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.

From Safety to Efficiency: Why Industrial Electric Tote Heaters are Key in Process Plants

Industrial electric tote heaters, also known as IBC (Intermediate Bulk Container) tote heaters, play a crucial role in the daily operations of manufacturing facilities and process plants. Their importance stems from their capabilities to maintain, raise, or lower the temperature of the contents inside the IBC totes, which can be critical for a variety of reasons:

1. Process Optimization: Many industrial processes require specific temperature maintenance for optimal efficiency. If the temperature is too low or too high, the process might not work as effectively or be damaged. IBC tote heaters ensure that the materials remain at the optimal temperature throughout the process.
2. Preventing Material Solidification: Certain materials, such as certain oils, chemicals, or foodstuffs, can solidify or thicken at low temperatures, making them difficult to work with or damaging equipment. Tote heaters can prevent this from happening by maintaining a stable temperature.
3. Improving Material Flow: By maintaining or increasing the temperature of the materials, tote heaters can improve the flow of viscous materials, making processes more efficient and preventing blockages in machinery.
4. Safety: In some cases, materials might need to be kept at a specific temperature to prevent them from becoming hazardous. For example, certain chemicals might become volatile or corrosive if they get too cold or too hot. Tote heaters can help maintain a safe temperature.
5. Product Quality: Maintaining the correct temperature can also be necessary to ensure the final product's quality. For example, a food product at the wrong temperature could spoil or develop off-flavors.
6. Cost-Efficiency: Electric tote heaters are often more energy-efficient than other heating methods, which can save money in the long term. They also provide uniform heat distribution, which is more efficient and prevents hotspots.
7. Flexibility: Many electric tote heaters are adjustable and portable, quickly moved between different totes or adjusted to accommodate other materials or process requirements.

Electric tote heaters are essential to many manufacturing facilities and process plants by providing precise temperature control, safety, and process efficiency. They enable these facilities to function effectively, safely, and economically.

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

LIDAR Non-contact Level Transmitters

LIDAR (Light Detection and Ranging) level transmitters are a type of sensor that uses laser technology to measure the distance between the sensor and the surface of a material. They are used in various industrial applications to detect the level of materials in a process. Here are some of the benefits of using these devices:

1. High Accuracy: LIDAR level transmitters can provide accurate measurements, often down to the millimeter level, making them highly effective for precise measurement tasks.
2. Non-Contact Measurement: These devices use lasers for measurement, so they do not need to touch the material physically, making them ideal for use with corrosive, hot, or otherwise hazardous materials.
3. Versatile: LIDAR level transmitters measure the level of a wide range of materials, including solids, liquids, and sludges.
4. Long Range: These devices can typically measure distances up to several hundred meters, making them suitable for use in large tanks and silos.
5. Real-Time Monitoring: LIDAR level transmitters can provide real-time level data, automating processes and improving efficiency.
6. Resistance to Interference: Unlike other types of sensors, LIDAR level transmitters are unaffected by dust, steam, or other environmental factors, making them reliable even in difficult operating conditions.
7. Low Maintenance: These devices generally require less maintenance than other level sensors due to their non-contact nature.

LIDAR level transmitters are typically best suited for materials that have a relatively flat and reflective surface, as this allows the laser reflection back to the sensor. They are effective with various materials, including multiple liquids (like water, oil, and chemicals), bulk solids (like grain, coal, and plastic pellets), and even sludges or slurries. However, they may not be as effective with highly absorbent materials or have a very uneven surface, as this can scatter the laser light and make it difficult for the sensor to detect the reflection.

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

Smart Planning: Tackle Your Freeze Protection Winterization in the Warm Season

Piping systems, valves, tanks, vessels and gutters require freeze protection in cold weather. The term winterization refers to safeguarding these components against freezing temperatures. The winter season presents numerous challenges for property and business owners, particularly in protecting their structures from freezing temperatures, snow, and ice. Frozen pipes, gutters, and roofs during winter can damage property. Utilizing freeze protection products like heat trace systems, roof, gutter kits, and insulation can effectively safeguard you and your property from harsh weather conditions in various ways. 

But when should your freeze protection preventive maintenance effort begin?

Let's discuss undertaking winterization during the non-winter months, a prudent strategy for several reasons:

1. Mild weather conditions provide better access to areas requiring winterization, ensuring a thorough and efficient process.
2. Performing winterization in advance allows for careful planning and assessment of the facility's needs, minimizing the chances of overlooking vulnerabilities.
3. It enables businesses to schedule professional services during periods of lower demand, which can lead to cost savings and better availability of resources.

Ultimately, by proactively winterizing facilities during non-winter months, companies can reduce downtime and costly repairs caused by freezing temperatures and other winter-related issues, ensuring the smooth operation of their industrial plants and factories throughout the colder months.

Easy Access

Setting up freeze protection solutions in mild weather conditions enables effortless access to the installation locations. In comparison, winter months may cause these areas to be obstructed by snow or ice, making access challenging or hazardous. Taking a proactive approach ensures you protect property without jeopardizing your safety or that of others.

Strategic Planning and Readiness

Implementing freeze protection solutions during warmer periods allows you to strategize and prepare for the upcoming winter, minimizing potential stress and eliminating the need for rushed decisions. You can evaluate your property's requirements and choose the most suitable solutions. Additionally, you can engage a professional to guarantee proper and efficient installation.

Financial Benefits

Opting for freeze protection solutions in warmer months may save long-term costs. You can avert emergency repair expenses that tend to be considerably higher during winter when the demand for such services and products peaks.

Damage Prevention

Setting up freeze protection solutions before winter arrives helps avert property damage caused by freezing temperatures. It spares you the inconvenience and costs of adequately preparing for unfavorable issues.

In summary, opting for freeze protection solutions during warmer months is a forward-thinking strategy for safeguarding your property against the detrimental impacts of freezing temperatures. By planning proactively and taking early action, you can ultimately save time and money and reduce stress in the long term.

Alliance Technical Sales 

https://alliancets.com

630-321-9646

The Mettler Toledo InPro X1 HLS is a Digital, Food-safe, In-line pH Sensor

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pH measurement is essential in the food and beverage industry to ensure food safety, maintain product quality and consistency, optimize taste and flavor, comply with regulations, control chemical reactions, and preserve nutrient content.

The Mettler Toledo InPro X1 HLS pH sensor is designed specifically for Food & Beverage applications. The InPro X1 HLS construction includes high-quality materials that make it highly durable and more applicable than a glass pH sensor. 

The InPro X1 HLS:

• Resists Clean-in-Place Processes - The InPro X1 HLS is the premier food-safe, in-line pH sensor, maintaining accuracy and longevity without compromising its ability to withstand cleaning processes.
• Improves Product Yield and Quality - Accurate in-line pH measurement enables absolute process control, resulting in enhanced product quality, increased yield, and reduced batch times.
• Meets All Major Food Regulations - The InPro X1 HLS features a hygienic design, using materials chosen explicitly for food and beverage contact applications, and holds certifications such as 3A, EHEDG, EC1935/2004, ATEX, and FM.
• Eliminates Risk of Glass Contamination - The unbreakable X-Chip pH-sensing technology allows for in-line pH measurement without the hazard of glass fragment contamination.

Why is pH Measurement Critical for the Food and Beverage Processing Industry?

• Food safety and shelf life: pH levels can affect the growth of microorganisms, such as bacteria, yeast, and mold. A lower pH (higher acidity) usually inhibits the growth of harmful organisms, improving food safety and extending shelf life. Measuring and controlling pH can help prevent spoilage and ensure the safety of products.
• Product quality and consistency: pH significantly impacts the taste, texture, and appearance of food and beverages. It can influence enzymatic reactions, protein denaturation, and Maillard browning reactions. Manufacturers can maintain product quality and consistency across different batches by controlling pH.
• Flavor and taste: pH affects the taste profile of food and beverages. For example, acidic products (lower pH) have a sour taste, while basic products (higher pH) tend to taste bitter. Balancing pH is essential to achieving the desired flavor profile and consumer acceptance.
• Regulatory compliance: Food and beverage industries must adhere to strict regulations and guidelines, which often include specific pH requirements. Meeting these regulations ensures that products are safe for consumption and reduces the risk of product recalls.
• Chemical reactions: pH influences the rate and extent of chemical reactions in food and beverage products, such as fermentation, emulsification, and gelation. Manufacturers can optimize these reactions by monitoring and controlling pH to achieve the desired product characteristics.
• Nutrient availability and stability: pH levels can influence the stability and availability of nutrients, such as vitamins and minerals, in food and beverages. Controlling pH can help maintain nutrient content and improve the nutritional value of products.

Alliance Technical Sales 

https://alliancets.com

630-321-9646

Easy Chloramination Monitoring

A chloramination analyzer is a device used to measure the concentration of chloramines in water treatment systems, a type of disinfectant. Chloramines are a mixture of chlorine and ammonia. They are an alternative to chlorine in water treatment because they are more stable and have a more prolonged residual effect.

Chloramination analyzers use various techniques to measure the concentration of chloramines in the water, including colorimetric methods, amperometric methods, and ultraviolet-visible spectrophotometry. These methods measure the volume of chloramines in a water sample and provide a numerical reading of the concentration.

Chloramination analyzers are typically used in water treatment plants to monitor the effectiveness of the chloramination process. They are also used to ensure that the concentration of chloramines in the treated water meets the required levels for safe drinking water. Additionally, they monitor the effectiveness of the chloramination process and ensure that the concentration of chloramines in the treated water is at the correct level for safe drinking water.

In summary, Chloramination Analyzer is a device used to measure the concentration of Chloramines in water treatment systems. Chloramines are used as an alternative to chlorine in water treatment because they are more stable and have a more prolonged residual effect. Chloramination analyzers are typically used in water treatment plants to monitor the effectiveness of the chloramination process and ensure that the concentration of chloramines in the treated water meets the required levels for safe drinking water.

The HF scientific MCX Monochloramine Analyzer features a unique pump design for more straightforward maintenance and accurate readings every 15 minutes. You can enjoy continuous monitoring and smoother day-to-day operations when you have a reliable, easy-to-use monochloramine analyzer in your facility.

For more information about the MCX Monochloramine Analyzer, contact Alliance Technical Sales. Call them at 630-321-9646 or visit them at https://alliancets.com.

Magnetic Level Gauges in Process Control

A magnetic level gauge is a type of instrument that is used to measure the level of a liquid in a tank or process vessel. It works by using a magnetically coupled float that moves up and down along a calibrated vertical scale as the level of the liquid changes. The position of the float is indicated by a pointer or display that is visible to the operator.

In process control applications, the magnetic level gauge is used to monitor and control the level of liquids in tanks, vessels, and other containers. This is important for a number of reasons, including safety, efficiency, and product quality. For example, if the level of a liquid is too low, it may indicate a leak or a problem with the process. On the other hand, if the level is too high, it may indicate that the process is running too quickly or that there is a risk of overflow.

The magnetic level gauge is typically mounted on the outside of the tank or vessel, which allows the operator to easily monitor the level of the liquid without having to open the vessel or disrupt the process. Some gauges may also be equipped with alarms or automatic control systems that can shut down the process if the liquid level becomes too high or too low.

Overall, the magnetic level gauge is an important tool in process control, as it helps to ensure the safe and efficient operation of industrial processes that involve the handling of liquids.

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