Gas analyzers are indispensable tools within chemical manufacturing applications, facilitating the precise measurement and continuous monitoring of gases participating in chemical processes. These manufacturing procedures are frequently distinguished by complex reactions that yield a diverse range of gases, encompassing reactants, intermediates, and final products. Vigilantly tracking these gases assumes paramount importance in upholding product excellence, optimizing process efficiency, and safeguarding the well-being of personnel.
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.
By leveraging our measurement solutions, you can ensure compliance with regulatory standards, minimize downtime, and enhance overall process efficiency. Our comprehensive gas analysis solutions empower you to make informed decisions, identify potential issues in real-time, and take proactive measures to maintain the integrity of your operations. Explore our Application Support.
We know your process and how critical it is for you to protect precious and limited resources. We will work to match your needs and budget and provide the optimal, and most stable process analysis solution for your application.
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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.
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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 Quad O, HON, MON and EMACT, RSR, Subpart Ja, HRVOC, 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.
Our gas analyzer solutions for flare gas monitoring include:
- Total Sulfur Gas Analyzers ATOM INSTRUMENT™ FGA-1000™
- Injection Style Calorimeter for Zero-Hydrocarbon Emissions for BTU and Flare Control COSA XENTAUR™ 9800 CXi™ Injection Style Calorimeter
- Real-Time Industrial Mass Spectrometers for Compliance and Flare Control EXTREL™ MAX300-RTG™ 2.0
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FUEL GAS MONITORING
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.
- 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
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GASIFICATION | SYNGAS
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.
In today’s ever-increasing search for inexpensive alternative fuel sources, gasification is a technology that is steadily gaining popularity. Gasification takes a variety of different raw materials and by-products, such as coal, biomass, petroleum, or biofuel, and through a partial-oxidation process, converts these materials into usable Syngas. Syngas can be used in a diverse range of applications such as creating electricity, chemical manufacturing, or even powering turbines. Monitoring the different stages of these processes becomes significant to ensure proper combustion, maintain efficiency and identify unknowns and potentially unwanted by-products.
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HYDROGEN ISOTOPE & HELIUM / DEUTERIUM ANALYSIS
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.
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.
INSTRUMENT AIR & DRYERS
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 solutions include:
- Aluminum Oxide Dew Point Meters and Transmitters with Hyper-Thin-Film Technology for Portable/Fixed/Loop-Powered Applications COSA XENTAUR™ XDT™ | XPDM™ | LPDT2™
- CRDS Analyzer for UHP Moisture in TIGER OPTICS™ Spark
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PROCESS CONTROL
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 solutions include:
- FTIR/FT-NIR Process Analyzer for Liquids, Solids and Gases ANALECT PCM 1000™
- Industrial Mass Spectrometers for Real-Time, Multi-Stream Process Control EXTREL™ MAX300-RTG™ 2.0
- Real-Time, Multi-Stream Process NIR Spectrometer GUIDED WAVE™ NIR-O™
- Dual Beam Photometer for Continuous PAT Monitoring GUIDED WAVE™ ClearView db® VIS-NIR Dual-Beam Photometer
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PYROLYSIS & COMBUSTION ANALYSIS
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.
LABORATORY, SAFETY & COMPLIANCE
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 solutions include:
- Trace to Percent Oxygen Monitors for Portable and Fixed Applications ALPHA OMEGA INSTUMENTS™ Series 3520™ and OXY-SEN™
- Real-Time Hydrogen Peroxide Vapor Sterilant Gas Monitoring System GUIDED WAVE™ ClearView db® Hydrogen Peroxide Vapor System
- Total Sulfur-Total Nitrogen Gas Analyzers ATOM I NSTRUMENT™ XT-2000™
- Chilled Mirror Dew Point Meters MBW™
- Real-Time Air Analyzers for Environmental Health and Safety EXTREL™ MAX300-AIR™
- FTIR Environmental Vapor Monitoring Analyzer ANALECT™
- TOC Water Analyzers for Pure and Process Water Applications for Laboratories LAR™ QuickTOCpurity™
- COD Water Analyzer for Laboratories LAR™ QuickCODlab™
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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. 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 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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STEAM METHANE REFORMER
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.
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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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
Wastewater is generated as a byproduct of chemical manufacturing and can be used in a variety of ways, depending on its quality and characteristics. 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.