On-line Monitor Analyzers

How do on-line monitoring analyzers work? 

On-Line Monitoring Analyzers, also known as process analyzers, are analytical instruments that continuously monitor process streams in real-time. These analyzers are typically installed in industrial processes such as chemical manufacturing, oil refining, and wastewater treatment, where they are used to provide process control and optimization, detect process upsets, and ensure product quality and consistency. 

On-Line Monitoring Analyzers work by continuously extracting a representative sample from the process stream, analyzing the sample for one or more process variables, and transmitting the analyzed data to a control system for process control or to an operator for analysis and decision-making. The sample extraction and analysis are performed using a combination of hardware and software components, which are integrated into a complete analyzer system. 

The hardware components of an On-Line Monitoring Analyzer typically include a sample probe, a sample conditioning system, an analyzer module, and a data transmission system. The sample probe is responsible for extracting a representative sample from the process stream and delivering it to the sample conditioning system. The sample conditioning system then prepares the sample for analysis by removing any unwanted impurities, adjusting the sample temperature and pressure, and ensuring that the sample is at the correct flow rate and composition. The analyzer module is responsible for analyzing the prepared sample for one or more process variables using one or more analytical techniques such as spectroscopy, chromatography, or electrochemistry. Finally, the data transmission system is responsible for transmitting the analyzed data to the control system or operator using a variety of communication protocols such as 4-20 mA, Modbus, Ethernet, or OPC. 

The software components of an On-Line Monitoring Analyzer typically include a control algorithm, a calibration algorithm, and a data acquisition and management system. The control algorithm is responsible for receiving the analyzed data from the analyzer module and using it to adjust the process variables in real-time to achieve the desired process outcomes. The calibration algorithm is responsible for ensuring that the analyzer module is calibrated correctly and that the analysis results are accurate and repeatable over time. Finally, the data acquisition and management system are responsible for collecting and storing the analyzed data and making it available to the control system or operator for analysis and decision-making. 

Advantage of On-line monitoring analyzers 

On-Line monitoring analyzers offer several advantages over other types of analyzers, such as grab samplers or laboratory-based methods. 

• Real-time monitoring of process conditions allows for immediate response to changes in the process, optimizing efficiency, reducing waste, and ensuring product quality. 
• Ability to monitor multiple parameters simultaneously provides a comprehensive understanding of the process conditions, enabling more informed decision-making. 
• Non-invasive measurement capability enables the measurement of process conditions without interfering with the process itself, reducing variability. 
• Automated operation requires minimal operator intervention, reducing the potential for human error and improving the consistency and accuracy of the data collected. 

Industries and applications that uses On-Line monitoring analyzers 

On-line monitoring analyzers play a crucial role in various industries and applications where continuous, real-time monitoring of process conditions is essential. These analyzers are designed to measure process variables in real-time and provide instant feedback to operators or control systems, allowing for immediate responses to changes in the process conditions. 

One of the primary industries that extensively uses on-line monitoring analyzers is water treatment plants, where water quality is monitored and controlled to ensure that it meets the required standards for consumption. In addition to pH, dissolved oxygen, turbidity, and chlorine levels, on-line monitoring analyzers can also measure other water quality parameters like total dissolved solids, conductivity, and temperature. 

In chemical manufacturing, on-line monitoring analyzers are utilized to ensure that the desired product specifications are met. These analyzers can monitor the chemical composition of process streams in real-time to detect any deviations from the target values. Parameters such as pH, temperature, and concentration of various chemical species can be monitored to ensure that the reaction is proceeding as expected. 

Pharmaceutical production is another critical application of on-line monitoring analyzers. These analyzers are used to monitor the quality of the product as it is manufactured, ensuring that it meets the required specifications. Parameters such as pH, temperature, and concentration of active pharmaceutical ingredients are continuously monitored to ensure product quality. 

Food and beverage production also relies heavily on on-line monitoring analyzers to monitor the quality of the product as it is processed. These analyzers can measure parameters such as pH, dissolved oxygen, and conductivity, providing operators with the necessary information to ensure that the product is safe for consumption and meets the desired quality standards. 

In oil and gas production, on-line monitoring analyzers are used to monitor the composition and quality of the extracted fluids. These analyzers can measure parameters such as flow rate, density, and viscosity in real-time, ensuring that the extracted fluids meet the required specifications. 

Finally, in power generation plants, on-line monitoring analyzers are utilized to monitor the quality of the water used for cooling purposes. Parameters such as pH, conductivity, and dissolved oxygen are monitored in real-time to ensure that the water is free from contaminants and does not corrode the equipment, ensuring maximum efficiency and reliability. 

Important considerations when selecting on-line monitoring analyzers 

When selecting on-line monitoring analyzers, there are several important considerations to keep in mind: 

• Application requirements: The specific needs of the application should be carefully considered, including the process parameters that need to be monitored, the required accuracy and precision of the measurements, and the environmental conditions in which the analyzer will operate. 
• Analyzer type: There are many different types of on-line monitoring analyzers available, each with their own strengths and weaknesses. It is important to select an analyzer that is well-suited for the specific application and process being monitored. 
• Calibration and maintenance: On-line monitoring analyzers require periodic calibration and maintenance to ensure that they continue to provide accurate and reliable measurements. The ease and cost of calibration and maintenance should be considered when selecting an analyzer. 
• Installation and integration: The analyzer must be installed properly and integrated into the existing process control system. Considerations include the space available for the analyzer, the required electrical and communication connections, and the level of automation desired. 

Why buy on-line monitoring analyzers from AxFlow 

AxFlow offers on-line monitoring analyzers for the widest range of industries and applications. Only at AxFlow do you receive individual advice from industry-experienced process engineers and the manufacturer-independent selection of the world's leading process technology. Do you need support in selecting the right analyzers for your needs? Do not hesitate to get in touch. AxFlows experts and engineers can provide guidance for selecting, specifying, installing, and maintaining your fluid handling equipment.