Fuel blending is one of the most critical and profitable operations in refining and petrochemical processing. Achieving the right balance of sulfur, heating value, octane, viscosity, and product quality directly impacts profitability and regulatory compliance. Process Insights provides advanced real-time fuel blending analyzers that help refiners reduce rework, minimize product giveaway, optimize blend ratios, and maintain consistent fuel specifications across gasoline, diesel, biofuel, and alternative fuel applications. Existing Process Insights solutions include FTIR, NIR, sulfur analysis, and calorimetry technologies designed specifically for blending optimization.
Our three powerful product lines – the ANALECT® Series FTIR analyzers, the GUIDED WAVE™ Dispersive NIR series and the ATOM INSTRUMENT™ Total Sulfur Lab Analyzer.
Get Started with Smarter Fuel Blending
Whether your priority is real-time process control or end-product validation, Process Insights has the solution to match your needs. Contact us today to learn more about integrating our fuel blending analyzers into your operation.
Challenges in Fuel Blending Operations
Refineries and petrochemical operators commonly face:
- Delayed laboratory results slowing process decisions
- Off-spec product requiring expensive reblending
- Excessive giveaway reducing margins
- Difficulty controlling sulfur content in blended fuels
- Variability in heating value and fuel composition
- Maintaining EPA and ASTM compliance requirements
- Limited visibility into real-time blend performance
- Feedstock variability impacting product
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✅ ANALECT® Hydrocarbon SmartSystem
Precision Analytics for Final Blends and Crude Planning
The ANALECT® Hydrocarbon Smart System is a fully automated FTIR process analyzer designed for final fuel blend validation. It delivers exceptional precision and reliability through its integrated sample conditioning system and the automatic capture of outlier samples.
Key Benefits:
- High-accuracy FTIR-based gas and liquid analysis
- Integrated RefineIR™ lab analyzer for crude oil blend planning
- Ideal for end-of-line fuel certification
- Supports regulatory and quality compliance for final fuel products
This system is perfect for applications where validated measurement of the finished fuel blend is critical, and less emphasis is placed on monitoring individual feed streams.
✅ GUIDED WAVE™ Process NIR-O™
Real-Time, Inline Multi-Point Fuel Blending Monitoring
The GUIDED WAVE Process NIR-O analyzer is a robust dispersive NIR system engineered for continuous, real-time process monitoring across multiple points. Supporting up to 12 remote fiber optic probes, the NIR-O enables distributed, inline analysis without the need for stream switching or fast loops.
Key Features:
- Supports multi-probe fuel blending applications
- Remote operation—up to 300 meters from the process
- Delivers real-time data for process optimization
- Suitable for gasoline, diesel, and biofuel blending operations
Whether you’re optimizing blending ratios, reducing off-spec product, or maintaining EPA/ASTM compliance, the NIR-O system offers superior insight into each component stream in your blending process.
✅ ATOM INSTRUMENT™ Lab XT-2000™
Real-Time, Inline Multi-Point Fuel Blending Monitoring
The ATOM Instrument XT-2000 Lab Total Sulfur Analyzer offers rapid, precise, and continuous sulfur measurement, directly in the blending stream or at key process points. Its advanced Excimer UV fluorescence technology delivers accurate results in seconds, allowing operators to make real-time adjustments and maintain sulfur compliance with confidence. Compact, robust, and low-maintenance, ATOM empowers refiners to minimize rework, reduce giveaway, and improve operational efficiency in fuel blending.
- Employs our proprietary Excimer UV-Fluorescence (EUVF) detection, delivering highly sensitive total sulfur analysis with minimal interference from nitrogen—critical in mixed-element samples.
- Provides the highest dynamic range available in its class, enabling accurate measurement of sulfur (and nitrogen) across a wide spectrum of concentrations in a single calibration.
- Delivers fast analysis, making it efficient for labs needing quick turnaround.
✅ COSA XENTAUR™ 9800 CXi Injection-Style Zero Hydrocarbon Emissions Calorimeter
This is a fast response, injection-style zero-hydrocarbon emissions calorimeter. It can provide measurement of Heating Value over the full measurement range. A real advantage with the 9800CXi calorimeter is that it can handle high sulfur concentrations with an H2 measurement option coming soon.
Key Benefits:
- BTU without the need for a Specific Gravity Cell
- Direct Measurement of Calorific Value
- Furnace at 1000°C for complete combustion of Sulfurs
- O2 Cell mounted outside of furnace
- Wall mounted small footprint
- Industrial PLC System, touchscreen HMI
- High temperature combustion
- Flameless / no flameouts
- Built for indoor, outdoor, dirty, and corrosive environments
- Precise measurement of air fuel ratio
✅ COSA XENTAUR™ 9610 CXc Continuous Measurement, Wobbe Index, Heating Value, CARI Calorimeter
Our 9610 CXc calorimeter Wobbe Index measurement is based on the analysis of the oxygen content in the flue gas after combustion of the sample. A continuous gas sample is mixed with dry air at a precisely maintained constant ration, which depends on the BTU range of the gas to be measured. The fuel air mixture is oxidized in a combustion furnace in the presence of a catalyst at 800°C, and the oxygen concentration of the combusted sample is measured by a zirconia oxide cell.
Key Benefits:
- Measures Low BTU Gases
- Low Maintenance
- Flameless/ No Flameouts
- Measures Wobbe and CARI
- Hazardous Area Approved
- No Special Enclosure REquired for Outdoor Use