Spectroscopy finds widespread applications in the petrochemical and refining sectors, serving as a reliable tool for real-time monitoring of reaction conditions and ensuring the quality assessment of final petrochemical products within refineries. This entails the utilization of both Near Infrared (NIR) spectroscopy and Ultraviolet and Visible (UV-VIS) wavelength spectroscopy for inline and at-line measurements. Process Insights delivers:

• Real time process analyzers for naphtha conversion, catalytic conversion, upgrading units, isomerization, alkylation, and gasoline and diesel blending
• Monitor catalyst efficiency
• PIONA content of reformate, octane numbers, volatility (RVP, vapor-to-liquid ratio), aromatics content, olefins, oxygen, benzene, distillation parameters, Fuel ID, and Fuel Color + Turbidity

Near-Infrared (NIR) spectroscopy plays a crucial role in the Petrochemical and Refining Industries by monitoring the hydrocarbon composition of different streams. The above infographic highlights the installation of sample interfaces at each processing stage within a refinery, enabling real-time data and actionable insights. Throughout the refinery’s stages, NIR spectroscopy is utilized to monitor specific characteristics, such as the Research Octane Rating, Benzene content, and Butane content.

Our solutions include:

• Dual Beam Photometer for Continuous PAT Monitoring Available in Several Enclosure Options GUIDED WAVE™ ClearView db VIS-NIR Dual-Beam Photometer 
• Benchtop NIR Spectrometer for QC lab and Pilot Plant Operations GUIDED WAVE™ Lab NIR-O™
• Real-Time, Multi-Stream Process NIR Spectrometer GUIDED WAVE™ NIR-O™
• FTIR/FT-NIR Process Analyzer for Refining Applications ANALECT® RefinIR™
• Process FTIR Analyzer for Refinery Monitoring ANALECT® Hydrocarbon SmartSystem™

The Environmental Protection Agency (EPA) in the United States regularly updates and revises regulations to address environmental concerns and ensure compliance with emission standards. Flare gas regulations typically aim to reduce the release of harmful pollutants into the atmosphere by implementing stricter controls on flare operations, improving monitoring and reporting requirements, and promoting the adoption of more efficient and environmentally friendly practices in the petrochemical industry.

The strictness of the EPA flare gas regulations can vary depending on several factors, including the type and size of the facility, the location, and the specific emission limits set by the EPA. Compliance with these regulations is essential for petrochemical companies to meet environmental obligations, avoid penalties, and maintain good standing with regulatory authorities.

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 Our solutions include:

Our solutions include:

• Fast, Multi-Cycle Total Sulfur Gas Analyzer ATOM INSTRUMENT™ SGA-1000™
• Real-Time Total Sulfur in Liquids Analyzer ATOM INSTRUMENT™ SLA-1000™
• Laboratory Total Sulfur and Total Nitrogen in Liquid and Gases ATOM INSTRUMENT™ XT-2000™
• Industrial Mass Spectrometers for Real-Time, Multi-Stream Fuel Compliance and Control EXTREL™ MAX300-RTG™ 2.0
• UV-VIS Process Analyzer for H2S to SO2 Ratio GUIDED WAVE™ M508plus™

Fuel blending, as defined by the US Energy Information Administration, involves the mixing of different fractions of crude oil distillations to produce specific grades of gasoline or diesel fuel. This process may also incorporate various amounts of ethanol, a common biofuel additive for gasoline, along with other additives. By effectively blending these diverse components, the desired octane rating or required emission standards for the fuel can be achieved, creating a homogenized and optimized end product.

Near-Infrared Spectroscopy has been effectively implemented in oil refineries for several years. Its application in NIR process spectroscopy allows for rapid detection of multiple parameters of interest within seconds. This real-time information proves invaluable in monitoring the fuel blending process, leading to significant cost savings for refineries. Some additional benefits of real-time fuel blending monitoring with NIR include:

• Swift response times and efficient quality control.
• Enhanced product quality and optimized refining processes.
• Reduced investment, analysis, and maintenance expenses.
• Accurate and precise measurement results.
• Lower cost per sample point compared to FT-NIR methods.

NIR spectroscopy offers the ability to simultaneously measure a wide range of properties throughout the refinery, including octane numbers, volatility (RVP, vapor-to-liquid ratio), aromatics content, olefins, oxygen, benzene, distillation parameters, ethanol, MTBE, ETBE, and more. Traditionally, determining these parameters involved time-consuming, costly, and complex reference methods like multi-dimensional GC, test engines for octane evaluation, or distillations. In comparison, spectroscopy presents a more cost-effective alternative to gas chromatographs.

Petrochemical fuels are liquefied petroleum gas (LPG), kerosene, diesel, gasoline, and jet fuels.  Fuel gases are composed of hydrocarbons likes methane, propane, hydrogen, carbon monoxide, or a mixture.  We use fuel gases because they a high Calorific value.  It is possible for a fuel gas to be undetected and cause a gas explosion. 

Our gas analyzers are commonly used in fuel gas petrochemical applications to monitor the composition and quality of the fuel gas used in various processes, such as heating, power generation, and chemical production. Here are some examples of how gas analyzers are used in fuel gas petrochemical applications:

• Combustion control
• Sulfur removal
• Catalyst monitoring
• Safety monitoring

Our solutions also include:

• Fast, Multi-Cycle Total Sulfur Fuel Gas Analyzer ATOM INSTRUMENT™ FGA-1000
• Direct Heating Value Analyzer for BTU, CARI, Wobbe and Density COSA XENTAUR™ 9610 CXc Calorimeter
• In Situ O2 and COe for Combustion Monitoring for Burner Optimization COSA XENTAUR™ O2CX Monitor
• Industrial Mass Spectrometers for Real-Time, Multi-Stream Fuel Compliance and Control EXTREL™ MAX300-RTG 2.0

Moisture analysis in refining is of critical importance for several key reasons. First and foremost, moisture content in crude oil and refined products can have adverse effects on the quality and performance of various petrochemical products. Water can promote corrosion and degradation of equipment and infrastructure, leading to increased maintenance costs and potential safety hazards. It can also negatively impact the efficiency of refining processes and reduce the quality and stability of the final products.

Moreover, moisture can have a significant impact on the refining process itself. Water can react with certain components in crude oil or intermediate products, leading to the formation of undesirable byproducts and impurities. This can result in decreased yields, reduced product quality, and additional processing steps needed to remove these impurities, leading to higher production costs and potentially lower profits.

In addition to product quality and process efficiency, moisture analysis is essential for meeting regulatory requirements and compliance standards. Many petrochemical products have strict moisture content specifications set by regulatory bodies, industry standards, or customer demands. Failing to meet these specifications can result in product rejection, financial penalties, and damage to a company’s reputation.

By employing accurate and reliable moisture analysis techniques, refineries can identify and control moisture levels at various stages of the refining process. This allows them to optimize their operations, maintain product quality, ensure compliance with regulations, and ultimately enhance the overall efficiency and profitability of their refining activities.

Our solutions include:

• Continuous moisture analysis in instrument air and dryers and portable spot checking with Aluminum Oxide Dew Point Meters for Portable/Fixed/Loop-Powered Applications COSA XENTAUR™ XDT / XPDM / LPDT2
• Trace moisture in clean dry air, ppb to % with CRDS Analyzer for UHP Moisture in Air TIGER OPTICS™ Spark

The petrochemical industry involves the handling of hazardous materials and processes, so it is crucial to implement appropriate lab safety measures to ensure the safety of personnel and the environment.  Gas analyzers are commonly used in petrochemical laboratories to measure the concentration of various gases in samples of air, water, or other substances. The petrochemical industry involves the handling of hazardous gases, such as hydrogen sulfide, carbon monoxide, and volatile organic compounds (VOCs), which can pose a significant risk to personnel and the environment if not properly controlled.

Here are some examples of how our gas analyzers are used in petrochemical laboratories:

• Environmental monitoring
• Process control
• Safety monitoring
• Quality control

The steam reformer holds tremendous significance in the petrochemical industry as a crucial unit for the production of valuable hydrogen and synthesis gas. This versatile and fundamental piece of equipment is used to carry out the steam reforming process, which involves reacting hydrocarbons with steam at high temperatures to yield hydrogen gas and carbon monoxide. Hydrogen is a key building block for various petrochemical processes, including the production of ammonia, methanol, and other essential chemicals.

Additionally, synthesis gas, which is a mixture of hydrogen and carbon monoxide, serves as a precursor for various synthesis reactions, such as the production of synthetic fuels and organic compounds. The steam reformer’s ability to efficiently produce hydrogen and synthesis gas makes it a cornerstone of the petrochemical industry, supporting a wide range of processes and applications that are essential for modern economies and the advancement of various industrial sectors.

Our solutions include:

• Benchtop Mass Spectrometers for Real-Time, ppb-level, Multi-Impurity Analysis EXTREL™ MAX300-LG™ 
• Industrial Mass Spectrometers for Real-Time, Multi-Stream Process Control EXTREL™ MAX300-RTG™ 2.0
• Injection Style Heating Value Analyzer for Zero-Hydrocarbon Emissions for BTU and Flare Control COSA XENTAUR™ 9800 CXi™ Calorimeter
• Portable and Fixed Aluminum Oxide Dew Point Meters COSA XENTAUR™ XPDM™ 
• Real-time Cavity Ring Down Spectroscopy (CRDS) Impurity Analyzers for H2O, CO, CH4 and CO2 | TIGER OPTICS™ CO-rekt™ and Prismatic 3™

Sulfur analysis in the petrochemical industry is of paramount importance due to its significant impact on the environment, product quality, and compliance with regulations. Crude oil and its derived products often contain sulfur compounds, which, when combusted, contribute to the formation of harmful pollutants such as sulfur dioxide (SO2) and sulfur trioxide (SO3). These pollutants are major contributors to acid rain, smog formation, and adverse health effects. Therefore, accurate and reliable sulfur analysis is essential to monitor and control sulfur levels in fuels and other petrochemical products.

Additionally, strict regulations are in place to limit the sulfur content in fuels to minimize environmental pollution and ensure compliance with emission standards. By employing advanced sulfur analysis techniques refineries can optimize their processes, adhere to environmental standards, and produce cleaner, more sustainable products that benefit both the industry and the planet.

Our sulfur analysis solutions include:

• Fast, Multi-Cycle Total Sulfur Gas Analyzer ATOM INSTRUMENT™ SGA-1000™
• Real-Time Total Sulfur in Liquids Analyzer ATOM INSTRUMENT™ SLA-1000™
• Laboratory Total Sulfur and Total Nitrogen in Liquid and Gases ATOM INSTRUMENT™ XT-2000™
• Industrial Mass Spectrometers for Real-Time, Multi-Stream Fuel Compliance and Control EXTREL™ MAX300-RTG™ 2.0
• UV-VIS Process Analyzer for H2S to SO2 Ratio GUIDED WAVE™ M508plus™

In the production of petrochemicals, process water is used for a variety of purposes, including cooling, heating, and washing. The water is typically treated to remove impurities before it is used in the manufacturing process to ensure that it does not cause any adverse effects on the equipment, or the products being produced.

To ensure that the process water is of the required quality, it is closely monitored throughout the production process. This involves testing the water for various parameters, such as pH, dissolved solids, and chemical contaminants, as well as monitoring the flow rates to ensure that the correct amount of water is being used at each stage of the process.

Our LAR™ QuickTOCuv™ TOC water analyzer is a state-of-the-art instrument that is commonly used in the petrochemical industry to monitor process water quality. This instrument is specifically designed to measure the total organic carbon (TOC) levels in water, which is an important indicator of water quality.  It is typically used to monitor the quality of process water at various stages of the manufacturing process. This includes monitoring the quality of incoming water, as well as the water used in cooling, heating, and other process applications.

Refineries, power stations, smelters, and chemical plants generate substantial amounts of wastewater that require treatment to eliminate harmful chemicals before being discharged back into the environment.

Nevertheless, owners of water-intensive facilities can adopt strategies to recycle the processed wastewater in a continuous loop. This can be achieved through various water treatment methods, including desalination or other specialized processes, depending on the specific composition of the wastewater.

In the production of petrochemicals, wastewater is generated as a byproduct of the manufacturing process. This wastewater contains a variety of contaminants, including organic compounds, heavy metals, and other pollutants, which can be harmful to the environment if not properly treated and disposed of.  To minimize the impact of wastewater on the environment, it is typically treated and reused within the production process or discharged into the environment in a manner that meets regulatory requirements. The treatment process typically involves a series of physical, chemical, and biological processes that are designed to remove contaminants and improve the quality of the wastewater.