Instrumentation and control
Analytical Analysis in Chemical Process Control
Ms. Sobia Anwar
Modelling and Simulation 24. Oktober 2024 / Dr. –Ing Naveed Ramzan
1
Introduction
Purpose of Measuring Physical Properties
- Control Product Quality
- Maintain Safe Operation
- Process Optimization
Outline
Instruments for measurement of:
Composition
pH
Viscosity
Optical properties
Composition Measurement: Analyzers in the Process Industry
Reactor Control
Environmental Monitoring
Purpose Product Compositions
Control of chemical
processes
Requirements
Low Maintenance
Simplicity
“Ruggedness”
Few or no moving parts
Challenges in Analyzer Design
Exposure to corrosive environments
Material Selection: Choosing materials that
resist corrosion while maintaining accuracy is
critical. This often involves using specialized
alloys or coatings.
Sealing and Protection: Ensuring that
sensitive components are well-sealed against
corrosive substances is vital for long-term
functionality.
Challenges in Analyzer Design
Must withstand non-ideal concentrations of
secondary components
Dynamic Range: Analyzers must be designed
to accurately measure a wide range of
concentrations, including varying levels of
interfering substances.
Calibration: Regular calibration protocols are
necessary to account for the effects of secondary
components on measurements.
Challenges in Analyzer Design
Maintenance only once every few months
Components should be durable and designed for
minimal wear and tear to extend intervals
between maintenance.
Designing analyzers with easy access to critical
components can facilitate quicker checks and
repairs, even if maintenance is infrequent.
Reliability is key
Analyzers must undergo rigorous testing under
various operational conditions to ensure
reliability in the field.
Classification of Process Analyzers
Analyzers
Nonspecific Specific
(Inexpensive) (Costly)
Gas Liquid Gas Liquid
Thermal Electrical Gas IR/UV-VIS
Conductivity Conductivity Chromatography Spectroscopy
Sampling Systems
Sample Sample Analyzer
Extraction Conditioning
Process Sample
Stream Return
Sampling Systems
In-line sampling
Direct sampling in process line
Advantage: no sampling delay
Disadvantage: measurement affected by
temperature and pressure variations
On-line sampling
Extract sample continuously and send to
instrument
Advantage: control of temperature,
pressure
Disadvantage: time lag before
measurement
Density meter
The density is measured with a U-shaped
hollow glass tube, which is put into oscillation.
The oscillation frequency of the tube filled with
the sample is measured.
The higher the weight of the sample the lower
the frequency. The density is calculated with
the measured frequency.
Density meter
Advantages
High Accuracy: Provides accurate density measurements due to
the direct relationship between oscillation frequency and density.
Minimal Calibration: Requires limited calibration if the system is
well-designed and maintained.
Robust Design: The glass tube is relatively simple and durable,
suitable for many laboratory environments.
Considerations
Temperature Effects: Density is temperature-dependent, so
temperature control is essential for accurate measurements.
Sample Properties: Viscosity and other physical properties of the
sample can influence oscillation and should be considered during
measurement.
Cleaning: Proper cleaning is necessary to prevent contamination
between different samples.
Turbidity meter
The phenomenon of turbidity is measured using
optoelectronic meters. An artificial light source emits a
known intensity of light through a sample.
The suspended particles scatter or absorb the light The
scattered light is generally measured at an angle of 90°.
This measurement principle is known as nephelometry.
A nephelometer is therefore a turbidity meter that
measures scattered light at an angle of 90°. The results
are shown in NTU (Nephelometric Turbidity Unit).
Turbidity meter
Advantages
Non-Destructive: The sample remains intact during
measurement, allowing for further analysis if needed.
Easy Calibration: Nephelometers can be calibrated with
standard solutions, facilitating accurate measurements.
Considerations
Interference: Other factors, such as color or absorbance of
the sample, can affect turbidity readings and should be
accounted for.
Maintenance: Regular cleaning of optical components is
necessary to prevent contamination and ensure accurate
measurements.
Conductivity meter
The common laboratory conductivity meters employ a
potentiometric method and four electrodes. Often, the
electrodes are cylindrical and arranged concentrically.
The electrodes are usually made of platinum metal. An
alternating current is applied to the outer pair of the
electrodes. The potential between the inner pair is
measured.
Conductivity could in principle be determined using the
distance between the electrodes and their surface area
using Ohm's law but generally, for accuracy, a
calibration is employed using electrolytes of well-known
conductivity.
Conductivity meter
Advantages
Non-Destructive: The sample remains unchanged during
measurement.
Calibration Flexibility: Calibration with known standards
allows for precise measurements across different solutions.
Considerations
Temperature Dependence: Conductivity is temperature-
sensitive, so many meters come with temperature
compensation features.
Electrode Maintenance: Regular cleaning and maintenance
of electrodes are necessary to ensure accuracy and longevity.
pH meter
A pH meter is a scientific instrument that measures
the hydrogen-ion activity in water-based solutions,
indicating its acidity or alkalinity expressed as pH.
The pH meter measures the difference in electrical
potential between a pH electrode and a reference
electrode, and so the pH meter is sometimes referred to
as a "potentiometric pH meter".
The difference in electrical potential relates to the
acidity or pH of the solution.
pH meter
Advantages
Non-Destructive: The measurement does not alter the
sample.
Ease of Use: Modern pH meters are user-friendly, often
featuring digital displays and automatic calibration functions.
Considerations
Calibration: Regular calibration with standard buffer solutions
is essential for accurate readings.
Temperature Sensitivity: pH can be affected by temperature,
so many meters include temperature compensation features.
Electrode Maintenance: Proper care and maintenance of the
electrodes are necessary to ensure accuracy.
Viscosity meter
A viscometer is an instrument used to measure
the viscosity of a fluid.
Viscometers only measure under one flow condition.
In general, either the fluid remains stationary, and an
object moves through it, or the object is stationary, and
the fluid moves past it. The drag caused by relative
motion of the fluid and a surface is a measure of the
viscosity. The flow conditions must have a sufficiently
small value of Reynolds number for there to be laminar
flow.
Viscosity meter
Advantages
Precision: Viscometers provide accurate and repeatable
viscosity measurements under controlled conditions.
Versatility: Suitable for a wide range of fluids, from low-
viscosity liquids to highly viscous materials.
Considerations
Calibration: Regular calibration with standard fluids is necessary
to ensure accuracy.
Temperature Control: Viscosity is temperature-dependent;
thus, maintaining a consistent temperature during measurements
is critical.
Flow Conditions: Care must be taken to ensure laminar flow
conditions are maintained to avoid inaccuracies in
measurements.
