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

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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Find out how a fertilizer production facility increased sensor lifetime by 500%

The production of nitrogen-based fertilizers is one industry where pH control is very important and the conditions mean sensor lifetime is usually very short.

For a US fertilizer producer, the two-week sensor lifetime of pH sensors in their ammonium nitrate process was unacceptable.

The cost of regular sensor replacement, and exposure of staff to hot and dangerous chemicals, were significant concerns.

This Success Story shows how a US fertilizer produced switched to a METTLER TOLEDO pH solution and increased sensor lifetime by 500%.

Success Story: Condition-based maintenance at the Mitsubishi Chemical Corporation

The Engineering Department at an MCC plant near Okayama was not satisfied with the performance of their pH sensors and they did not have predictive sensor maintenance. The probes were failing in less than three months and had to be exchanged regularly to minimize chances of failure.

This success story looks at why the Mitsubishi Chemical Corporation (MCC) switched from analog pH sensors to digital sensors with ISM technology.

Now they know when their sensors will need to either be calibrated or replaced.

MCC calls ISM "indispensable".

Success Story: Chlor-Alkali Process pH Measurement

80% Reduction in Sensor Maintenance

Elevated temperatures, the presence of chlorine and high salt concentration throughout the chlor-alkali process make stable and reliable pH measurement with conventional pH sensors a constant challenge. Further, the conditions mean sensor lifetime is usually short, so sensor maintenance and replacement costs are high, impacting operational efficiency.

Evonik Industries Fine Chemicals Co., Ltd. is a Sino-German joint venture that produces cyanuric chloride as well as the main raw materials for its production: sodium cyanide and chlorine.

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