Safety Risks and Frequent Accidents: Traditional laboratory testing methods involve hazardous sampling, with high exposure risks for operators. In chemical raw materials, free alkali (such as sodium hydroxide) is strongly corrosive, effective chlorine solutions are irritating and toxic, and dimethylol propionaldehyde can cause skin allergies upon contact. Traditional sampling requires manually opening the reactor sampling port and drawing raw materials with a glass tube, during which liquid splashes are prone to occur. In one chemical plant, three accidents occurred due to sampling in the past year: one case of free alkali splashing on the arm causing burns, and two cases of effective chlorine gas irritation leading to respiratory discomfort, with operators averaging 3 days of leave per incident.
Online Liquid Spectral Analyzer (pressure-resistant edition) · ONLINE MONITORING
Fine Chemicals
Chemical Raw Material Online Monitoring
Places changing chemical raw-material concentrations into a continuous monitoring workflow, reducing waiting and repeated sampling.
CASE OVERVIEW
- Application
- Cooling Systems
- Product
- Online Liquid/Solid Spectral Analyzer (Pressure-Resistant Version)
- Monitoring Focus
- Ethylene Glycol Content Monitoring
Pain Points
01Pain Points
Severe Frostbite Risk in Manual Sampling: Manual sampling exposes operators to extreme cold, with coolant temperatures typically between –10°C and –5°C. Opening pipeline valves can cause liquid splashes, and tools frost over upon contact, risking skin injury. One factory recorded three frostbite incidents in a year, including one case requiring a week of medical leave.
Solution
02Solution
Seamless Pressure-Resistant Integration Design: The Online Liquid Spectral Analyzer (Pressure-Resistant Version) module features a pressure-resistant and corrosion-proof design, enabling direct integration into reactor system discharge pipelines or circulation lines without modifying the main reactor structure. It adapts to reactors made from various materials, such as stainless steel or enamel, and withstands high temperatures (≤120°C), high pressures (≤2MPa), and acid-alkali mist environments in chemical production.
All-Weather Real-Time Concentration Monitoring: Provides 7×24 hour online monitoring of percentage concentrations for raw materials like free alkali, effective chlorine, and dimethylol propionaldehyde. Spectral analysis technology captures real-time concentration changes, generating data every 10 seconds and transmitting it synchronously to the production monitoring terminal. The interface dynamically displays concentration values and trend curves, with automatic alerts for anomalies.
Value
03Value
Significant Improvement in Operational Safety: Replaces traditional sampling and testing, reducing operator exposure risks and enhancing production safety. The sampling process is fully automated by the module, eliminating the need for operators to handle raw materials or sampling ports, reducing exposure risks by over 98%. After implementation, one company reported no sampling-related safety incidents in the past year, and the proportion of "sampling protection" content in safety training decreased from 30% to 10%.
Instant Production Control Response: Real-time monitoring of raw material concentrations eliminates data delays, enabling timely production adjustments. When free alkali concentration falls below 8% (the lower qualification limit), the system instantly triggers an alarm and prompts "Add high-concentration alkali solution"; when effective chlorine concentration exceeds 12% (the upper qualification limit), it prompts "Reduce reaction temperature." After adoption, one factory reduced the detection time for concentration anomalies from 1.5 hours to within 10 seconds, improving response speed by 540 times.
Efficiency and Cost Optimization Benefits: Enhances chemical raw material production efficiency, ensuring stable and controllable processes. The rework rate due to concentration anomalies dropped from 12% to 2%, and single-batch production time was shortened by 15 minutes (as traditional methods required waiting for test results before proceeding). Additionally, raw material concentration fluctuations narrowed from ±1.5% to ±0.3%, improving production stability by 80% and reducing annual raw material waste costs by over $25,000.
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Start with Your Application
Describe your sample, measurement target and deployment environment. We will assess a practical path based on your requirements.