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Optimizing chemcial industry processes

Mettler Toledo is a leading provider of precision instruments and solutions for various industrial sectors, generating $2.4 billion in revenue in 2015. The company specializes in process analytics with divisions like Ingold and Thornton focused on in-line analytical systems for chemical, pharmaceutical, and food industries. Their innovative sensor technologies help optimize manufacturing processes by providing reliable measurements and reducing maintenance costs.

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Process Analytical Solutions Optimizing Chemical Industry Processes ChemicalIndustry INGOLD Leading Process Analytics THORNTON Leading Pure Water Analytics
2 Representative (main office) Market organization (main office) Representative (branch office) Market organization (branch office) Manufacturing 2 METTLER TOLEDO Group Our company specializes in providing precision ­instrument equipment and related services to industrial customers. In 2015, METTLER TOLEDO generated revenues of US$ 2.4 billion. The company’s stock has been ­publicly traded on the New York Stock Exchange since 1997. METTLER TOLEDO Commitment to Innovation and Quality Worldwide presence We have a worldwide distributor network and a workforce of more than 13,500 employees. We sup- port our customers in industry by providing comprehensive solutions for each step of their manufacturing processes – from receipt of materi- als throughout all manufacturing stages with in-line process mea- surement, through to final packag- ing control, logistics and shipping. METTLER TOLEDO instruments are used in research and development, manufacturing process control, and for quality control. The pharmaceu- tical, biotech, chemical, food and beverage, and cosmetic industries are among the principal users. Innovation and quality Our company enjoys an excellent reputation as an innovator demon- strated by R & D expenditures above the average for the industry. We make every effort to achieve the highest level of quality by applying Total Quality Management at both product and process level, particu- larly as part of the support we ­provide to our customers to help them comply with international guidelines. Process Analytics Division Within the METTLER TOLEDO Group, the Process Analytics Division concentrates on in-line analytical system solutions for industrial man- ufacturing. The Division consists of two business units, Ingold and Thornton, both internationally recog- nized leaders in their respective markets and technologies. The division recently expanded into Gas Analytics with a series of TDL analyzers offering unique in situ solutions. METTLERTOLEDOCompetency 2
333 Ingold was founded in 1948 by Dr. Werner Ingold. Today, Ingold provides the broadest range of in- line analytical measurement solu- tions for industrial processes in the biotechnology, pharmaceutical, chemical, and beverage industries. Ingold offers systems for the meas- urement para­meters of pH / ORP, dissolved oxygen (DO), dissolved CO2, conductivity and turbidity. Latest developments include optical DO sensors and intelligent in-line sensor management solutions for optimized maintenance manage- ment in demanding applications. Ingold – Leading Process Analytics Ingold has a long track record of innovative high-quality solu- tions for demanding process analytics applications. Thornton Inc., founded in 1963 by Dr. Richard Thornton, a Professor at Massachusetts Institute of Technol- ogy, has been part of the Process Analytics Division since 2001. Thornton offers innovative analyti- cal instruments and sensors for the measurement of resistivity, conduc- tivity, TOC, bioburden, pH, dissolved oxygen (DO), sodium, silica and ozone. Thornton instrumentation is trusted globally in the pharmaceutical, biotech, power generation and micro­electronics sectors. With the intro­duction of its microbial con- tamination analyzer, Thornton is the world’s only producer of conductiv- ity, TOC and ­bioburden measure- ment solutions for USP-regulated ultrapure waters. Thornton – Leading Pure Water Analytics Thornton is the market leader in critical ultrapure and pure water analytics, where accuracy and reliability are essential. In Gas Analytics we provide a broad range of in situ and at-line analytical measurement solutions for industrial processes in the chemical, petro­chemical, refining and pharma­ceutical industries. Our innovative sensors and analyzers cover oxygen, carbon monoxide, carbon dioxide, hydrogen sulfide, hydrogen chloride and water vapor, with more parameters to come. The employed tunable diode laser and optical technology combine high measurement accuracy with ease of installation and use. Rethinking Gas Analytics – Unique Approaches to In Situ Gas Measurement Providing leading-edge technology for gas measurement wherever it is required.
44 Visit our website www.mt.com / pro-chemical The chemical industries are characterized by a wide range of processes. Our extensive know-how and involvement in these operations help our customers to remain competitive. From raw material storage to preparation, from chemical synthesis to end products, our measurement solutions play a role of ever-increasing importance. ChemicalProcesses Efficient Unit Operations In and Around the Process 4 High quality at all times, in all situations For robust process control, sustain- ing plant equipment integrity, and ensuring safe operations METTLER TOLEDO provides highly depend- able in-line analytical instrumentation. Our innovative solutions for gas analysis and measuring pH, ORP, conductivity, dissolved oxygen, and turbidity endure the toughest process conditions and are recog- nized across the chemical industry for their reliability and accuracy. In the analysis of high purity boiler makeup water our sodium, silica, and chloride / sulfate ion analyzers are vital for efficient cycle chemistry management. What all our instruments have in common is their low maintenance requirement and unsurpassed user- friendliness. In addition, METTLER TOLEDO solutions can be seam- lessly integrated into all major pro- cess automation architectures.
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66 Intelligent Sensor Management (ISM® ) has established itself as a leading tech- nology in process analytical measurement solutions. With ISM, sensor failure in the process is avoided, traceability is simple, and maintenance is reduced by up to 75 %. Greater Process Integrity And Less Maintenance 6 IntelligentSensorManagement Built-in intelligence Digital ISM pH and oxygen sensors feature an on-board microproces- sor. This allows a number of bene- fits that analog sensors cannot match, including predictive diag- nostics, sensor calibration in a safe environment, and a signal that is immune to interference. Calibrate in the workshop With ISM, buffer solutions do not have to be taken to the measure- ment point for pH sensor calibra- tion. Instead, using iSense™ soft- ware and a PC or laptop, sensors can be calibrated conveniently in a maintenance workshop then stored until they are required. When a sensor needs replaced, ISM’s Plug and Measure feature means the procedure takes only a minute. Increase process reliability with predictive diagnostics Being able to predict when a pH sensor needs replaced and there- fore prevent a failing sensor from being used, would significantly im- prove process reliability. This is precisely the function of ISM’s Dy- namic Lifetime Indicator (DLI): By constantly monitoring process con- ditions and sensor “health”, the DLI provides a clear indication of a pH sensor’s remaining reliable operat- ing life. Efficient maintenance Measurement point maintenance is usually based on a planned sched- ule. On the one hand this means maintenance is often conducted when there is no need for it, and on the other sometimes happens after a sensor has already failed. The in- formation from ISM’s predictive di- agnostics mean maintenance can be scheduled for when it is actually needed, saving time and costs. • Predictive diagnostics reduce operating costs and improve productivity • Digital sensor-transmitter communication ensures signal transmission stability • Sensors are immediately recognized by the transmitter when connected ISM sensors
777 • Multi-parameter, single-channel transmitter • Accepts ISM and analog sensors • Displays ISM sensor diagnostics • HART interface provides simple integration of sensor diagnostics into process control and asset manage- ment systems • Verification and calibration of ISM sensors in a convenient location • Electronic documentation of sensor calibration and maintenance Intelligent transmitter M400 2-wire iSense software
88 The diversity of processes and process conditions in chemical plants demands a specialist approach to measuring analytical parameters. In individual production steps, quality and yield can be significantly improved and operating costs reduced through continuous, real-time analysis. Securing stable and robust processes requires in-line sensors that can withstand harsh conditions and enable reliable process control. ChemicalSynthesis Secure Product Quality With Less Reagents and Additives Highly reliable pH measurement in reactors In various synthesis steps, whether organic or inorganic, pH is often a critical process parameter. METTLER TOLEDO pH electrodes are designed to provide dependable measurement performance across the widest range of process conditions. A clean sensor means good measurement During many processes, a drop in analytical parameter measurement accuracy is not due to a fault with the sensor; it is simply that the sen- sor is not clean. METTLER TOLEDO automated cleaning systems keep sensors in top condition, prolong sensor lifetime, and reduce operat- ing costs. Low maintenance conductivity sensors for chemical concentra- tion control Getting the desired concentration of acids, bases, and salt dilutions is fast and easy with conductivity measurements. Our conductivity sensors perform reliably in all these applications with little or no maintenance. More efficient crystallization through turbidity measurement To improve product purity and re- duce filtration and washing cycle time, crystal growth rate from start to end can be controlled efficiently with METTLER TOLEDO’s durable tur- bidity meters. • For the harshest process conditions • Covers the widest range of applications thanks to multiple choice of electrolyte • Enhanced sensor diagnostics for predictive maintenance Refillable pH electrode InPro 2000 i
99 • Easy sensor rinsing and cleaning without process interruption • Highly efficient cleaning chamber and large bore size design ensures particles/dirt is flushed away. • If no sensor is installed, no action is possible, prevent- ing unwanted operation. • Multi-parameter loop-powered transmitter • ISM functionality for easiest sensor handling • HART interface provides easy integration of sensor diagnostics into process control and asset manage- ment systems Sensor cleaning system EasyClean™ 200 e and retractable housing InTrac® 781 Intelligent transmitter M400 2-wire
10 Turbidity sensors detect how much light is scattered by particles in the process liquid. In solid / liquid separation, deteriorating filter media or overfilled centrifuges lead to out-of-spec product. Also, in decantation processes in liquid / liquid separation, contamination or product loss easily occurs due to sluggish detec- tion of the interface layer. Turbidity and conductivity sensors can quickly detect filtration and phase separation issues, allowing rapid corrective action. PhaseSeparation Faster Cycle Times In Phase Separation and Filtration 10 Greater efficiency in filtration processes Breakthrough of filter media can be detected at an early stage with METTLER TOLEDO in-line turbidity sensors. These enable operators to take rapid corrective action, ensur- ing that the quality of the filtrate is kept within specifications. Higher yield in centrifuge operations The solid particle content in clari- fied liquids depends largely on the flow of the feedstock. Using turbid- ity values to control the flow is highly effective and greatly in- creases process yield. Our turbidity sensors have been designed to provide dependable, worry-free operation. Improved liquid / liquid separation Detecting the interface level be- tween organic and aqueous liquids when decanting is easy with METTLER TOLEDO’s maintenance free, inductive conductivity sensors. • High reproducibility in suspended solids concentration measurement applications • Chemical-resistant sapphire window • Suitable for phase separation processes Dual-fiber turbidity sensor InPro 8200
1111 • Multi-parameter and multi-channel • Color touchscreen simplifies operation • Self-explanatory menu structure • Error-free installation and commissioning • Excellent reproducibility in chemical preparation and phase separation applications • Maintenance free • Handles high temperatures, aggressive chemicals, oil, and wastewater Multi-parameter transmitter M800 Inductive conductivity sensor InPro 7250
12 • Innovative probe design and single flange connection ensure simple installation • Immune to interference from background gases and most dusty and wet environments • No sample extraction or conditioning required Storage, loading, and offloading of flammable liquids always carries the risk of fire and explosion when oxygen is present. In addition, products and chemicals can deteriorate in the presence of oxygen. Elimination of oxygen and air is therefore of great importance and needs to be care- fully monitored and controlled. BlanketingandInerting Safety First In Situ Oxygen Analysis 12 Safer vapor recovery and flare gas processes In flares and in the recovery of va- pors of fuels and organic solvents from storage and process vessels, ingress of air is potentially very dangerous and needs to be kept below critical levels. This usually involves diluting the gas mixture with an inert gas. METTLER TOLEDO tunable diode laser oxygen sensors provide highly reliable in situ oxygen measurement that helps to ensure oxygen levels are within safe limits at all times. Cost-efficient nitrogen blanketing To prevent flammable mixtures forming and to maintain product quality, vessel headspaces are typ- ically flooded with nitrogen. Con- trolling the nitrogen feed based on the oxygen concentration in a ves- sel not only increases safety but can also substantially reduce nitro- gen consumption. Amperometric oxygen sensors can be installed di- rectly in the vessel and are easy to maintain. In situ sensors mean no measure- ment delay All METTLER TOLEDO oxygen sen- sors are installed in situ and require no sample extraction or conditioning systems. This greatly improves safety as the number of components that potentially can fail are reduced to a minimum. A fur- ther benefit is real-time analysis: Whereas conventional extractive analyzers suffer from measurement time lag, METTLER TOLEDO’s in situ technology provides accurate, real- time measurements allowing you to take action before problems develop. Tunable diode laser O2 sensor GPro 500
13 • True in-line measurement without gas sampling system • Advanced ISM functionality for easy installation and predictive diagnostics • High measurement stability • Multi-parameter, single-channel transmitter • Available with HART, FOUNDATION fieldbus and PROFIBUS • Approved for hazardous area use • Accepts digital ISM and analog sensors • Integrated PID controller • 6 output relays 13 Amperometric oxygen sensor InPro 6850 i G Intelligent transmitter M400 2-wire
14 Controlling high purity water for cogeneration requires sensitive and highly accurate analytical instrumentation. As a leader in meeting stringent deion- ized water quality requirements METTLER TOLEDO measurement solutions are the accepted standard for water quality in many contract makeup water systems. WaterPreparation Reliable Cycle Chemistry Control Makeup Water Treatment 14 Keep reverse osmosis systems at peak efficiency RO system operations demand continuous monitoring of analytical parameters to detect and correct abnormal operating conditions and prevent damage to costly membranes. Our instrument platforms include measurements of pH and ORP. The same platforms measure conductivity and temperature for close surveillance of RO system performance. METTLER TOLEDO so- lutions help ensure RO systems are operating efficiently at all times. Accurate pH measurement, even in demi water Efficient operation and regeneration of ion exchangers also depends on continuous monitoring of key pa- rameters. Due to the lack of con- ductivity of demineralized water, measuring pH poses one of the biggest challenges to analyzer technicians. METTLER TOLEDO’s range of pHure Sensor® pH sys- tems ensures stable and accurate measurement at all times. Improved boiler and turbine performance To avoid corrosion and deposition in boilers and on turbines, highly pure feedwater production also re- quires continuous monitoring of conductivity, sodium, silica, and chloride / sulfate ions. Our analyz- ers provide a complete picture of water quality with real-time infor- mation for immediate corrective ac- tion when needed. • Pressurized gel electrolyte for stable measure- ment at ultra-low conductivity • Accurate, fast responding temperature compensator • Low-resistance glass membrane Pure water pH electrode pHure Sensor
1515 • Ultrapure water monitoring at sub-ppb sodium levels • Reagent addition confirmation by pH to ensure consis- tent measurement results • Fully automatic, unattended calibration • Automatic zeroing with every measurement ensures measurement stability • Automatic, unattended calibration • Convenient grab sample capability Compact sodium analyzer 2300Na Trace sensitivity silica analyzer 2800Si
16 • Pre-pressurized electrolyte provides stable readings in demanding applications • Simultaneous pH and ORP measurements • Long operating lifetime All industrial water systems are vulnerable to corrosion, scaling, and foul- ing. A good water treatment program helps to control the water quality and maximize the number of cooling water cycles without compromising the integrity of heat exchangers and piping. CoolingWater Stay Ahead of Corrosion and Scaling Maintaining Heat Transfer Efficiency 16 Stop corrosion and deposition with pH and conductivity measurements To prevent corrosion and scaling in cooling water systems, pH needs to be controlled in a narrow range. In order to minimize mineral build-up, cooling water blowdown is initiated when the total dissolved solids (TDS) concentration reaches an upper level. METTLER TOLEDO pH electrodes and conductivity instruments pro- vide dependable performance for pH and TDS measurement. Rapid detection of heat exchanger leakage If process media leak into the cool- ing water system, ionic contamina- tion is normally detected through increased conductivity, or a change in pH or oxidation reduction poten- tial (ORP). In hydrocarbon indus- tries, when process fluids are organic and non-conducting, an excellent way of detecting hydro- carbons in cooling water is by measuring turbidity. Easy disinfection control Both the temperatures and high oxygen levels in cooling water sys- tems provide excellent growth con- ditions for all kinds of biological foulants. Measuring the ORP is the most efficient way to control disin- fection with oxidants such as chlo- rine or hypochlorite. Versatile pH / ORP electrode InPro 3250 i
17 • Fast response time • WideRange™ technology keeps sensor small and easy to install • Compatible with a variety of housings • Single-channel, multi-parameter, head mount transmitter • Explosion proof / flameproof enclosure and intrinsically safe electronics • HART communication 17 Four-electrode conductivity sensor InPro 7100 i Robust transmitter M100
18 Glass Measuring solution Open junction Xerolyt® Extra solid polymer electrolyte To satisfy environmental regulations, industrial wastewater streams need extensive treatment. Thanks to accurate in-line analysis, high effluent water cleanliness with minimal chemical consumption and maintenance can easily be achieved. WastewaterTreatment Cleaner, Faster, More Economical Effluent Treatment Control 18 Meeting regulatory requirements with in-line sensors In-line measurement of pH, con- ductivity, and turbidity is invaluable in providing assurance that treated waste meets regulatory require- ments. In addition, control of these parameters can help process waste more efficiently and cost-effectively through preventing over-use of re- agents and flocculants. Real-time dissolved oxygen mea- surements lower compressor use Measurement of dissolved oxygen in activated sludge is effective for balancing the required oxygen concentration with a minimum of energy costs for running compres- sors. Low-maintenance sensors that resist fouling are ideal for this purpose. Automated sensor maintenance reduces costs To deal with the conditions in wastewater treatment, METTLER TOLEDO offers fully automated cleaning / calibration systems for pH, dissolved oxygen, and turbidity sensors. These systems relieve the burden on maintenance personnel, reduce operating costs, and pro- long sensor life. • Solid polymer electrolyte for precise measurement and long lifetime • Open junction eliminates clogging if suspended solids are present Open junction pH electrode InPro 4260 i
1919 • Completely automatic sensor rinsing • Modular design for flexibility • Universal components allow easy servicing • Accepts digital ISM and analog sensors • Integrated PID controller • 4 current outputs • 6 output relays Automatic sensor rinsing unit EasyClean 150 Multi-parameter transmitter M400
20 • Tough titanium body • Resistant to strong oxidizing media and solvents • Dirt-repelling PTFE diaphragm • Diagnostics tools provide continuous monitoring of sensor “health” Inefficient wet gas scrubber operations carry risks of pollution and equip- ment corrosion from undesired gases. pH, ORP and conductivity mea- surements can be used to monitor scrubbing solution quality to ensure chemical reagents are neither being wasted nor insufficiently fed. EmissionsControl Highly Efficient Gas Scrubbing And Lower Chemical Consumption 20 Reduced corrosion and scaling To increase effectiveness, the strength of the scrubbing solution must be continuously measured and controlled. Lack of control carries risks of pollutants being released to atmosphere and corrosion of plant equipment. In addition, scaling of the scrubber vessel and plugging of pipes caused by a build-up of by- products reduces efficiency further, and inevitably leads to expensive maintenance. Precise monitoring of scrubbing solution improves effectiveness In batch scrubbers, the scrubbing solution depletes and will at some point lose its ability to absorb pol- lutants. A conductivity measure- ment can detect this lower limit and initiate blowdown or increase the bleeding of spent solution and ad- dition of fresh solution. Benefits of pH / ORP control in continuous scrubbers pH measurement is widely used in continuous scrubbers. With accu- rate control of the pH value, the scrubbing potency of the solution is optimized and scaling or corrosion problems can be avoided. Oxida- tion reduction potential (ORP) measurement can be used for monitoring a scrubber process when reducing or oxidizing agents are to be removed. Highly durable pH / ORP electrode InPro 4881i
21 • Uses plug-in modules for flexibility • Analog, Profibus PA or Foundation fieldbus output • Compatible with EasyClean 400 automatic cleaning / calibration system • Electrodeless design is unaffected by coating or contamination • PEEK or PFA body for aggressive chemical environments • High temperatures tolerant 21 Multi-parameter transmitter M700 Inductive conductivity sensor InPro 7250
2222 Service Offerings Covering our Products for End Users and Project Engineers at EPCs TrainingandServices METTLER TOLEDO Service embraces the complete range of service offerings provided by METTLER TOLEDO. We offer an attractive range of services to cus- tomers, from product guidance, over installation through to service contracts. METTLER TOLEDO Service METTLER TOLEDO offers complete services from product consultation to installation and service contracts. Our comprehensive sales consulting and high level technical services have established us as a competent partner for our customers every- where around the world. Many global manufacturing companies rely on our competence and our long-standing experience. Distribution network Based at several global production sites, with more than 40 market organizations and numerous inter- national sales offices, METTLER TOLEDO maintains a worldwide distribution network and is always close to its customers. Plant engineering and system integration Time is money. Our detailed techni- cal product documentation together with local support during specifica- tion, installation and commissioning contribute to on-schedule project realization. Service Offerings • Repair work at service depot • Sensor refurbishment • Installation / commissioning • Training / seminars / webinars • Maintenance contracts • Factory re-calibration • On-site qualification / verification • Quality documentation • Validation support • Support in compiling SOPs
Maintenance station Operator station DCS/PLC FOUNDATION fieldbus™ www.hartcomm.com www.fieldbus.org HART® is a registered trademark of the HART Communication Foundation. FOUNDATION fieldbus™ is a registered trademark of the Fieldbus FOUNDATION. 2323 SystemIntegration Asset Management and Plant Maintenance With HART, FOUNDATION Fieldbus and PROFIBUS Greater process control can be achieved with open fieldbus integration of analytical ­measurement technology into your control system via ­digital fieldbus technology. Integrating ISM sensor data and diagnostics increases process reliability and simplifies maintenance planning. METTLER TOLEDO integration with HART, FOUNDATION fieldbus and PROFIBUS These open communication proto- cols are regarded as a standard in the process industry and allow a central overview of the whole plant network. In addition, they offer the opportunity of comfortable instru- ment configuration and a higher level of process information to im- prove process performance. Fieldbus communication with 21CFR Part 11, asset manage- ment and predictive maintenance By applying HART, FOUNDATION fieldbus or PROFIBUS your efforts to comply with FDA requirements 21 CFR Part 11 will be minimized. The use of asset management and predictive main- tenance is an important issue for improvements in plant management. Easy integration of sensor data ISM offers the unique opportunity to not only transmit measurement data to a process control system, but also real-time diagnostic infor- mation as well as characteristic sensor data. This allows techni- cians to improve process control and monitor the “health” of sensors across an entire facility. Unplanned shutdowns due to unforeseen sen- sor failure no longer occur, result- ing in improved productivity and lower operating costs.
ISM, InPro, iSense, EasyClean, InTrac, pHure Sensor, WideRange and Xerolyt are trademarks of the Mettler-Toledo Group. Visit us online to discover how METTLER TOLEDO products and solutions can improve processes at your facility. • Product information • White papers • Application notes • On-demand webinars • Videos 4www.mt.com/pro-chemical METTLER TOLEDO Website The Latest News on Applications and Products For more information www.mt.com Mettler-Toledo GmbH Process Analytics Im Hackacker 15 CH-8902 Urdorf Phone +41 44 729 62 11 Subject to technical changes ©04 / 2016 Mettler-Toledo GmbH Printed in Switzerland. 52 900 312.

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Optimizing chemcial industry processes

  • 1.
    Process Analytical Solutions OptimizingChemical Industry Processes ChemicalIndustry INGOLD Leading Process Analytics THORNTON Leading Pure Water Analytics
  • 2.
    2 Representative (main office)Market organization (main office) Representative (branch office) Market organization (branch office) Manufacturing 2 METTLER TOLEDO Group Our company specializes in providing precision ­instrument equipment and related services to industrial customers. In 2015, METTLER TOLEDO generated revenues of US$ 2.4 billion. The company’s stock has been ­publicly traded on the New York Stock Exchange since 1997. METTLER TOLEDO Commitment to Innovation and Quality Worldwide presence We have a worldwide distributor network and a workforce of more than 13,500 employees. We sup- port our customers in industry by providing comprehensive solutions for each step of their manufacturing processes – from receipt of materi- als throughout all manufacturing stages with in-line process mea- surement, through to final packag- ing control, logistics and shipping. METTLER TOLEDO instruments are used in research and development, manufacturing process control, and for quality control. The pharmaceu- tical, biotech, chemical, food and beverage, and cosmetic industries are among the principal users. Innovation and quality Our company enjoys an excellent reputation as an innovator demon- strated by R & D expenditures above the average for the industry. We make every effort to achieve the highest level of quality by applying Total Quality Management at both product and process level, particu- larly as part of the support we ­provide to our customers to help them comply with international guidelines. Process Analytics Division Within the METTLER TOLEDO Group, the Process Analytics Division concentrates on in-line analytical system solutions for industrial man- ufacturing. The Division consists of two business units, Ingold and Thornton, both internationally recog- nized leaders in their respective markets and technologies. The division recently expanded into Gas Analytics with a series of TDL analyzers offering unique in situ solutions. METTLERTOLEDOCompetency 2
  • 3.
    333 Ingold was foundedin 1948 by Dr. Werner Ingold. Today, Ingold provides the broadest range of in- line analytical measurement solu- tions for industrial processes in the biotechnology, pharmaceutical, chemical, and beverage industries. Ingold offers systems for the meas- urement para­meters of pH / ORP, dissolved oxygen (DO), dissolved CO2, conductivity and turbidity. Latest developments include optical DO sensors and intelligent in-line sensor management solutions for optimized maintenance manage- ment in demanding applications. Ingold – Leading Process Analytics Ingold has a long track record of innovative high-quality solu- tions for demanding process analytics applications. Thornton Inc., founded in 1963 by Dr. Richard Thornton, a Professor at Massachusetts Institute of Technol- ogy, has been part of the Process Analytics Division since 2001. Thornton offers innovative analyti- cal instruments and sensors for the measurement of resistivity, conduc- tivity, TOC, bioburden, pH, dissolved oxygen (DO), sodium, silica and ozone. Thornton instrumentation is trusted globally in the pharmaceutical, biotech, power generation and micro­electronics sectors. With the intro­duction of its microbial con- tamination analyzer, Thornton is the world’s only producer of conductiv- ity, TOC and ­bioburden measure- ment solutions for USP-regulated ultrapure waters. Thornton – Leading Pure Water Analytics Thornton is the market leader in critical ultrapure and pure water analytics, where accuracy and reliability are essential. In Gas Analytics we provide a broad range of in situ and at-line analytical measurement solutions for industrial processes in the chemical, petro­chemical, refining and pharma­ceutical industries. Our innovative sensors and analyzers cover oxygen, carbon monoxide, carbon dioxide, hydrogen sulfide, hydrogen chloride and water vapor, with more parameters to come. The employed tunable diode laser and optical technology combine high measurement accuracy with ease of installation and use. Rethinking Gas Analytics – Unique Approaches to In Situ Gas Measurement Providing leading-edge technology for gas measurement wherever it is required.
  • 4.
    44 Visit ourwebsite www.mt.com / pro-chemical The chemical industries are characterized by a wide range of processes. Our extensive know-how and involvement in these operations help our customers to remain competitive. From raw material storage to preparation, from chemical synthesis to end products, our measurement solutions play a role of ever-increasing importance. ChemicalProcesses Efficient Unit Operations In and Around the Process 4 High quality at all times, in all situations For robust process control, sustain- ing plant equipment integrity, and ensuring safe operations METTLER TOLEDO provides highly depend- able in-line analytical instrumentation. Our innovative solutions for gas analysis and measuring pH, ORP, conductivity, dissolved oxygen, and turbidity endure the toughest process conditions and are recog- nized across the chemical industry for their reliability and accuracy. In the analysis of high purity boiler makeup water our sodium, silica, and chloride / sulfate ion analyzers are vital for efficient cycle chemistry management. What all our instruments have in common is their low maintenance requirement and unsurpassed user- friendliness. In addition, METTLER TOLEDO solutions can be seam- lessly integrated into all major pro- cess automation architectures.
  • 5.
  • 6.
    66 Intelligent Sensor Management(ISM® ) has established itself as a leading tech- nology in process analytical measurement solutions. With ISM, sensor failure in the process is avoided, traceability is simple, and maintenance is reduced by up to 75 %. Greater Process Integrity And Less Maintenance 6 IntelligentSensorManagement Built-in intelligence Digital ISM pH and oxygen sensors feature an on-board microproces- sor. This allows a number of bene- fits that analog sensors cannot match, including predictive diag- nostics, sensor calibration in a safe environment, and a signal that is immune to interference. Calibrate in the workshop With ISM, buffer solutions do not have to be taken to the measure- ment point for pH sensor calibra- tion. Instead, using iSense™ soft- ware and a PC or laptop, sensors can be calibrated conveniently in a maintenance workshop then stored until they are required. When a sensor needs replaced, ISM’s Plug and Measure feature means the procedure takes only a minute. Increase process reliability with predictive diagnostics Being able to predict when a pH sensor needs replaced and there- fore prevent a failing sensor from being used, would significantly im- prove process reliability. This is precisely the function of ISM’s Dy- namic Lifetime Indicator (DLI): By constantly monitoring process con- ditions and sensor “health”, the DLI provides a clear indication of a pH sensor’s remaining reliable operat- ing life. Efficient maintenance Measurement point maintenance is usually based on a planned sched- ule. On the one hand this means maintenance is often conducted when there is no need for it, and on the other sometimes happens after a sensor has already failed. The in- formation from ISM’s predictive di- agnostics mean maintenance can be scheduled for when it is actually needed, saving time and costs. • Predictive diagnostics reduce operating costs and improve productivity • Digital sensor-transmitter communication ensures signal transmission stability • Sensors are immediately recognized by the transmitter when connected ISM sensors
  • 7.
    777 • Multi-parameter, single-channel transmitter • AcceptsISM and analog sensors • Displays ISM sensor diagnostics • HART interface provides simple integration of sensor diagnostics into process control and asset manage- ment systems • Verification and calibration of ISM sensors in a convenient location • Electronic documentation of sensor calibration and maintenance Intelligent transmitter M400 2-wire iSense software
  • 8.
    88 The diversity ofprocesses and process conditions in chemical plants demands a specialist approach to measuring analytical parameters. In individual production steps, quality and yield can be significantly improved and operating costs reduced through continuous, real-time analysis. Securing stable and robust processes requires in-line sensors that can withstand harsh conditions and enable reliable process control. ChemicalSynthesis Secure Product Quality With Less Reagents and Additives Highly reliable pH measurement in reactors In various synthesis steps, whether organic or inorganic, pH is often a critical process parameter. METTLER TOLEDO pH electrodes are designed to provide dependable measurement performance across the widest range of process conditions. A clean sensor means good measurement During many processes, a drop in analytical parameter measurement accuracy is not due to a fault with the sensor; it is simply that the sen- sor is not clean. METTLER TOLEDO automated cleaning systems keep sensors in top condition, prolong sensor lifetime, and reduce operat- ing costs. Low maintenance conductivity sensors for chemical concentra- tion control Getting the desired concentration of acids, bases, and salt dilutions is fast and easy with conductivity measurements. Our conductivity sensors perform reliably in all these applications with little or no maintenance. More efficient crystallization through turbidity measurement To improve product purity and re- duce filtration and washing cycle time, crystal growth rate from start to end can be controlled efficiently with METTLER TOLEDO’s durable tur- bidity meters. • For the harshest process conditions • Covers the widest range of applications thanks to multiple choice of electrolyte • Enhanced sensor diagnostics for predictive maintenance Refillable pH electrode InPro 2000 i
  • 9.
    99 • Easy sensor rinsingand cleaning without process interruption • Highly efficient cleaning chamber and large bore size design ensures particles/dirt is flushed away. • If no sensor is installed, no action is possible, prevent- ing unwanted operation. • Multi-parameter loop-powered transmitter • ISM functionality for easiest sensor handling • HART interface provides easy integration of sensor diagnostics into process control and asset manage- ment systems Sensor cleaning system EasyClean™ 200 e and retractable housing InTrac® 781 Intelligent transmitter M400 2-wire
  • 10.
    10 Turbidity sensors detecthow much light is scattered by particles in the process liquid. In solid / liquid separation, deteriorating filter media or overfilled centrifuges lead to out-of-spec product. Also, in decantation processes in liquid / liquid separation, contamination or product loss easily occurs due to sluggish detec- tion of the interface layer. Turbidity and conductivity sensors can quickly detect filtration and phase separation issues, allowing rapid corrective action. PhaseSeparation Faster Cycle Times In Phase Separation and Filtration 10 Greater efficiency in filtration processes Breakthrough of filter media can be detected at an early stage with METTLER TOLEDO in-line turbidity sensors. These enable operators to take rapid corrective action, ensur- ing that the quality of the filtrate is kept within specifications. Higher yield in centrifuge operations The solid particle content in clari- fied liquids depends largely on the flow of the feedstock. Using turbid- ity values to control the flow is highly effective and greatly in- creases process yield. Our turbidity sensors have been designed to provide dependable, worry-free operation. Improved liquid / liquid separation Detecting the interface level be- tween organic and aqueous liquids when decanting is easy with METTLER TOLEDO’s maintenance free, inductive conductivity sensors. • High reproducibility in suspended solids concentration measurement applications • Chemical-resistant sapphire window • Suitable for phase separation processes Dual-fiber turbidity sensor InPro 8200
  • 11.
    1111 • Multi-parameter and multi-channel • Colortouchscreen simplifies operation • Self-explanatory menu structure • Error-free installation and commissioning • Excellent reproducibility in chemical preparation and phase separation applications • Maintenance free • Handles high temperatures, aggressive chemicals, oil, and wastewater Multi-parameter transmitter M800 Inductive conductivity sensor InPro 7250
  • 12.
    12 • Innovative probe designand single flange connection ensure simple installation • Immune to interference from background gases and most dusty and wet environments • No sample extraction or conditioning required Storage, loading, and offloading of flammable liquids always carries the risk of fire and explosion when oxygen is present. In addition, products and chemicals can deteriorate in the presence of oxygen. Elimination of oxygen and air is therefore of great importance and needs to be care- fully monitored and controlled. BlanketingandInerting Safety First In Situ Oxygen Analysis 12 Safer vapor recovery and flare gas processes In flares and in the recovery of va- pors of fuels and organic solvents from storage and process vessels, ingress of air is potentially very dangerous and needs to be kept below critical levels. This usually involves diluting the gas mixture with an inert gas. METTLER TOLEDO tunable diode laser oxygen sensors provide highly reliable in situ oxygen measurement that helps to ensure oxygen levels are within safe limits at all times. Cost-efficient nitrogen blanketing To prevent flammable mixtures forming and to maintain product quality, vessel headspaces are typ- ically flooded with nitrogen. Con- trolling the nitrogen feed based on the oxygen concentration in a ves- sel not only increases safety but can also substantially reduce nitro- gen consumption. Amperometric oxygen sensors can be installed di- rectly in the vessel and are easy to maintain. In situ sensors mean no measure- ment delay All METTLER TOLEDO oxygen sen- sors are installed in situ and require no sample extraction or conditioning systems. This greatly improves safety as the number of components that potentially can fail are reduced to a minimum. A fur- ther benefit is real-time analysis: Whereas conventional extractive analyzers suffer from measurement time lag, METTLER TOLEDO’s in situ technology provides accurate, real- time measurements allowing you to take action before problems develop. Tunable diode laser O2 sensor GPro 500
  • 13.
    13 • True in-line measurementwithout gas sampling system • Advanced ISM functionality for easy installation and predictive diagnostics • High measurement stability • Multi-parameter, single-channel transmitter • Available with HART, FOUNDATION fieldbus and PROFIBUS • Approved for hazardous area use • Accepts digital ISM and analog sensors • Integrated PID controller • 6 output relays 13 Amperometric oxygen sensor InPro 6850 i G Intelligent transmitter M400 2-wire
  • 14.
    14 Controlling high puritywater for cogeneration requires sensitive and highly accurate analytical instrumentation. As a leader in meeting stringent deion- ized water quality requirements METTLER TOLEDO measurement solutions are the accepted standard for water quality in many contract makeup water systems. WaterPreparation Reliable Cycle Chemistry Control Makeup Water Treatment 14 Keep reverse osmosis systems at peak efficiency RO system operations demand continuous monitoring of analytical parameters to detect and correct abnormal operating conditions and prevent damage to costly membranes. Our instrument platforms include measurements of pH and ORP. The same platforms measure conductivity and temperature for close surveillance of RO system performance. METTLER TOLEDO so- lutions help ensure RO systems are operating efficiently at all times. Accurate pH measurement, even in demi water Efficient operation and regeneration of ion exchangers also depends on continuous monitoring of key pa- rameters. Due to the lack of con- ductivity of demineralized water, measuring pH poses one of the biggest challenges to analyzer technicians. METTLER TOLEDO’s range of pHure Sensor® pH sys- tems ensures stable and accurate measurement at all times. Improved boiler and turbine performance To avoid corrosion and deposition in boilers and on turbines, highly pure feedwater production also re- quires continuous monitoring of conductivity, sodium, silica, and chloride / sulfate ions. Our analyz- ers provide a complete picture of water quality with real-time infor- mation for immediate corrective ac- tion when needed. • Pressurized gel electrolyte for stable measure- ment at ultra-low conductivity • Accurate, fast responding temperature compensator • Low-resistance glass membrane Pure water pH electrode pHure Sensor
  • 15.
    1515 • Ultrapure water monitoringat sub-ppb sodium levels • Reagent addition confirmation by pH to ensure consis- tent measurement results • Fully automatic, unattended calibration • Automatic zeroing with every measurement ensures measurement stability • Automatic, unattended calibration • Convenient grab sample capability Compact sodium analyzer 2300Na Trace sensitivity silica analyzer 2800Si
  • 16.
    16 • Pre-pressurized electrolyte providesstable readings in demanding applications • Simultaneous pH and ORP measurements • Long operating lifetime All industrial water systems are vulnerable to corrosion, scaling, and foul- ing. A good water treatment program helps to control the water quality and maximize the number of cooling water cycles without compromising the integrity of heat exchangers and piping. CoolingWater Stay Ahead of Corrosion and Scaling Maintaining Heat Transfer Efficiency 16 Stop corrosion and deposition with pH and conductivity measurements To prevent corrosion and scaling in cooling water systems, pH needs to be controlled in a narrow range. In order to minimize mineral build-up, cooling water blowdown is initiated when the total dissolved solids (TDS) concentration reaches an upper level. METTLER TOLEDO pH electrodes and conductivity instruments pro- vide dependable performance for pH and TDS measurement. Rapid detection of heat exchanger leakage If process media leak into the cool- ing water system, ionic contamina- tion is normally detected through increased conductivity, or a change in pH or oxidation reduction poten- tial (ORP). In hydrocarbon indus- tries, when process fluids are organic and non-conducting, an excellent way of detecting hydro- carbons in cooling water is by measuring turbidity. Easy disinfection control Both the temperatures and high oxygen levels in cooling water sys- tems provide excellent growth con- ditions for all kinds of biological foulants. Measuring the ORP is the most efficient way to control disin- fection with oxidants such as chlo- rine or hypochlorite. Versatile pH / ORP electrode InPro 3250 i
  • 17.
    17 • Fast response time • WideRange™technology keeps sensor small and easy to install • Compatible with a variety of housings • Single-channel, multi-parameter, head mount transmitter • Explosion proof / flameproof enclosure and intrinsically safe electronics • HART communication 17 Four-electrode conductivity sensor InPro 7100 i Robust transmitter M100
  • 18.
    18 Glass Measuring solution Open junction Xerolyt® Extra solid polymer electrolyte Tosatisfy environmental regulations, industrial wastewater streams need extensive treatment. Thanks to accurate in-line analysis, high effluent water cleanliness with minimal chemical consumption and maintenance can easily be achieved. WastewaterTreatment Cleaner, Faster, More Economical Effluent Treatment Control 18 Meeting regulatory requirements with in-line sensors In-line measurement of pH, con- ductivity, and turbidity is invaluable in providing assurance that treated waste meets regulatory require- ments. In addition, control of these parameters can help process waste more efficiently and cost-effectively through preventing over-use of re- agents and flocculants. Real-time dissolved oxygen mea- surements lower compressor use Measurement of dissolved oxygen in activated sludge is effective for balancing the required oxygen concentration with a minimum of energy costs for running compres- sors. Low-maintenance sensors that resist fouling are ideal for this purpose. Automated sensor maintenance reduces costs To deal with the conditions in wastewater treatment, METTLER TOLEDO offers fully automated cleaning / calibration systems for pH, dissolved oxygen, and turbidity sensors. These systems relieve the burden on maintenance personnel, reduce operating costs, and pro- long sensor life. • Solid polymer electrolyte for precise measurement and long lifetime • Open junction eliminates clogging if suspended solids are present Open junction pH electrode InPro 4260 i
  • 19.
    1919 • Completely automatic sensorrinsing • Modular design for flexibility • Universal components allow easy servicing • Accepts digital ISM and analog sensors • Integrated PID controller • 4 current outputs • 6 output relays Automatic sensor rinsing unit EasyClean 150 Multi-parameter transmitter M400
  • 20.
    20 • Tough titanium body • Resistantto strong oxidizing media and solvents • Dirt-repelling PTFE diaphragm • Diagnostics tools provide continuous monitoring of sensor “health” Inefficient wet gas scrubber operations carry risks of pollution and equip- ment corrosion from undesired gases. pH, ORP and conductivity mea- surements can be used to monitor scrubbing solution quality to ensure chemical reagents are neither being wasted nor insufficiently fed. EmissionsControl Highly Efficient Gas Scrubbing And Lower Chemical Consumption 20 Reduced corrosion and scaling To increase effectiveness, the strength of the scrubbing solution must be continuously measured and controlled. Lack of control carries risks of pollutants being released to atmosphere and corrosion of plant equipment. In addition, scaling of the scrubber vessel and plugging of pipes caused by a build-up of by- products reduces efficiency further, and inevitably leads to expensive maintenance. Precise monitoring of scrubbing solution improves effectiveness In batch scrubbers, the scrubbing solution depletes and will at some point lose its ability to absorb pol- lutants. A conductivity measure- ment can detect this lower limit and initiate blowdown or increase the bleeding of spent solution and ad- dition of fresh solution. Benefits of pH / ORP control in continuous scrubbers pH measurement is widely used in continuous scrubbers. With accu- rate control of the pH value, the scrubbing potency of the solution is optimized and scaling or corrosion problems can be avoided. Oxida- tion reduction potential (ORP) measurement can be used for monitoring a scrubber process when reducing or oxidizing agents are to be removed. Highly durable pH / ORP electrode InPro 4881i
  • 21.
    21 • Uses plug-in modulesfor flexibility • Analog, Profibus PA or Foundation fieldbus output • Compatible with EasyClean 400 automatic cleaning / calibration system • Electrodeless design is unaffected by coating or contamination • PEEK or PFA body for aggressive chemical environments • High temperatures tolerant 21 Multi-parameter transmitter M700 Inductive conductivity sensor InPro 7250
  • 22.
    2222 Service Offerings Coveringour Products for End Users and Project Engineers at EPCs TrainingandServices METTLER TOLEDO Service embraces the complete range of service offerings provided by METTLER TOLEDO. We offer an attractive range of services to cus- tomers, from product guidance, over installation through to service contracts. METTLER TOLEDO Service METTLER TOLEDO offers complete services from product consultation to installation and service contracts. Our comprehensive sales consulting and high level technical services have established us as a competent partner for our customers every- where around the world. Many global manufacturing companies rely on our competence and our long-standing experience. Distribution network Based at several global production sites, with more than 40 market organizations and numerous inter- national sales offices, METTLER TOLEDO maintains a worldwide distribution network and is always close to its customers. Plant engineering and system integration Time is money. Our detailed techni- cal product documentation together with local support during specifica- tion, installation and commissioning contribute to on-schedule project realization. Service Offerings • Repair work at service depot • Sensor refurbishment • Installation / commissioning • Training / seminars / webinars • Maintenance contracts • Factory re-calibration • On-site qualification / verification • Quality documentation • Validation support • Support in compiling SOPs
  • 23.
    Maintenance station Operator station DCS/PLC FOUNDATION fieldbus™ www.hartcomm.com www.fieldbus.org HART® is aregistered trademark of the HART Communication Foundation. FOUNDATION fieldbus™ is a registered trademark of the Fieldbus FOUNDATION. 2323 SystemIntegration Asset Management and Plant Maintenance With HART, FOUNDATION Fieldbus and PROFIBUS Greater process control can be achieved with open fieldbus integration of analytical ­measurement technology into your control system via ­digital fieldbus technology. Integrating ISM sensor data and diagnostics increases process reliability and simplifies maintenance planning. METTLER TOLEDO integration with HART, FOUNDATION fieldbus and PROFIBUS These open communication proto- cols are regarded as a standard in the process industry and allow a central overview of the whole plant network. In addition, they offer the opportunity of comfortable instru- ment configuration and a higher level of process information to im- prove process performance. Fieldbus communication with 21CFR Part 11, asset manage- ment and predictive maintenance By applying HART, FOUNDATION fieldbus or PROFIBUS your efforts to comply with FDA requirements 21 CFR Part 11 will be minimized. The use of asset management and predictive main- tenance is an important issue for improvements in plant management. Easy integration of sensor data ISM offers the unique opportunity to not only transmit measurement data to a process control system, but also real-time diagnostic infor- mation as well as characteristic sensor data. This allows techni- cians to improve process control and monitor the “health” of sensors across an entire facility. Unplanned shutdowns due to unforeseen sen- sor failure no longer occur, result- ing in improved productivity and lower operating costs.
  • 24.
    ISM, InPro, iSense,EasyClean, InTrac, pHure Sensor, WideRange and Xerolyt are trademarks of the Mettler-Toledo Group. Visit us online to discover how METTLER TOLEDO products and solutions can improve processes at your facility. • Product information • White papers • Application notes • On-demand webinars • Videos 4www.mt.com/pro-chemical METTLER TOLEDO Website The Latest News on Applications and Products For more information www.mt.com Mettler-Toledo GmbH Process Analytics Im Hackacker 15 CH-8902 Urdorf Phone +41 44 729 62 11 Subject to technical changes ©04 / 2016 Mettler-Toledo GmbH Printed in Switzerland. 52 900 312.