Chemical Processes - Enhance Plant Performance with In-Line Analytics

In chemical processes, where maintaining product quality, ensuring staff safety, and meeting environmental regulations are constant demands, METTLER TOLEDO Process Analytics stands as the ideal partner. Our advanced in-line sensors and analyzers provide real-time monitoring of critical analytical parameters throughout the production cycle. Designed to withstand harsh chemical processes, our instruments help optimize plant performance by ensuring consistent product quality and protecting staff and the environment.

Ready to boost your chemical plant's efficiency and quality?

Globalization has intensified competition and cost pressures in the chemical industry. Fluctuations in raw material quality demand maximum production flexibility. At the same time, rising environmental awareness requires the adoption of stringent measures. Despite these challenges, maintaining consistently high product quality remains crucial for a company’s survival.

The chemical industry is very diverse, with few processes are identical across companies. Leveraging our deep expertise in both unit operations and processes, we have developed solutions that help customers stay competitive. From raw material storage and preparation to end-product manufacturing and waste treatment, our instruments and analyzers play an increasingly vital role throughout the production chain.

Chemical Industry Applications

Water Preparation

Managing boiler and steam-side operations requires a solid understanding of corrosion mechanisms and water behavior. Effective corrosion control significantly improves plant-wide equipment integrity. Continuous in-line measurement is crucial for combating corrosion, minimizing deposits, and maximizing energy efficiency. Key measurements in water preparation include:

pH and conductivity in reverse osmosis (RO)
pH and conductivity in demineralization
pH, dissolved oxygen (DO), conductivity, sodium, and silica in boiler feedwater
pH, conductivity, and turbidity in (re)boiler condensate

Reaction Control

In both batch and continuous operations, real-time in-line measurement of critical parameters such as pH, oxidation-reduction potential (ORP), turbidity, and conductivity enables rapid, precise process control. This ensures optimal product quality, consistency, yield, and safety. Gas-phase processes benefit from in situ gas analysis using tunable diode laser spectrometers, which offer the industry's smallest footprint for efficient and safe operation.

Phase Separation

In solid-liquid separation, deteriorating filter media and overflowing centrifuges can cause off-spec products. In-line turbidity monitoring is vital for effective process control and maintenance planning. Key measurement points include:

Turbidity during filtration
Turbidity in centrifuges
Oxygen level measurement in centrifuge headspace
Conductivity-based liquid-liquid separation

Neutralization

Neutralizing acidic or alkaline process media and waste is common across industries such as petrochemical, pulp and paper, and hydrometallurgical mining. Robust, process-resistant pH sensors provide accurate control during neutralization, safeguarding yield, product quality, and equipment integrity.

Cooling Water

Cooling water systems are prone to corrosion, scaling, and biological contamination, with impurity concentrations increasing due to evaporation. A strong water treatment program that maintains optimal pH, ORP, and conductivity controls water quality and maximizes cooling water cycles without compromising human health or equipment integrity, including heat exchangers and piping.

Chemical Industry Process Analytical Product Solutions

The Right Sensors for Your Processes

From raw material storage to waste treatment, chemical industry processes become more efficient, cost-effective, and safer when analytical parameters are continuously monitored and controlled.

METTLER TOLEDO’s durable in-line measurement solutions provide reliable, ongoing assessment of process conditions.

Our chemical industry brochure covers several key topics, including achieving greater process integrity and reduced maintenance, securing product quality with fewer reagents and additives, faster cycle times in phase separation and filtration, and highly efficient gas scrubbing.

Is Your Team Still Manually Maintaining Sensors?

Manual maintenance tasks such as cleaning and calibrating pH sensors are time-consuming and labor-intensive. However, regular maintenance is essential to ensure that in-line pH sensors provide accurate measurements.

Furthermore, manual upkeep of analytical sensors can put operators at risk by exposing them to hazardous conditions.

Switching to automated sensor cleaning and calibration offers a solution to the challenges of inconvenient, expensive, and unsafe maintenance work. It also enhances process consistency.

This guide explores four key reasons to adopt automated sensor maintenance.

Why Do Manual Sensor Maintenance if You Don’t Have To?

The EasyClean 500 is a compact system designed for fully automated routine cleaning and calibration of pH sensors. It offers six standard programs and two customizable options, allowing operators to tailor the system to their specific requirements.

When combined with METTLER TOLEDO’s Intelligent Sensor Management (ISM™) technology, predictive diagnostics trigger calibration only when needed, maximizing the efficient use of calibration buffers. The only technician involvement required is periodic refilling of cleaning and buffer solutions and occasional sensor replacements.

This significant reduction in maintenance makes it cost-effective to operate even maintenance-heavy measurement points.

10 Steps to Choosing Your Next Gas Analyzer

Selecting the right analyzers can be challenging, which is why a gas analyzer guide can be extremely helpful.

Choosing the appropriate gas analyzer not only affects process safety and efficiency but also influences maintenance requirements and environmental impacts. When looking to replace a gas analyzer, it might seem easy to buy the same model you’ve used before.

However, after 10 to 15 years, that model may no longer be available, and newer technologies may be better suited to your measurement needs.

This gas analyzer guide outlines 10 essential steps to help you select the best analyzers for your specific requirements.

Reliable Gas Measurement in Tight Spaces

Real-time gas analysis is essential in the chemical and petrochemical industries for safety and efficiency. Tunable diode laser (TDL) spectroscopy offers precise, maintenance-friendly in situ measurements, especially for oxygen detection.

Find out how METTLER TOLEDO’s TDLs with innovative wafer cell improves measurement accuracy in small pipes, ensuring reliable process control and safety in even the most challenging environments.

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Reliable Gas Measurement in Tight Spaces

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Explore Our Services - Tailored to Fit Your Equipment

We support and service your measurement equipment throughout its entire lifecycle, from installation to preventive maintenance, calibration, and equipment repair.

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Chemical Processes - Enhance Plant Performance with In-Line Analytics