value is then calculated based on the amount of heat released and the mass of the sample. The analyzer is specifically designed for zero-hydrocarbon emissions, meaning it can operate without venting any hydrocarbons to the atmosphere, making it ideal for environmentally sensitive applications.

Wastewater is generated as a byproduct of chemical manufacturing and can be used in a variety of ways, depending on its quality and characteristics. Here are a few examples of how wastewater is used in chemical manufacturing:

• Recirculation: In some cases, treated wastewater can be recirculated back into the manufacturing process as a source of process water. This can help to conserve water resources and reduce the amount of wastewater that needs to be discharged.
• Cooling: Wastewater can be used for cooling equipment and processes in chemical manufacturing, similar to process water.
• Dilution: Wastewater can be used to dilute concentrated chemicals to the desired concentration for manufacturing processes.
• Treatment: Wastewater must be treated to remove impurities and contaminants before it can be discharged into the environment. Treatment processes can vary depending on the type and concentration of contaminants in the wastewater.

Wastewater can be reused in chemical manufacturing in some cases, but it depends on the quality of the wastewater and the manufacturing process requirements. Before wastewater can be reused, it must be treated to remove any contaminants or impurities that could negatively affect the quality of the final product or the manufacturing equipment.

There are several benefits to reusing wastewater in chemical manufacturing. First, it can help to reduce the demand for freshwater resources, which can be particularly important in areas where water is scarce. Second, it can help to reduce the amount of wastewater that is discharged into the environment, which can help to minimize the impact on water bodies and ecosystems. Finally, reusing wastewater can also help to reduce the operating costs of chemical manufacturing by reducing the need to purchase and treat freshwater sources.

Our LAR™ NitriTox™ water analyzer can be used to monitor wastewater in chemical manufacturing. The analyzer is designed to measure the concentration of nitrate and nitrite in water and can provide accurate and reliable measurements in a variety of wastewater samples.  

In chemical manufacturing, the presence of nitrate and nitrite in wastewater can be an indication of nitrogen-based contaminants, which can be harmful to the environment and human health. By monitoring the concentration of these contaminants, manufacturers can ensure compliance with regulatory requirements and take steps to reduce their environmental impact.

The NitriTox water analyzer uses a chemiluminescence method to measure the concentration of nitrate and nitrite in water. The method involves the reaction of nitrate and nitrite with a reagent to produce light, which is then measured by a detector. The intensity of the light is proportional to the concentration of nitrate and nitrite in the sample, allowing for accurate and precise measurements.

Process water is an important component of chemical manufacturing and is used in a variety of ways. Here are a few examples of how process water is used in chemical manufacturing:

• Chemical reactions: Process water is often used as a solvent or a reactant in chemical reactions. Water can be used to dissolve and transport chemicals, or it can be used as a reactant in chemical processes.
• Cooling: Process water is used to cool equipment and processes in chemical manufacturing. For example, water can be circulated through heat exchangers to remove heat generated by chemical reactions.
• Cleaning: Process water is used to clean equipment, vessels, and other components used in chemical manufacturing. Water is often used to flush out reactors and pipelines to remove residual chemicals and impurities.
• Dilution: Process water is used to dilute concentrated chemicals to the desired concentration for manufacturing processes.
• Steam generation: Process water is used to generate steam for heating and process purposes.

The LAR™ QuickTOCeco™ water analyzer is designed to monitor process water in chemical manufacturing by measuring the Total Organic Carbon (TOC) content of the water. TOC is a measure of the amount of organic material present in the water and is an important parameter for assessing water quality in industrial processes.  It uses a method called UV-promoted persulfate oxidation to measure TOC. The method involves oxidizing the organic material in the water using persulfate and then detecting the carbon dioxide produced by the oxidation process. The concentration of carbon dioxide produced is proportional to the TOC content of the water, allowing for accurate and reliable measurements.

It is capable of measuring a wide range of TOC concentrations, from very low levels in ultra-pure water to high levels in heavily contaminated wastewater. The QuickTOCeco water analyzer is also equipped with several features that make it ideal for use in chemical manufacturing. For example, it has a self-cleaning mechanism that prevents buildup of contaminants on the sensor, ensuring accurate and reliable measurements over time. It can also be integrated with a plant control system for automated monitoring and control of TOC levels.

Instrument air is used in many industrial processes, and it is important that the air is dry and free of moisture to prevent damage to equipment and ensure that the process operates correctly. Moisture meters are used to measure the moisture content of the air and ensure that it meets the required specifications.

Instrument air dryers are used to remove moisture from the air, and moisture meters are used to ensure that the air is dried to the required level. If the air contains too much moisture, it can cause corrosion and damage to equipment. If the air is too dry, it can cause static electricity, which can also damage equipment.

We know that in the chemical industry that the quality of products, raw materials and processes are held to high standards.  The monitoring of moisture to maintain the quality of their product is crucial.  You need a moisture measurement solution provider to ensure the optimization of drying.  We can deliver accurate and reliable results with intuitive, easy operation to eliminate any uncertainty.

Our COSA XENTAUR™ dew point moisture meters are designed to measure the moisture content of instrument air and dryers in industrial applications. These dew point meters use our patented aluminum oxide sensing technology, which provides accurate and reliable measurements of moisture content in air.  

Our dew point meters work based on the principle of capacitance. The aluminum oxide sensor is made of a thin layer of aluminum oxide, which acts as a dielectric material. The sensor is placed between two electrodes, which form a capacitor. As the moisture content in the air changes, the capacitance of the sensor changes, which is directly proportional to the moisture content in the air. The meter measures this capacitance and calculates the moisture content in parts per million (ppm).

Another option, our MBW™ MODEL 437™ chilled mirror analyzer is designed to monitor the moisture content in gases and liquids, including those used in chemical manufacturing processes. The analyzer uses a principle called the chilled mirror dew point technique to provide accurate and reliable measurements of moisture content.

The chilled mirror dew point technique works by cooling a mirror surface to a temperature below the dew point of the gas or liquid being measured. As the gas or liquid is passed over the mirror, moisture condenses onto the surface, forming droplets that can be detected by a sensor. The temperature of the mirror at which moisture starts to condense is known as the dew point temperature and is a direct measure of the moisture content of the gas or liquid.

Gasification and syngas technologies are being developed and optimized to increase efficiency and reduce emissions in chemical manufacturing. For example, the use of renewable feedstocks, such as biomass and waste, can reduce greenhouse gas emissions and contribute to a more sustainable chemical manufacturing industry. In addition, the use of advanced gasification and syngas technologies, such as fluidized bed gasifiers and plasma gasification, can improve efficiency and reduce emissions compared to traditional gasification technologies.

Hydrogen isotope and helium/deuterium analysis are analytical techniques used to measure the isotopic composition of hydrogen and helium gases. These techniques are commonly used in a variety of applications, including geochemistry, environmental monitoring, and nuclear power production.

Hydrogen isotopes, which include protium (1H), deuterium (2H), and tritium (3H), have different masses and chemical properties, which can be used to differentiate between different sources or processes. Helium isotope analysis is used similarly, to determine the isotopic composition of helium gas, which can also help identify sources and processes.  Applications of hydrogen isotope and helium/deuterium analysis include:

• Environmental monitoring: The isotopic composition of hydrogen and helium gases can be used to track the movement of water and other substances in the environment, which can be useful in monitoring groundwater contamination or studying water cycles in natural systems.
• Nuclear power production: Deuterium and tritium are used as fuel in nuclear fusion reactions, and the analysis of hydrogen isotopes is important for monitoring the fuel supply and optimizing the fusion process.
• Geochemistry: The isotopic composition of hydrogen and helium gases can be used to study the formation and evolution of rocks and minerals, providing insights into geological processes and the history of the Earth.

For hydrogen isotope and helium and deuterium analysis our flange mounted mass spectrometers have been providing unmatched performance for nuclear, gas production and fuel cell industries for decades.  Our EXTREL™ VeraSpec™ HRQ total analytical system was engineered and designed for high throughput. Heavy water analysis, low mass isotopic analysis and Helium purity are some of the industries the HRQ was designed for.  Along with high resolution capabilities our molecular beam axial ionizer which allows for very fine control of ionization energies allowing for appearance potential studies through low energy soft ionization of the individual molecules.

Pyrolysis and combustion analysis are two analytical techniques used in chemical manufacturing to determine the composition of organic compounds. These techniques involve heating the sample to high temperatures and analyzing the resulting gases.

In pyrolysis analysis, the sample is heated in an inert atmosphere, such as nitrogen or helium, to a high temperature of around 500-1000°C. As the sample heats up, it breaks down into smaller molecules, which are released as gases. The gases are then analyzed using a gas chromatograph (GC) or mass spectrometer (MS) to determine the composition of the sample. Pyrolysis analysis is commonly used to determine the composition of polymers, plastics, and other organic materials. It can provide information on the types of monomers, additives, and other components present in the sample.

In combustion analysis, the sample is burned in a stream of oxygen gas, and the resulting gases are analyzed. The combustion reaction converts the organic compounds in the sample to carbon dioxide and water, which are then analyzed using a GC or MS.  Combustion analysis is commonly used to determine the composition of organic compounds, such as fuels, oils, and fats. It can provide information on the types and amounts of carbon, hydrogen, and other elements present in the sample.

Both pyrolysis and combustion analysis are two analytical techniques used in chemical manufacturing to determine the composition of organic compounds. Pyrolysis involves heating the sample in an inert atmosphere, while combustion involves burning the sample in a stream of oxygen gas. Both techniques provide valuable information on the composition of organic materials and are important tools for quality control and product development in chemical manufacturing.