Process Insights is your SINGLE SOURCE for complete flare gas analysis for total compliance – Quad O, HON, MON and EMACT, RSR, Subpart Ja, HRVOC and more.
Petrochemicals find application in a wide range of products, spanning from clothing to electrical appliances. Within the Petrochemical Industry, there is a diverse array of applications that require monitoring of substances like Ethane, Propane, Ethylene, Polyethylene, Ethylene Oxide, Chloride, Carbon Monoxide, and more. The exploration of alternative methods to enhance the production processes, specifically involving ammonia, ethylene, and ethylene oxide, is of utmost importance.
Operating in the petrochemical industry involves the handling and processing of hazardous gases, which can present significant safety hazards if not monitored diligently. By utilizing gas analyzers, operators can identify and measure the presence of toxic, flammable, or explosive gases in the environment, enabling them to implement appropriate safety precautions to avert accidents and safeguard personnel.
The EPA introduced the new Emissions Guidelines in December 2023, outlining procedures for states to formulate plans to restrict methane emissions from existing sources. Acknowledging the critical role of oil and natural gas operations as the most significant industrial source of methane pollution in the U.S., this initiative represents a pivotal step toward a cleaner and more sustainable future. Read the new EPA guidelines regarding Quad O https://ow.ly/YG1850QguNJ
We know midstream applications. We will work to match your needs and budget and provide the optimal, and most stable process analysis solution for your application. We’re here to help.
WE’RE HERE FOR YOU
Get the most reliable, most precise gas analysis technologies available on the market today. We will work to match your needs and budget and provide the optimal, and most stable process analysis solution for your application.
For a complete range of analytical instrumentation, applications, systems, and service options, we will work to match your needs and budget and provide the optimal, and most stable process analysis solution for your application
APPLICATION SUPPORT
Allow our Support Team, consisting of Factory Trained and Certified professionals, to assess your application and specific requirements. We acknowledge that external conditions can lead to changes in your process parameters, necessitating the addition of components to an existing stream or the incorporation of a new stream. In response to this, we provide a wide range of cost-effective turnkey solutions that deliver exceptional performance, catering to your unique application needs. Explore our Application Support.
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FLARE GAS MONITORING
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.
Process Insights is your SINGLE SOURCE for complete flare gas analysis for total compliance – Quad O, HON, MON and EMACT, RSR, Subpart Ja, HRVOC and more.
Our gas analyzer solutions for flare gas monitoring 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™
- 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™
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Fuel Blending
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.
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FUEL GAS
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
Crude Oil Processing
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.
Our solutions include:
- For Continuous PAT Monitoring 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™
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Moisture Analysis
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.
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
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SAFETY AND COMPLIANCE
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.
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Steam Methane Reformer
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™
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Sulfur Analysis
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™
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PROCESS WATER
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.
Our solutions include:
- TOC Water Analyzer for Harsh Wastewater Applications LAR™ QuickTOCultra™
- TOC Water Analyzer for Clean Water Applications LAR™ QuickTOCuvll™
- TOC Water Analyzer for Municipal and Cooling Water Applications LAR™ QuickTOCeco™
- COD Water Analyzer for Laboratories LAR™ QuickCODlab™
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WASTEWATER
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.
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.
Our solutions include:
- TOC Water Analyzer for Harsh Wastewater Applications LAR™ QuickTOCultra
- TOC Water Analyzer for Clean Water Applications LAR™ QuickTOCuv ll
- TOC Water Analyzer for Municipal and Cooling Water Applications LAR™ QuickTOCeco
- COD Water Analyzer for Laboratories LAR™ QuickCODlab
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FEATURED PRODUCT
EXTREL™ MAX300-TGM™
Real-Time Toxic Gas Monitoring Solution in Ambient Air
Our NEW EXTREL™ MAX300-TGM™ Toxic Gas Monitor is a real time monitoring solution with analysis speeds of 0.4 seconds per chemical and gas clearing times of less than 3 seconds. These impressive speeds exceed industry requirements for continuous monitoring. With the ability to analyze 15+ chemicals per sample point, the MAX300-TGM toxic gas analyzer provides maximum efficiency at an extremely low cost-per-chemical, per sample point.
MAX300-TGM Advantages Include:
- Versatile and flexible analyzer – detect multiple chemicals on up to 46 sample points
- Fast measurement with high sensitivity, reducing false alarms
- Highly responsive to changes in chemical concentration – reducing down time after an event
- Streamlined operation – centralized analyzer for full facility monitoring
- Low cost of ownership and streamlined operation – decreasing complexity in maintenance and upkeep
- Industry leading application expertise and technical support with decades of experience with ambient air monitoring
- Large, user-friendly touch screen interface for at-a-glance updates with customizable alarm verifications
