Insights in Chemical Process Analytics

1 Internal usage only

ApplicationsAcidsFertilizersPesticidesAdhesivesChlor alkaliFlavors & fragrances

Typical Conditions & RequirementsTemperatures up to 130°C, pressure up to 16 barHazardous areasSticky / dirty media Rugged designMaterial certificates

INGOLD SolutionsAccurate and long lifetime pH & ORP electrodesATEX/FM hazardous area approvalsReliable turbidity solutionsAutomated cleaning and calibration systemsRetractable housings with ATEX approvalAdvanced Line transmitters in 4- and 2-wire with HART®, Profibus® PA and Foundation Fieldbus

Chemical Synthesis

2 Internal usage only

Example Chlor-Alkali Membrane Cell Process

Source: www.eurochlor.org

Cooling

Brine Saturation

Chlorate destruction

Storage

Electrolysis

Fine purification

Filtration

Precipitation

ConcentrationCompression

Evaporation

Dechlorination

Drying

LiquefactionCooling

CoolingCooling

Water

Water

Caustic solution

Hydrogen

Precipitants

Salt

Purified brine

Caustic solution

Diluted brine

Chlorine

HydrogenAnolyte

Hydrochloric acidHydrochloric acid

Caustic solution

Residue

Raw brine

Caustic soda

Chlorine

pH pH measurements

Conductivity Cond

pH

pH

Cond

Cond

pH

pH

Salt cycle

- Wastewater control

- Coolwater control

- Brine cycle Cond

Cond

pH

pH

ORP ORP Measurement

ORP

3 Internal usage only

pH pH measurements

Conductivity Cond

Source: Reference document on the Production of Sulfuric id

Filtration Filtration Evaporation

Air

Mixing

Hot Tail Gas

Ammonia

FiltrationHeatingCompression

Absorption

Catalytic Reactor

Nitric Acid

Expander

Steam Turbine

NOxAbatement

Heat recovery

Power

Steam Export

Superheated Steam Power

Hot Tail Gas

Process WaterCooling Water

Cold Tail Gas

Boiler Feed Water

Cooling Water

Atmosphere

Heat

Heat recovery

Cooler condenser

Reducing Agent

NOx compressor

Heat recovery

Power

Cooling Water

Not in single pressure plants

Cond

pHCond

CondpH

Cond

Cond

or

or

Dual & Single Pressure Process (see differentiation below)

Example Nitric Acid Production Process

4 Internal usage only

Example Refining pH Control at Desalter Influent

Why pH Measurement?

Process Step

The separation process is often influenced by pH. Typical pH 5.0 - 8.0Control of chemicals dosingpH varies with the quality of crude oil and wash water and have to be adjusted by adding chemicals, e.g. caustic or acid

Water is mixed with crude oil in order to dissolve salts and remove other impuritiesDemulsifiers are added and an electrostatic field breaks the emulsionChemicals may be added to water: ammonia to reduce corrosion and caustic or acid to adjust the pH of the water wash

pH control of desalter influent improves yield and quality of the crude oil and reduces time of demulsifying and separation process

Demulsifiers

pH1

ChemicalsWash Water

Crude Oil

5 Internal usage only

Key Chemical Applications

Controlling Oxidative Disinfectant Chemistries Using On-Line ORP -> click here

Optimized pH Measurement Improves Sulfide Control in Scrubber -> click here

Long Term Accuracy and Reliability of pH Measurement at Degussa -> click here

Reliable and cost efficient monitoring of Process Off-Gasses at Wacker -> click here

pH Measurement in Amine-based Quench Water -> click here

Oxygen Measurement in Nitrogen Blanketing -> click here

Please note that the file will open in a separate window

6 Internal usage only6

Intelligent Sensor Management - ISM®

Installation Configuration calibrations Trouble shooting Replacement

ISM is METTLER TOLEDO’s solution for easy loop maintenance

ISM simplifies:- installation- configuration - handling and operation- ...and helps reducing loop maintenance

costs

7 Internal usage only

Plug & Measure for Easy Installation

Installation Configuration Calibration Mainten-ance ReplacementCalibration Mainten-

ance Replacement

Easy installation with pre-calibrated sensors

Automatic sensor recognition

Characteristic sensor data stored in sensor head

Calibration history 7

8 Internal usage only

Advanced Diagnostics for pH & DO

Installation Configuration Calibration Mainten-ance Replacement

Wear monitor

CIP/SIP cycles

Min/max temperature

8

9 Internal usage only9

Benefits of ISM Digital Sensors

Digital ISM sensors contain electronics embedded in each sensor to cover the following additional functions:

Low-impedance digital signal transmission

Protection from interferences

Reliable, easy to use connector and cable (IP68 class connection)

Better process control

For harsh environments

High Process reliability

Long lifetime, longer transmitter- sensor distances

Increased measurement accuracy

10 Internal usage only

Digital ISM Concept

M700 with module technology

Fully digital ISM sensor:digital communication

diagnostics integrated in sensor

pH and oxygen

Fully digital system with flexibility and expandability

One module per parameter for:analog sensorsanalog ISM sensorsdigital ISM sensors

DigitalIEEE

protocol

11 Internal usage only

pH Solutions for all Chemical Applications

Application Requirement for pHGeneral chemical applications such as acids and alkalis

High accuracy at long lifetime

Strongly contaminated media, suspensions/emulsions, solutions containing protein

Reliable and dust resistant electrical contact between reference and media

Sulfide-bearing media and organic solvents

Chemically resistant reference system

Toughest chemical applications such as oxidizing media, very strong acids or alkalis

Diaphragm/reference system that avoids electrical shifts due to contaminations

Applications with high temperature and/or pressure

Design and materials suited for extreme conditions

Applications in low temperatures Custom-tailored glass membraneLow ionic strength media Glass membrane with low impedance and

ionic cloud around the diaphragm due to electrolyte outflow

Applications in presence of hydrofluoric acids

Resistant glass membrane

12 Internal usage only

InPro 3250 series

InPro 4800 series

InPro 4250 series

pressure

temp

accuracy

low maintenanceorganic solvents

low cond.

gases

life time

pressure

low maintenanceorganic solvents

gases

life time

temp

accuracy

low cond.

pressure

temp

accuracy

low maintenanceorganic solvents

low cond.

gases

life time

pressure

temp

accuracy

low maintenanceorganic solvents

low cond.

gases

life time

InPro 2000 series

pH electrodes for all Requirements

13 Internal usage only

InPro4800 InPro 3250 InPro 4250 InPro 2000

pH Solutions for Chemical Synthesis Step

InFit 761e InFit 764eInTrac 777e

pH 2100e M700

pH electrode

Housings

pH transmitter

14 Internal usage only

Integration Capabilities

OperatorWorkplace

EngineeringWorkplace

15 Internal usage only

Digital communicationHART/AMS integration of

- 2-wire Advanced Line transmittersProfibus PAFOUNDATION Fieldbus

Automated pH measurementFully automated pH measurement in harsh environment

- Improve uptime- Greater safety- Unattended system operation frees up

maintenance personal

Hazardous area approvalsFM for pH, DO sensorsFM for retractable housingsFM for EasyCleanFM, CSA for transmitters

FM Approved Products

16 Internal usage only

EasyClean is Mettler-Toledo’s solution for automated measurement loops, tailored to your application’s needs.

Different levels of rinsing, cleaning and calibration options can be complemented with a comprehensive offering of housings and transmitters to fit your application.

Control of retractable InTrac housings

Available with system integration solutions

Cleaning & Calibration Systems

tm

17 Internal usage only

EasyClean 150 in Chemical Industry

Water recovery: neutralization of acid water in the flue gas scrubber

In a waste combustor

Where is it measured?

Why EasyClean 150?Regularly cleaning with water required

High maintenance effort

Cleaning every 18 Min. for 3 Min.

Increased electrode lifetime and reduced maintenance effort. Continuous accurate and reliable measurement.

System set up:Electrode: InPro3200Housing: InTrac777eHousing: InFlow762Transmitter: M700/ module pH2700

18 Internal usage only

Cost of Ownership Reduction with EasyClean

19 Internal usage only

Complete Product Offering

Housing

pH

Cond

Turb

TOC

CO2

Value Advanced Premium

DO/O2/O3

Products

sensor housing

ERP

plant widecontrol system

cleaning & calibration

system

devicecontrol

communicationinterface

20 Internal usage onlyMO Branch OfficeMO Main OfficeRepresentative Branch Office

Representative Main Office

Manufacturing

Urdorf: INGOLDR&D Centre and Production

Shanghai:Production

São Paolo: Production

Bedford: THORNTON R&D Centre and Production

Global Process Analytics Presence