Give You the Most Reliable pH Diagnostics - mt.com the correct concentration during the wet sulfuric...

8NewsINGOLDLeading Process Analytics

THORNTON Leading Pure Water Analytics

ProcessPerspectives in Liquid Process Analytics

Sensors That LearnGive You the Most Reliable pH DiagnosticsTo maximize product quality and yield, you need to know if your sensors

are performing correctly. That is why we have always made diagnostics

the main focus of Intelligent Sensor Management (ISM®). And with our

new version of ISM we offer a world’s first – sensors that actually learn

from your processes to give you unequalled diagnostics performance.

Breakthrough innovationSince its launch in 2006, ISM technology has gone on to help hundreds of compa-nies across the world increase process reli-ability, reduce maintenance costs and simplify sensor handling. One of the central features of ISM is its diagnostic algorithms that predict when sensor maintenance, cleaning or replacement will be required.

With our new, advanced algorithms we provide a breakthrough innovation – sen-sors that actually learn from and adapt to processes. This gives you exceptionally reliable diagnostics that are specific for every single process.

No more guessworkISM sensor diagnostics do not give you raw

data that has to be interpreted: they pro-vide easy-to-read tools that tell operators what needs to be done and when, to keep sensors and your processes running reliably.

Sensor diagnostics mean you can confi-dently plan maintenance for when it is actually needed – neither late which can damage production, nor early when it is not required.

Keep your processes in the leadThere is a huge variation in processes found across manufacturing, so the latest ISM sensors actually adapt to the condi-tions they operate in. As a consequence, ISM diagnostics represent each and every process more accurately than ever before. This enables you to further optimize

2 METTLER TOLEDO Process News 8

maintenance and calibration procedures to get the most out of your resources.

Diagnostics speed saves timeExchanging sensors can lead to risk expo-sure as a measurement point is taken off-line, so a fast ramp-up and getting back to reliable operation is key. To always ensure your sensors are up and running quickly, the new algorithms provide ac-curate diagnostics in only 24 hours.

They not only learn – they teachIn some applications the process condi-tions mean that it can take some time for algorithms to stabilize and give you pre-cise diagnostics data.

We have solved this by giving ISM sensors the ability to learn from other sensors that have already been used in an application. For example, when a pH probe is removed from a process and is connected to our iSense™ software, information on the conditions of that particular process can be stored as an application profile. This profile can then be transferred into a dif-ferent pH sensor.

When this second sensor is installed in the same process, because it carries the knowl-edge of its predecessor, it does not need

time to acclimatize. And if conditions in the process alter, the sensor diagnostics adjust themselves appropriately.

Sensor maintenance exactly when it is neededNow diagnostics are accurate as soon as a sensor is installed and you can be sure you are conducting maintenance when it is necessary. Which means that you can be certain your sensors are always perform-ing at their best.

Beyond Plug and MeasureWith the application profile database on iSense and the ability to calibrate ISM sensors away from the process, you can build a stock of ready-to-go application specific sensors. Now you can replace a sensor at the measurement point in seconds, without having to adjust the transmitter.

For today’s processes and tomorrow’sThe new advanced diagnostics and other ISM developments, such as a mobile app that provides a quick sensor check on the go, mean that ISM will remain the leading technology in analytical measurement.c www.mt.com/sensors-that-learn

“I can transfer the knowledge of one sensor to another with just a click.”

Request a free demo:c www.mt.com/ISM-onsite

Publisher / Production Mettler-Toledo AG

Process Analytics

Im Hackacker 15

CH-8902 Urdorf

Switzerland

IllustrationsMettler-Toledo AG

ISM, InTrac, InPro, GPro, 7000RMS and iSense are

trademarks of the Mettler-Toledo Group. All other

trademarks are the property of their respective

holders. Subject to technical changes.

© Mettler-Toledo AG 01 / 16. Printed in Switzerland.

http://www.mt.com/sensors-that-learn

METTLER TOLEDO Process News 8 3

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sensors are unable to withstand the ex-tremely acidic, high temperature process conditions. The chemical company was looking for a precise and process-tolerant measurement system that would provide continuous concentration data. Their re-search identified solutions based on in-ductive conductivity sensors as being most suitable. Company engineers decided on a METTLER TOLEDO InPro® 7250 induc-tive conductivity sensor with perfluoroalk-oxy (PFA) coating.

The InPro 7250 sensors have been designed specifically for mea-surement in such applica-tions. As there is no electrode in direct contact with the process liquid, they are not affected by

media that would

foul tradi-tional contacting

probes. In addition, the sensorʼs PFA coat-ing is highly resistant to aggressive chemi-

cals.

Reliable sensor improves productivityFor our customer, the InPro 7250 sensor and subse-quent control of the SO3 feed means H2SO4 concen-tration can now be main-

tained within the

desired range. Sulfuric acid that

is either too weak or too strong is no longer

produced, reducing waste of SO3 and increasing the

plantʼs productivity.

c www.mt.com/InPro7250

Sulfuric acid production requires constant monitoringA global player in the chemical industry operates a production site in Brazil where large quantities of sulfur trioxide are produced. The compound is used at the plant as a prime material in the manufac-ture of other products. The SO3 is gener-ated in a continuous process, and at times when it cannot be used elsewhere at the facility it is washed with water to produce sulfuric acid which is subsequently sold to other companies.

Control of H2SO4 concentration is vital as too weak a solution cannot be sold and too strong a solution means overuse of SO3 and a reduction in profit margin. Due to the exothermic nature of the reaction it is not practical to dilute a highly concentrated solution in a later process. Likewise, it is not worth the production costs involved in making weak solutions stronger. There-fore, successful production involves con-tinuous monitoring of the H2SO4 as it is generated.

Inductive conductivity sensors for harsh environmentsDetermination of acid concentration by in-line conduc-tivity measurement is ideal for this appli-cation; however, most

Resilient Conductivity SensorSucceeds in Harsh Acidic ProcessMaintaining the correct concentration during the wet sulfuric acid process relies on

constant control of sulfur trioxide hydration. Conductivity measurement is ideal for

monitoring purposes, but only METTLER TOLEDO inductive conductivity sensors can

tolerate the conditions. For a Brazilian company, implementation has lowered pro-

duction costs.

METTLER TOLEDO Process News 8 5 4 METTLER TOLEDO Process News 8

GPr

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0 G

as A

naly

zers Flexible and Dependable

Award-Winning Gas AnalyzerThe GPro® 500 series of in situ TDL gas analyzers is proving its reliability

and flexibility in chemical and petrochemical plants worldwide. Now,

four new analyzers plus an adaption for trace level measurements will

further its range of applications. For simple, accurate and reliable gas

measurement, get the GPro 500.

wide range of processes make the GPro 500 very attractive. The addition of new ana-lyzers to the range will widen its suitabil-ity still further.

GPro 500 has been available for O2, CO and moisture measurement. Now, models for O2 plus temperature, CO%, CO2%, and a combined CO2% plus CO% make the full GPro 500 portfolio suitable for many re-finery processes where paramagnetic and

extractive NDIR analyzers are normally used. Some of these process applications are outlined below.

Greater catalyst regeneration efficiency in FCC unitsFluidized Catalytic Cracking (FCC) is an essential operation in most modern refin-eries. FCC units break (crack) the long chain hydrocarbons in heavy gas oils into short chain hydrocarbons to produce gasoline and fuel oils.

The catalyst used in the process must be regenerated to maintain its functionality. Conditions in the regenerator must be maintained in a narrow range or else the catalyst can be damaged or regeneration is not complete. Catalyst regeneration can be controlled by monitoring O2, CO and CO2.

Due to the presence of catalyst particles, narrow tubing carrying a sample can easily become blocked and extractive sample cells fouled. In addition, there is a delay in measurements due to the time required for sample transportation and conditioning.

Flexible installation, fast response and minimal maintenanceSince their launch in 2012, the GPro 500 series (winner of a Frost & Sullivan Best Practice Award) of tunable diode laser analyzers have simplified gas measure-ment in chemical and petrochemical ap-plications across the globe. Their ease of installation, speed of response, low main-tenance and flexibility to be utilized in a

Reactor

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Flue gasCatalyst

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air

CO boiler

Catalyst fineshoppers

Regenerator

715 °C2.41 barg

Tota

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Measurementpoint GPro 500

Gas analysis measurement points in FCC unit

Frost & Sullivan Best Practice Award


The GPro 500 series works on the principle of laser absorption spectroscopy which is a non-contact measurement technique, so no tubing is involved. And because the GPro 500 measures in situ, measurements are almost instantaneous.

Prevent thermal runaways in ethylene oxide generationEthylene oxide is a very important raw material with a wide range of uses in ag-rochemicals, detergents, textiles, pharma-ceuticals, etc.

Controlling O2 during production is criti-cal for safety as a level higher than around 25 % will result in thermal runaway. Therefore, speed of response and continu-ous measurement are essential. Paramag-netic analyzers not only have a long measurement time, the paramagnetic cell is delicate. If either the analyzer or the maintenance-heavy extraction equipment is off-line, the reaction is running blind.

The GPro 500 O2 sensor has a response time of less than two seconds, and other than annual verification, requires no maintenance.

Safer purified terephthalic acid productionPTA is mainly used as a precursor in the production of multi-purpose plastics such as PET.

The level of O2 in production off-gas is a vital measurement to prevent explosions

and prevent uncontrolled oxidation. CO2

is also usually measured to provide data on reaction progress and for safety reasons.

As mentioned above, paramagnetic O2 analyzers are fragile, they are also expen-sive to replace should this become neces-sary. For CO2 measurement, commonly-used NDIR analyzers typically use motors and broadband IR sources which need periodic replacement.

The GPro 500 series has no moving parts. This ensures high reliability and a long operational lifetime. In addition, as both its laser source and detectors are in the sensor head, the GPro 500 does not need alignment.

White cell for low-range applicationsFor processes where accurate, low-range extractive measurement is required, the new White cell adaption for the GPro 500 series provides an effective path length of 10 m and boosts measurement resolution by a factor of 10.

Simple, accurate and reliable When it comes to process safety for protect-ing the environment, people, and assets, only the best equipment will do. The GPro 500 offers the convenience and ease of use of an in-line sensor, combined with the performance of a powerful gas ana-lyzer. With the GPro 500, gas measure-ment across a wide range of applications is simpler and more dependable than ever before.c www.mt.com/TDL


PurifiedWater

Biob

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New! Real-Time Bioburden AnalyzerContinuous, On-line, AccurateMeasuring microbial levels in Purified Waters has almost exclusively depended

on time-consuming and error-prone culture-based lab measurements. Now,

the 7000RMS™ offers accurate, continuous, on-line determination of microbial

contamination.

group of seven leading pharmaceutical companies formed the Online Water Bio-burden Analyzer (OWBA) workgroup.

Lab measurements are slow and costlyThe real-time monitoring of the conduc-tivity and Total Organic Carbon level of Purified Water and Water for Injection is well-established and widely used. But for another vital pharmaceutical waters measurement, microbial counts, it is the traditional lab measurement of cell cul-ture growth in an agar media that domi-nates. This method is not only time-con-suming and retrospective, it regularly results in the costly investigation of false-positive results.

Further, due to the high number of points-of-use (POU) in an average pro-duction facility, a single POU may only be tested a few times in a month. This can make the identification and remedia-tion of microbial issues a significant challenge.

Industry requirement for on-line analyzersThe pharmaceutical industry therefore requires real-time monitoring to provide instant notification of microbial excur-sions. In 2013, in recognition of this, a 7000RMS bioburden analyzer


The OWBA believes that pharmaceutical companies can benefit from an on-line microbial analyzer in a number of ways, including: 1. Lower costs through a reduction in labor

due to less sampling, and reduced con-ventional testing and materials.

2. Fewer investigations of, and improved responsiveness to, microbial excur-sions.

3. Greater process understanding and product safety through real-time moni-toring.

Spectroscopic measurement techniqueLaser-induced fluorescence (LIF) is a bioburden measurement technique that can meet industry needs. All microorgan-isms contain metabolites which are used to regulate organism growth and develop-ment. These metabolites fluoresce when exposed to light of certain wavelengths. LIF is a highly sensitive technique that exploits this phenomenon to detect microbes.

Accurate, real-time bioburden data METTLER TOLEDO Thorntonʼs 7000RMS is a new on-line analyzer for real-time measurement of bioburden in pharma-ceutical water systems. It uses LIF to instantly and continuously measure mi-crobial levels and also determines con-tamination from inert particles that can come from diaphragms, filters, etc.

The accuracy of the analyzerʼs measure-ments results in a significant reduction in false-positive results. And unlike other microbial analyzers, the 7000RMS does not use any dyes or reagents and has no moving parts. It is therefore very easy to operate and maintain.

The analyzerʼs touchscreen interface dis-plays the readings for microbes and inert particles. Alarms can be set for alert, ac-tion and specification limits. The 7000RMS offers SCADA connectivity with ModBus TCP, multiple analog outputs and is Wi-Fi capable.

Improved product quality at a lower costThe advanced LIF technology employed in the 7000RMS analyzer can provide con-tinuous and accurate data on bioburden contamination throughout a water sys-tem. Assurance of in-specification micro-bial levels and real-time identification of excursions leads to improved product quality, greater process understanding, risk reduction and lower operating costs.

c www.mt.com/7000RMS


pH M

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olut

ion

Advanced METTLER TOLEDO solutionAfter discussing the issue with METTLER TOLEDO, a system comprising the InPro®

4260 i pH sensor, InTrac® 777 pneumatic housing and M400 transmitter was deter-mined to be the best solution for the company’s requirements and was installed at the mill.

No More Sensor BreakagesThanks to Durable pH SystemConsistently producing superior high-end papers demands rigid pH control. For a major

manufacturer of paper products, robust pH solutions with Intelligent Sensor Management

are helping to ensure sheet quality meets customer requirements, reel after reel.

Critical pH control in paper productionBased in Sweden is a leading producer of papers and boards with facilities in a number of European countries. The com-pany specializes in creative papers where tight pH control is essential during pro-duction in order that final products meet strict quality criteria.

At one of the company’s mills instrumen-tation engineers were having difficulty with in-line pH measurements in a pulper. Here, paper bales are loaded into a vessel and broken down with water and the ad-dition of chemicals, which is monitored through pH determination. When bales are added to the vessel the pH sensor is susceptible to damage and replacement was a regular occurrence. Engineers wanted a robust solution with a sensor that would also measure reliably in the high solids content of the vessel.

The key to the success of the system is the housing: the InTrac 777 is a retractable design which allows the pH sensor to be withdrawn automatically from the pulper vessel. The housing is linked to the con-veyor that loads the bales into the pulper.

When the conveyor starts the sensor is retracted. Once the bale has broken up the probe is reinserted into the process, pro-viding an in-line reading without risking damage to the sensor.

The same system is being used in two other process steps. In the wet end of the paper machine it is used in control of the dosing of acid and base to provide the correct pH value to the stock. The system is also employed in the size press where pH con-trol is used to improve sizing efficiency and produce acid-free paper.

Glass XEROLYT®Measuring solution

Glass

Measuringsolution

Openjunction

Xerolyt® Extrasolid polymer

electrolyte

InPro 4260 i pH sensor with solid electrolyte

Retractable housing InTrac 777

Multi-parameter transmitter M400


No more sensor breakages Since installation, our customer’s instru-mentation engineers have noticed signifi-cant improvements. The retractable housing has eliminated pH sensor break-age at the pulper vessel and simplified sensor cleaning and calibration. ISM has reduced the time spent on sensor mainte-nance and increased process reliability. Confidence in sustaining final product quality is now much higher.

c www.mt.com/InPro4260

• ISM sensors can be pre-calibrated and stored until required. The Plug and Measure feature means measurement point start-up using a pre-calibrated probe is fast and error-free.

• Advanced predictive diagnostics are calculated within the sensor and dis-played on and distributed by ISM-equipped transmitters. These tools allow time-saving predictive rather than reactive maintenance, meaning sensors can easily be kept operating at their best.

Sensor housing for greater process safety In addition to being able to retract the connected sensor from the process, the InTrac 777 housing features a flushing chamber where the sensor can be cleaned and calibrated without interrupting the process.

High-performance transmitter The M400 is a robust, 4-wire, multi- parameter transmitter line that offers superior performance and leading-edge functionality. The unit offers full support of ISM Plug and Measure and predictive diagnostics features.

Intelligent pH sensor The InPro 4260 i is a combined pH sensor and temperature sensor designed for demanding chemical applications. Unlike most sensors, instead of containing a liquid reference electrolyte the InPro 4260 i has a solid polymer electrolyte, Xerolyt® Extra, which is in direct contact with the measuring solution. This elimi-nates the potential of junction clogging from pulp fibers, fillers and sizing pig-ments. Xerolyt Extra is resistant to organic resins, strong acids and alkalis – meeting the requirements specified by the applica-tions and the maintenance expectations of our customer.

The sensor’s Intelligent Sensor Manage-ment (ISM®) technology allows a number of valuable operational and maintenance benefits.

• The pH measurement is calculated in the sensor rather than by the transmit-ter, and is output by the sensor digitally. Calculating pH in the sensor itself gives a more accurate measurement, and because the signal is digital it is im-mune to electrical interference, cable effects and moisture in the environ-ment.


Cogeneration News

Protecting Turbineswith a Self-Calibrating Silica AnalyzerSilica in return condensate can damage turbines and cause unplanned shutdowns. A major

cogeneration operation in Russia chose the 2800 Si Analyzer to monitor silica levels in the

condensate. Its accurate and reliable measurements are providing a truer picture of water

quality to help keep their turbines operating.

2800

Si S

ilica

Ana

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r

The enemy of turbine bladesSilica in purified water can cause signifi-cant damage to turbines. Increased tem-perature and pressure in boilers leads to silica volatilizing with the steam. Subse-quent decreases in temperature and pres-sure during the steamʼs passage through the turbine results in the formation of silica deposits on turbine blades, erosion of turbine blades, imbalance, and poten-tial unplanned and costly shutdowns.

For cogeneration applications, where the plant produces steam for production pro-cesses, the returning condensate may contain contaminants, such as silica, that originate outside the water-steam cycle. Timely detection of excess concentration of these contaminants is key to taking

corrective action and ensuring reliable operation of the equipment.

Return condensate must be closely monitored In May 2014, a major cogeneration power plant in Russia initiated a project to monitor the return condensate collected from the adjacent fertilizer plant it sup-plies power to. Based on the process re-quirements, pH, total dissolved solids, and silica were monitored. For silica monitor-ing a 2800 Si Analyzer was used.

The data collected over two weeks is shown in the graph below.

As can be seen, even though the values of pH and TDS content (as ppb NaCl) did not

change, the concentration of silica varied significantly. This shows that: • Partial monitoring (pH and TDS) and

laboratory testing do not give a complete and timely picture of fluctuations in key indicators of water quality.

• The use of on-line analyzers allows dynamic monitoring of changes in a timely manner, leading to quick re-sponse to any deviation in key param-eters.

Reliable and accurate silica analyzer The 2800 Si Analyzer offers easy installa-tion, exceptional reliability and has minimal maintenance requirements. With automated calibration and opera-tion, the analyzer ensures consistently

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pHNaClSiO2

Changes in return condensate pH, TDS, and silica levels over two week period. Only monitoring pH and TDS would not have shown the variation in water quality.


Continuous and dependable measurementsChemists at the power plant noted that the analyzer provided stable and accurate

measurements continuously, even when the water sample temperature and pres-sure changed. The precision of the on-line measurements was much higher than the laboratory analyses they previously relied on, leading to far greater confidence in their water treatment decisions.

Reduced chance of operator errorThe analyzerʼs design and safety features, such as a lockable enclosure, help prevent accidental damage to the unit. The super-visory staff appreciated the automatic unattended calibration and operation of the analyzer, which reduce operator error and ensure reliability of measurements at all times. Moreover, specialists from METTLER TOLEDO were available to train plant personnel and assist in start-up and maintenance of the analyzer, thus provid-ing local support whenever needed.

c www.mt.com/Thornton-silica

accurate measurements to help detect any deviations in silica levels. Large reagent bottles enable long-term operation before refilling becomes necessary.

2800 Si Silica Analyzer

Get in-line with METTLER TOLEDO

Visit for more informationwww.mt.com/pro

FREE Guide: pH Sensor CalibrationQuick, easy and error-free

pH systems with Intelligent Sensor Management (ISM®) drastically minimize the maintenance workload, meaning far less time spent at measurement points.

Find out everything you need to know about getting the most from your pH sensors in our new guide.

c www.mt.com/ISM-calibration-guide

Mettler-Toledo AGProcess AnalyticsIm Hackacker 15CH-8902 UrdorfSwitzerland

Give You the Most Reliable pH Diagnostics - mt.com the correct concentration during the wet sulfuric...

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