Delayed Detection Weakens Antifreeze Protection: Manual sampling and lab testing are slow, preventing real-time tracking of ethylene glycol concentration. Cooling systems must maintain 30–40% concentration (too low reduces antifreeze capability, too high affects heat transfer). Traditionally, samples are taken every 4 hours and lab results return in 1 hour, meaning the system runs for nearly 5 hours without updates. One chemical plant missed a drop to 25%, causing localized pipe freezing and reduced heat exchange efficiency.
UV · 240nmCase StudiesNIR · 1700nm
Online Liquid/Solid Spectral Analyzer (pressure-resistant edition) · ONLINE MONITORING
Petrochemicals
Cooling-system Glycol Monitoring
Continuously observes glycol-content changes beside circulating coolant lines to support day-to-day cooling-system operation.
CASE OVERVIEW
- Application
- Cooling System
- Product
- Online Liquid/Solid Spectral Analyzer (Pressure-Resistant)
- Monitoring Focus
- Ethylene Glycol 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.
Cooling Regulation Disruption Triggering Domino Effects: Delayed data cannot support timely refrigeration adjustment, risking production instability. Some reactions require strict temperature control (e.g., 20°C ±1°C for a polymerization process). If glycol concentration fluctuations affect cooling, delayed adjustments can cause temperature swings. One plant saw temperatures fluctuate between 17°C–23°C, leading to off-spec polymer molecular weight distribution and a 15% drop in yield.
Solution
02Solution
Armored Integration for –30°C Extreme Environments: The Online Liquid/Solid Spectral Analyzer is used for quantitative monitoring of ethylene glycol concentration in circulating coolants. Designed for low-temperature, high-pressure environments, it can be directly mounted on the main coolant pipeline, operating reliably from –30°C to 50°C, suitable for sealed cooling systems in chemical and pharmaceutical industries.
Millisecond-Scale Real-Time Concentration Monitoring: Replaces manual sampling and lab testing with online, real-time measurement. The built-in concentration sensor contacts the coolant directly, generating readings every 30 seconds and transmitting them to the production monitoring platform, displaying live values and trend curves without manual intervention.
Temperature-Concentration Dual-Variable Interlock Protection: Addresses delayed data and sampling safety risks with a robust monitoring mechanism. The system triggers audio-visual alarms when glycol concentration falls below 30% or rises above 40%. It also links to the refrigeration control system, prompting early "Prepare to adjust cooling power" alerts when abnormal concentrations affect cooling performance, preventing delays caused by manual judgment.
Value
03Value
Lean Cost Model for Coolant Monitoring: Greatly reduces sampling and testing time and cost while improving efficiency. Traditionally, two operators perform round-the-clock sampling, consuming about $30/day in bottles and insulated containers, with a 5-hour testing cycle. With the solution, no manual sampling is required, consumable costs drop to under $40/month, and real-time data saves over $12,000 annually per plant.
Zero Frostbite, Redefined Human-Machine Safety: Eliminates frostbite risk from manual sampling, significantly enhancing workplace safety. All sampling is automated, requiring no human contact with low-temperature coolant. Within a year of implementation, no frostbite incidents occurred, and operator safety satisfaction rose from 65 to 92 (out of 100).
Precision Cooling and Production Quality Upgrade: Real-time monitoring stabilizes cooling performance at optimal power, improving both quality and efficiency. Temperature fluctuations narrowed from ±3°C to ±0.5°C, raising polymer product yield from 82% to 98%. Simultaneously, on-demand cooling adjustments reduced energy waste, cutting monthly electricity costs by 12%.
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