Chemical Manufacturing

ANALYTICAL SOLUTIONS FOR Chemical Manufacturing Applications

For decades, our products and solutions have had a long history in industrial gas, medical gas, and chemical processing enabling detection of moisture and other rogue impurities in process gas streams, including inert, reactive, corrosive, bulk and specialty gases.  We offer solutions for quality control, optimization of analysis in chemical laboratories, and field-proven instrumentation.  Process control is the ability to monitor and adjust a process to give a desired output to maintain quality and improve performance.

Process Insights:  We are revolutionizing measurement everywhere!

OUR CHEMICAL SOLUTIONS FLYER

Process Control

Rapid gas and liquid analyzers are able to deliver real-time control of process reactor resulting in fast, accurate process optimization for increased manufacturing yields, safer operation and reduced wear on equipment.  Enhanced process safety and meeting environmental constraints and compliances keep non-compliance fees down.  At the same time, satisfying product quality and specifications must be maintained. 

Moisture is everywhere. For dew point control, our COSA XENTAUR™ HTF™ sensor technology can be trusted where other methods have routinely failed. The stability, accuracy and life expectancy of our HTF™ sensors have set new a standard in the industry.  Dew point or moisture concentrations can have a very major effect on the quality of a process or final product.  Accurate dew point measurements are often of mission-critical nature.  We offer both online and spot control moisture measurement systems for gases and liquids suitable for use in hazardous areas.

Laboratories in the chemical industry have relied on our lab and elemental analyzers for decades. When it comes to the analysis of trace sulfur, nitrogen and chlorine, we follow ASTM methods to deliver unprecedented detection limits, accuracy and stability.  Regulatory agencies around the world have been implementing increasingly stricter fuel emissions guidelines over the past decades to limit air pollution. Regulations such as the American Tier IIIEuropean Euro 6 or the Indian Bharat VI set quantitative limits on the permissible number of specific pollutants that can be released during combustion.  Sulfur and nitrogen are both controlled under these regulations due to the health and environmental impact of their oxides: Sulfur Dioxide (SO2), Nitrogen Oxide (NO) and Nitrogen Dioxide (NO2), commonly referred to as NOx.  Accurate low-level measurement of total sulfur in natural gas and related LNG products is becoming increasingly important. The SGA-1000™ online process analyzer incorporates patented Excimer UV Fluorescence (EUVF) Technology and is ideally suited for measurement of total sulfur in a variety of applications, including low-level sulfur analysis in hydrocarbon products and process streams.

Our Stack Oxygen Analyzers are well-proven with thousands of installations in chemical and power plants, refinery process heaters, blast furnaces, coke ovens, incinerators and small boiler and furnace installations worldwide.  The small detector can easily be serviced or replaced while the probe remains in place, thus no disruption of the process is required.  Calibrations can be performed manually or automatically at user programmable intervals.  Until now, in situ measurements, used to tune boilers, were limited to O2 only. Now, there is a compact in-situ probe for combustion optimization to measure both COe and O2 simultaneously providing engineers an improved tool to lower excess air to previously unachieved levels, saving fuel costs. 

Sulfur Analysis

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. There are numerous methods for monitoring sulfur in a hydrocarbon stream.  Many of these methods are slow and not cost-effective.  Our Excimer UV Fluorescence technology for total sulfur analysis works in butane, diesel, liquid fuels, LNG, hydro-treaters, blenders and scrubbers, in Renewable Natural Gas (RNG) and biofuels manufacturing.

Our 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.  The FGA-1000 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. It provides complete TRS Data resulting in the total analysis of all sulfur compounds potentially present in flare gas streams, not just the analysis of a few selected sulfur compounds as with GC-type applications.   Our patented Excimer UV Fluorescence (EUVF) Technology is incorporated into our online analyzers. 

Driven by an increasing need for trace sulfur analysis in gas and LNG products, we developed the Trace S-1000™. This remarkable online process analyzer incorporates patented Excimer UV Fluorescence (EUVF) Technology and is specifically designed for measurement of trace total sulfur content in applications that require the ultimate in low-level sensitivity, such as polymer-related applications.  One application where the Trace S-1000 has demonstrated exceptional analytical performance is the measurement of total sulfur in butane at the ultra-low range of 0-1000 ppb/vol.  Acquired test results reflect excellent linearity, precision and long-term stability for this extremely low range.  Analytical results represented were obtained utilizing an oxygen/argon blend for combustion. The Trace S-1000 provides unparalleled sensitivity and rapid response to concentration changes with a typical analysis time of only 180 seconds.

In order to measure sulfur and nitrogen content in fuels, chemicals and petrochemicals, we designed the XT-2000 laboratory analyzer for both total sulfur (TS) and total nitrogen (TN) measurements. The XT-2000 also utilizes patented Excimer UV Fluorescence (EUVF) Technology for TS measurement and proprietary Chemiluminescence (CL) technology for TN measurement offering exceptional sensitivity that does not require a vacuum pump minimizing maintenance requirements and improving analytical stability.

  • Sulfur analysis in butane, diesel, liquid fuels, LNG, hydro-treaters, blenders and scrubbers
  • Renewable Natural Gas (RNG) and biofuels manufacturing
  • H2S, Total Sulfur and Total Nitrogen and Trace Sulfur
  • Net Heating Value/BTU (NHV), H2 and full speciated composition
  • Meets ASTM D5453 for compliance with regulations like US EPA Tier III, European Euro 6 or the Indian Bharat VI

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info@process-insights.com

Laboratory, Safety and Compliance

In chemical manufacturing, fenceline monitoring is the use of monitoring technology to measure the ambient air concentration of a specific chemical at the property line of a manufacturing plant.  The details of the fenceline monitoring work practice is prescribed in EPA Test Methods 325A and 325B.  Our solutions monitor fenceline data allowing sites to have additional insight into their emission sources and their potential impact.  

Laboratory safety is governed by numerous local, state and federal regulations to reduce injury and illness.  Our oxygen deficiency monitoring solutions were designed to chemical safety, health, environmental protection and compliance.  An oxygen deficient environment is defined by the Occupational Safety and Health Administration (OSHA) as one containingless than 19.5% oxygen by volume.

  • Air and fenceline monitoring compliant with regulations such as OSHA requirements, USEPA Method 320, and the RSR
  • O2 deficiency safety monitoring, sulfur and nitrogen in fuels and biofuels, moisture calibration of sensors and standards
  • Trace gas analyzers for H2O, O2, H2, CH4, NH3, CO, CO2, N2, Ar, He and hydrocarbons

FLARE GAS MONITORING

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.

Process Insights is your single source to meet 2023 EMACT and MON MACT compliance deadline.

  • Real-time gas analyzers for flare compliance and control
  • H2S, Total Sulfur, Net Heating Value/BTU (NHV), H2, and full speciated composition
  • Complete analysis for compliance with regulations such as EMACT, MONMACT, RSR, Subpart Ja, Ontario Reg. 530/18, Korean Facility Management Standards to
  • Many solutions to reduce Fugitive Emissions, and HRVOC rules

Our 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.  It provides complete TRS Data resulting in the total analysis of all sulfur compounds potentially present in flare gas streams, not just the analysis of a few selected sulfur compounds as with GC-type applications. Certification or CGA (Cylinder Gas Audit) is seamlessly provided by the incorporated calibration switching configuration and corresponding software menus for easy compliance testing. In addition, the FGA-1000 does not require installation in an enclosed shelter. During chemical processing, flaring is required for safety reasons.  

The MAX300-RTG 2.0 real-time gas analyzer is currently used at many US refineries for NSPS Subpart Ja sulfur monitoring. The analyzer measures the full, speciated composition of the flare gas and delivers continuous updates of NHV, H2S, and Total Sulfur several times per minute.  According to new requirements in the General Provisions, flares used as Air Pollution Control Devices (APCD) are expected to achieve 98% Hazardous Air Pollutant (HAP) destruction efficiencies. These updated requirements include monitoring of the pilot flame, visible emissions, flare tip velocity, net heating values, and dilution parameters, as well as maintaining a Flare Management Plan and a Continuous Parameter Monitoring System Plan.  The MAX300-RTG real-time gas analyzer is an ideal fit for this monitoring system plan.

Our NEW COSA 9800 CXi™ calorimeter is a fast response, injection-style zero-hydrocarbon emissions calorimeter.  It can provide direct measurement of Calorific Heating Value and BTU with a measurement range 0-3000 BTU/scfh.  A real advantage with our COSA 9800 calorimeter is that it can handle high sulfur concentrations with an H2 measurement option. Key advantages to using our measuring principle, based on the Residual Oxygen Measurement Method, are its insensitivity to changes in ambient temperature, very fast response times with the ability to measure BTU values down to zero.  A small constant volume of sample gas is injected into a continuous flow of combustion air with each measurement cycle, providing a precisely maintained fuel/air ratio profile.

Fuel Gas Monitoring

If your process requires any type of continuous analysis of a single component or multi-component, our continuous, real-time gas analyzers provide precise, reliable continuous analysis of process gas down to ultra-low ppm levels.

Steam Methane Reformer

Steam Methane Reforming (SMR) process feedstocks.  Feedstock can be methane, ethane, LPG or naphtha.  The main purpose of this is hydrogen production. Efficient hydrogen production can minimize the amount of fuel and feedstock required.  To do this, you need process control gas analyzer that can deliver real-time and continuous measurement. We deliver enhanced operational safety and process analysis solutions.  Steam reforming means producing hydrogen from a light hydrocarbon using high temperature steam (700-1000°C) at moderate pressures (15-30 bars). It is one of the few technologies of hydrogen production that is viable on an industrial scale. Leverage our broad range of sensors, gas analyzers, and expert engineering resources today.

  • Hydrogen and syngas process control, and hydrogen purity analysis
  • Increased accuracy and efficiency for all stages of the hydrogen economy- generation, storage, and delivery
  • Gas analyzers for H2O, CO, CO2, H2, N2, CH4, H2S, hydrocarbons and our Calorimeters for BTU, Wobbe, CARI, and Density measurement

HYDROGEN ISOTOPE & HELIUM / DEUTERIUM ANALYSIS

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 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.

Pure Water & Wastewater Analysis

Your specific chemical plant must maintain water compliance for pure and ultra-pure water treatment, steam generation, cooling processes, and industrial wastewater.  Our specialized water analysis approach and deep commitment to be your single source allows us deliver online and real-time water quality analysis. We know your process and can help you achieve the water quality requirements for use, reuse, or compliant discharge to the environment.

Using an Online High-Temp Water Analyzer

  • Avoid high costs by preventing product losses and reduce energy when condensate return is contaminated
  • Reduces additional pretreatment of water for (purified) water cycles and treatment of wastewater
  • Reduces additional charges for extending discharge limits and additional costs for repair/replacement of damaged equipment

Use of water as a raw operating material in many processes

  • Process water for heating or cooling purposes
  • As steam to drive turbines or as a reaction medium for cleaning

Adequate water management safeguards plant operation.  Recycling process water and its thermal energy delivers considerable savings.  Any disturbance in process water can lead to an entire plant shutdown.  Reliable and fast application-specific online water analyzers provide major advantages.

  • Seamlessly monitor TOC in water influent and effluent discharge control, process control, high purity, oil in water, cooling water, condensate return, water-steam cycles, and environmental compliance
  • For clean water applications, monitor TOC with our QuickTOCuvll
  • Monitor COD with no chemicals needed, with our QuickCODlab

Instrument Air & Dryers

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.

  • Monitor trace moisture in clean dry air, ppb to % with our Spark CRDS Analyzers 
  • Monitor moisture control for continuous moisture analysis in instrument air and dryers, and portable spot checking

Pyrolysis & Combustion Analysis

Pyrolysis and Combustion Analysis Requires very fast, stable chemical analysis of the combustion process or exhaust stream. Critical to the process is the use of a gas analysis system with high sensitivity and high resolution, to accurately monitor a wide range of applications while maintaining a small dead time between sample runs.  For in-depth analysis of biofuel sources, the VeraSpec MBx is the go-to choice for handling the difficulties of pyrolysis and combustion analysis. The VeraSpec MBx is the flagship instrument for the analysis of pyrolytic byproducts in the search for new biofuel sources.  The VeraSpec MBx has been the proven solution for pyrolytic by-product analysis by customers such as the National Renewable Energy Laboratory (NREL) and the University of Georgia’s Complex Carbohydrate Research Center (CCRC).

Other Applications

  • Gas Purity
  • Plasma Analysis
  • Atmospheric Chemistry Research
  • Biomaterial Research
  • Clusters and Nanoparticle Research
  • Chemical Vapor Deposition (CVD)
  • Vinyl: solvent composition
  • Polyurethane Synthesis
  • Polyester (PET) Synthesis
  • Viscosity in Polyurethane Polymer
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