Process Analytics: Measuring and Controlling Vital Parameters in Industrial Applications

Process analytics is fundamental to many industrial applications, particularly in water treatment, chemical processing, food and beverage production, and pharmaceutical manufacturing. These operations often depend heavily on precisely monitoring and controlling specific process parameters, such as pH, oxidation-reduction potential (ORP), dissolved and gaseous oxygen, dissolved CO2, ozone, conductivity, and turbidity. Understanding these parameters and how they can be effectively measured and regulated is critical to maintaining optimal process conditions, ensuring product quality, and complying with environmental and safety regulations.

What is Process Analytics?

Process analytics is the systematic analysis of various industrial processes to optimize performance and efficiency. It involves collecting, processing, and interpreting data to monitor process performance, pinpoint issues, make informed decisions, and implement operational improvements. The specific parameters monitored will vary depending on the industry and process in question, but they typically relate to the process medium's chemical, physical, and biological characteristics.

Understanding Key Parameters

pH

pH is a critical parameter in many industrial processes as it measures the acidity or alkalinity of a solution. It is essential in chemical reactions, biological processes, and corrosion control. Process analytics involves continuously monitoring pH to ensure it stays within specified limits. pH sensors, typically comprising a reference electrode and a pH-sensitive glass electrode, are used to measure this parameter.

Oxidation-Reduction Potential (ORP)

ORP measures the tendency of a solution to either gain or lose electrons, essentially quantifying its oxidizing or reducing potential. This parameter is critical in chemical reaction processes like wastewater treatment and disinfection. ORP sensors, similar to pH sensors, utilize a reference electrode and a sensing electrode to provide a voltage output proportional to the solution's ORP.

Dissolved and Gaseous Oxygen

A process's dissolved and gaseous oxygen concentration can significantly impact chemical reactions, microbial activity, and oxidation processes. Oxygen sensors, which can be optical or electrochemical, measure the oxygen present. The sensors apply in various applications, including fermentation, water treatment, and combustion control.

Dissolved CO2

In processes like fermentation, brewing, and carbonation, the concentration of dissolved CO2 is a critical process parameter. Too much or too little can dramatically affect product quality and process efficiency. Infrared absorption or chemical sensing methods are often used to measure dissolved CO2 levels.

Ozone

Ozone is a powerful oxidizing agent used in water treatment and bleaching processes. Concentration needs close control to ensure effective treatment while minimizing the risk of harmful byproducts. Ozone sensors usually work by measuring the absorption of UV light, a characteristic property of ozone.

Conductivity

Conductivity measures a solution's ability to conduct electricity related to the concentration of ions in the solution. It's a crucial parameter in processes involving aqueous solutions, such as water treatment and chemical production. Conductivity sensors typically operate based on the principle of Ohm's law.

Turbidity

Turbidity measures the cloudiness or haziness of a fluid caused by suspended solids. It is a crucial parameter in water and wastewater treatment, as it can indicate the effectiveness of filtration processes and the presence of pathogens. Turbidity sensors usually work by measuring the scattering and absorption of light.

The Role of Process Analytics

Process analytics plays a critical role in modern industrial operations. By continuously monitoring these parameters and controlling them within defined limits, operators can maintain optimal process conditions, maximize efficiency, and ensure the quality and consistency of their products. Furthermore, data from process analytics can be used for predictive maintenance, helping to prevent equipment failure and reduce downtime.

In summary, process analytics provides invaluable insights into industrial operations, offering real-time visibility and control over critical process parameters. As technology advances, process analytics capabilities will expand further, bringing even more significant benefits to a wide range of industries.

Alliance Technical Sales, headquartered in Clarendon Hills, Illinois, are experts in evaluating, specifying, and applying process analytics instrumentation across many industries. Contact them at 630-321-9646 or visit their website at https://alliancets.com.

Dissolved Oxygen Measurement for Craft Breweries

Oxygen is both friend and enemy to the brewer!

It gives yeast what it wants to breathe and survive during the fermentation process and then becomes your main antagonist after the yeast has done its job.

Any process or transfer where beer becomes exposed to oxygen post-fermentation is an opportunity for oxygen to cause staling, muting, and shelf-life reduction. One example is the packaging process. The added oxygen resulting from placing the beer in cans, kegs, or bottles can affect the final product's consistency and taste.

As a brewer, you want to concentrate on producing the best-tasting beer. Therefore, it is critical to know how oxygen affects the brewing process and how packaging can eventually impact your beer's taste. It will give you the trust you need to create award-winning flavors that customers will enjoy, no matter how long the beer sits on the shelf.

METTLER TOLEDO Process Analytics offers the most accurate and cost-effective solutions for measuring dissolved oxygen in brewing applications. These robust optical dissolved oxygen sensors are durable and require minimal maintenance.

For more information about METTLER TOLEDO Process Analytics products in Illinois, Indiana, Iowa, and Wisconsin call Alliance Technical Sales at 630-321-9646 or visit their website at https://alliancets.com.

5 Ways to Improve Bioprocessing Measurements

How to Optimize Bioprocessing with Digital Sensors

There are continuous requirements for improve pH, DO and CO2 bioprocessing measurements. Meeting quality objectives while enhancing bioprocessing is a tremendous challenge.

Intelligent Sensor Management (ISM®) is a digital technology for in-line process analytics that incorporates intelligent algorithms into sensors. ISM/digital sensors provide real-time sensor diagnostics information, improves pharmaceutical measurements, provides greater process control and maximizes process equipment reliability/revenue.

For an onsite or on-line demonstration, contact Alliance Technical Sales. Call them at 630-321-9646 or visit their website at https://alliancets.com.

Eliminate Delayed Oxygen Measurement Safety Risk in Your Process Gas Analyzer

Having a car alarm that goes off 15 seconds after a break-in puts you at risk of property damage and significant loss. If you wouldn't take this risk with your car, why take it in your process plant?

If you're using an extractive oxygen analyzer that requires sampling and conditioning to prevent explosive conditions, that's exactly what you're getting - an alert up to 60 seconds after an oxygen build up is started. Using an extractive analyzer that requires sampling and conditioning means it's impossible to get real-time information. Measurements are delayed by up to a minute as the sample travels through pipes to the analyzer. In addition oxygen in the sample can be diluted by the gas ahead of and behind it, resulting in a falsely flat excursion curve. An alarm threshold may not be met when it should, so you get one, perhaps inaccurate, result in one minute.

Eliminate the risk. Get continuous real-time measurement. The GPro 500 tunable diode laser gas analyzer from Mettler-Toledo measures in-situ, without the need for sampling and conditioning. It provides continuous measurement and safety-critical applications, so you'll know about oxygen excursions immediately. Don't leave your plant safety up to delayed measurement. Rethink safety. Rethink gas analytics.

For more information, contact Alliance Technical Sales. Call them at 630-321-9646 or visit their web site at https://alliancets.com.

Alliance Technical Sales Products

By combining world-class products, application expertise, and unsurpassed customer service, Alliance Technical Sales enables its clients to increase manufacturing efficiency, reduce production costs, and improve product quality and value. Each of the manufacturers we represent has extensive experience solving critical service applications with the products they manufacture.

Alliance Technical Sales, Inc.
https://alliancets.com
630-321-9646

Analytical Measurement Solutions for Optimization of Your Brewing Process

Stages of brewing and areas for process measurement.

The beer market is currently experiencing an intense globalization process, reflected in escalating competitive and cost pressures. In addition to this, there is growing diversification into new, innovative beverages that demand maximum production flexibility. The time to market is becoming ever shorter, and product quality has to be guaranteed at a consistently high level, accompanied by an increase in productivity.

In-line Measurements in the Brew House

Proper process control plays a vital role in determining the flavor, foam stability, and color of the finished beer. The relative measurement sensors are exposed to high temperatures, and solid particles and turbidity constituents, and must be capable of surviving multiple CIP cycles.

Turbidity Sensor

Measurements in the Fermentation and Storage Cellars

At standard fermentation temperatures, propagation of microorganisms is detrimental to the beer. In order to prevent this from occurring, hygienic plant design and use of materials resistant to CIP solutions are important criteria, as they are for in-line sensors.

DO and CO2 Sensors

Measurements in CIP Systems

The economic use of fresh water, as well as the multiple use of cleaning solutions, present a further basis for achieving overall cost reduction in line with the strive for greater efficiency of the brewing process. Here also, in-line systems are of help in monitoring and optimizing the relative sub-processes.

Measurements in Wastewater Treatment Facilities

Fouling of sensors in wastewater leads to uncertainty about the measurement results and can even result in measurement system failure. METTLER TOLEDO provides efficient and practical solutions in the wastewater treatment areas as well.

You can download the full "Analytical Measurement Solutions for Optimization of Your Brewing Process" brochure here, or view it in the embedded document below.

Analytical Measurement Solutions for Optimization of Your Brewing Process from Alliance Technical Sales, Inc.

Industrial Corrosion Protection Through Chemical Treatment

"An ounce of prevention is worth a pound of cure", particularly when dealing with corrosion and it's effects on process equipment. Production downtime, safety concerns, environmental damage and personnel health all outweigh the obvious repair and replacement cost of the damaged equipment. All taken, the annual costs due to corrosion are estimated in the process and power industries are estimated to be around $750 billion globally.

Exterior treatments, such as painting and specialized coatings provide satisfactory results to maintain structural integrity. However, internal protection of process equipment requires a different approach. Building equipment from exotic materials which are immune from corrosion exceed any practical concept of reasonable cost. Another, much more reasonable approach is corrosion protection based on chemical treatment.

This guide, courtesy of Mettler-Toledo Process Analytics shows you the role in-line analytics play in keeping corrosion under control and avoiding unnecessary chemicals consumption in chemical plants, refineries, power and Cogen facilities.

Your local Process Analytics specialist can help you select the best equipment and strategy. Their experience and knowledge will save you time, money, and ensure quality. 

Learn How a pH Sensor Works

pH Sensor (Mettler)

The video below will provide you with a basic visual understanding of the design of pH sensors and the principles behind pH probe operation. Before viewing the video, here are some pH basics:

What is pH measurement?

pH (potential of hydrogen) is a figure used to express the acidity or alkalinity of a solution on a logarithmic scale. On this scale 7 is neutral; lower values are more acidic and higher values are more alkaline, with a maximum measurement of 14. In process applications, pH is generally measured with an inline pH probe, the most common being the glass combination electrode. Additionally, an inline pH probe generally requires a process adaption, cable and transmitter.

How does a pH probe work?

A typical combination pH probe is made up of two separate electrodes built into one, a pH sensing electrode, and a reference electrode. In the simplest terms, a pH sensing electrode uses a special pH sensing glass membrane. H+ ions permeate the membrane creating a charge. The potential between the two electrodes is the measurement of hydrogen ions in the solution, giving the measure of pH. For more details, download the free pH Theory Guide.

What is the difference between a pH probe, a pH sensor and a pH electrode?

Absolutely nothing! The three terms are used interchangeably in the industry. They can be used for probes that are used in-process or in laboratory measurement. You may also hear the term "pH meter". This can be used for a piece of laboratory equipment, or the term pH meter can also be used to mean the combination of an inline pH probe, cable and transmitter.

https://alliancets.com
630-321-9646

Total Organic Carbon Analyzer

Mettler Toledo Thornton Model 500TOCi
Total Organic Carbon Analyzer
Image courtesy Mettler Toledo Thornton

Total Organic Carbon, or TOC, is one of several common water purity measurements. Purified water use in power generation, semiconductor manufacturing, and pharmaceutical production all depend upon minimum standards of quality to avoid adverse impact on process output or operation. Elevated levels of carbon compounds in purified process water indicates that water treatment equipment is not performing properly and needs attention.

TOC measurement involves oxidation of carbon compounds in the presence of UV light and a measurement of sample conductivity. Processing of the raw measurement yields a value for total organic carbon. Analytical instruments  that lessen the need for human involvement and deliver rapid and accurate results are preferred. Mettler Toledo provides an advanced solution for TOC measurement with it 5000TOCi analyzer.

• Fast continuous measurement
• Reagent and chemical free
• Reliable operation
• ISM Intelligent Sensor Management

More detail is provided in the document below. Share your process analytic challenges with fluid process specialists. Leverage your own knowledge and experience with their product application expertise to develop effective solutions.

TOC Total Organic Carbon Analyzer from Alliance Technical Sales, Inc.

Continuous Microbial Monitoring For Process Water

Real time microbial monitoring for process water builds
quality and production levels.

Monitoring process water microbial counts in the pharmaceutical industry has traditionally been a time consuming, hands-on operation. Sample preparation, plate counting, stains, reagents, and the time required to get results has kept microbial monitoring a cumbersome task that provides only snapshots of the process water quality at the time of sampling.

The Thornton Model 7000RMS from Mettler Toledo, a continuous on-line microbial monitoring system for purified water and water for injection, uses advanced laser based technology to provide immediate detection and quantification of microorganisms. Particles as small as .52 microns can be detected, and the monitor uses recent advancements in spectroscopic technology to differentiate between microbial and inert particles.

The 7000RMS puts on-line analytics for microbial contamination on the same timeline as TOC and conductivity, with all three critical aspects now subject to real time measurement.

The offers a white paper with a more detailed view of the system functions and the technology behind it. Additional product and application information is available. Share your water analysis and process analytic challenges with application experts, leveraging your own knowledge and experience with their product application expertise.

Continuous On-Line Microbial Monitoring of Pharmaceutical Waters from Alliance Technical Sales, Inc.

Process Analytics Product Guide

Ingold and Thornton brands provide wide ranging solutions
for process analytic challenges.
Image courtesy Mettler Toledo

Mettler Toledo is well known and regarded in the field of process analytical instrumentation. The company's line of sensors, transmitters, and analyzers delivers solid performance along with ease of use and reduced maintenance.

The full range of the company's Ingold and Thornton brand capabilities and applications for liquid, gas, and pure water analytics is illustrated in a newly available brochure. The document is useful as an overview of all potential intersections of your own work and the products and capabilities of Mettler Toledo.

Request a full copy of the brochure from a fluid analytics specialist. Share your measurement and analytical challenges with experienced professionals, leveraging your own process knowledge and experience with their product application expertise to develop effective solutions.

Mettler Toledo Process Analytics Product Guide from Alliance Technical Sales, Inc.

Online Chlorine Monitor

Online chlorine and TRO analyzer
Photo courtesy HF Scientific

Online chlorine analyzers are utilized throughout industrial and commercial applications for the monitoring and control of chlorine in potable water, seawater, swimming pool water, process water, waste water, food processing, pulp and paper, and more. Every application benefits from instrumentation delivering accurate and reliable results with a minimum amount of human intervention.

Many instruments are available, with each possibly having a set of construction and operational features that will make it an advantageous choice for a particular application or installation.

The CLX-XT2 online chlorine monitor from HF Scientific is optimized for high temperature marine applications and provides extended reagent life and unattended operation of up to 90 days. The instrument includes communications and output signals that can be used to control chemical feed pumps or provide alarm function.

More detail on the unit is provided below. Share your analytical measurement challenges with application specialists, combining your own knowledge and experience with their instrumentation application expertise to develop effective solutions.

Online Chlorine and TRO Monitor from Classic Controls, Inc.

Retractable Sensor Housing for Analytical Sensors

The retractable sensor housings are available in several configurations

Process analytical sensors generally require some "care and feeding" to maintain specified performance levels. This maintenance can require removal of the sensor from the process in which it is inserted. Clearly, it is seldom advantageous to shut down a process for maintenance when it could otherwise remain in operation. The challenge - how to service the pH, redox, conductivity, or dissolved oxygen sensors without process interruption.

Mettler Toledo, under their Ingold brand of process analytic products, provides a solution in the form of a retractable sensor housing. Models accommodate sensors for pH, redox, conductivity, and dissolved oxygen. The housings are designed to enable safe retraction of the sensor from the process, with in place sensor cleaning or further maintenance operations made simple with the process remaining in operation.

The document below provides additional detail. Share your process analytical challenges with an application expert, combining your own process experience and knowledge with their product application expertise to develop effective solutions.

Retractable Sensor Housings for Analytical Sensors from Alliance Technical Sales, Inc.

Improve Liquid Processing Performance With Sensor Technology

In the field of industrial processing, there is always a striving for improvement. Increasing output, improving output, and decreasing resource input are the watch phrases for process designers and operators in every industry.

Liquid processing often involves analytical instruments that produce periodic or continuous measurements of process conditions. The accuracy of these instruments will directly impact the quality and efficiency of the process, so great attention is paid to maintaining sensors and related instrumentation in top working order. Mettler Toledo, globally recognized leader in analytical sensor technology, provides a comprehensive solution for liquid analytical operations with its line of smart sensors and companion management software.

The ISM sensor technology couples the sensor with an onboard processor that continuously monitors sensor performance and delivers real time information about accuracy and time before maintenance. This empowers users to efficiently schedule maintenance tasks and operate with assurance that the data delivered by the sensor is reliable.

The video below sums up the ISM sensor benefits in under one minute. Share your process analytical challenges with application specialists and combine your process knowledge with their product application expertise to develop effective solutions.

Digital Sensor Technology For In-line Process Analytics

Digital sensor technology opens new
avenues for accuracy and efficiency
Courtesy Mettler Toledo

In-line process analytics deliver wide ranging data used to control production processes and assure the suitability and performance of end products. Strict adherence to established procedures and standards contribute to the accuracy and value of the measurements derived from instruments and equipment monitoring various process steps from start to completion.

Digital sensor technology, with an onboard microprocessor, provides a wealth of functionality not previously available that enhances accuracy and efficiency. Mettler Toledo is at the forefront of digital sensor technology for inline process analytics with their line of ISM (Intelligent Sensor Management) compatible sensors. The digital sensors interface with companion transmitters and software tools to deliver customers top flight process analytics performance.

• Simplified workflow.
• Increased measurement effectiveness and process confidence.
• Sensors are easily removed from the process for calibration, negating need for personnel to bring calibration gases or buffer solutions to the measurement point.
• Diagnostic functions provide easy to read tools, notifying operators of when and what to do to maintain proper performance.
• Each sensor stores its own set of calibration data, which is automatically uploaded to the companion transmitter.
• Self configuration executed when new sensor connected to transmitter.
• Supporting software facilitates the range of tasks necessary to maintain top flight operational status for every ISM sensor.
• Sensor output is a digital signal, not prone to degradation in the same manner as analog signals.
• Sensor learns from and adapts to process conditions to provide better overall performance.

There is much more to learn regarding how ISM sensors can dovetail into your process operation and deliver substantial increases in efficiency and accuracy. The document below provides the next layer of information. Reach out to an inline process measurement specialist, sharing your process measurement challenges. The combination of your process knowledge and their product application expertise will yield an effective solution.

Intelligent Sensor Management For Inline Process Analytics from Alliance Technical Sales, Inc.

New M300 Series Single and Multi-Variable Transmitters From Mettler Toledo

Mettler Toledo recently introduced a new line of transmitters to deliver maximum effectiveness from their array of water quality and process analytics sensors. The M300 is available in 1/2 DIN and 1/4 DIN sizes, with a single or dual channel configuration. Two versions are tailored for process analytics applications or water quality applications. Analog or digital ISM sensors for pH/ORP, conductivity, dissolved oxygen and ozone can be utilized with the new transmitter, which features intuitive operation and excellent ergonomics.

Learn more about the M300 transmitter and see it in action in the video. Reach out to a product specialist with your water and process analytical challenges, combining your process knowledge with their product application expertise to develop effective solutions.

Alliance Adds Thornton to Process Analytical Instrument Offering

Alliance Technical Sales, experienced provider of process analytical solutions throughout many industries, has added the Thornton brand of instruments to expand its offering of Mettler Toledo analytical products. Thornton specializes in on-line liquid process measurement solutions for pure and ultrapure water applications. The product line includes instrumentation and sensors providing high quality measurement of conductivity/resistivity, TOC, pH, ORP, dissolved oxygen, dissolved ozone, sodium, silica and bioburden. The Thornton line complements and expands the extent of Mettler Toledo products already available from Alliance Technical Sales.

Share your fluid process analytical challenges with product application experts, combining your process knowledge and experience with their product application expertise to develop effective solutions.

Process Analytics Product Catalog from Alliance Technical Sales, Inc.