The case describes 24/7 online monitoring with data generated every 10 seconds
The challenge
Safety Risks and Frequent Accidents
Traditional laboratory testing methods involve hazardous sampling, with high exposure risks for operators.
Read background
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.
Delayed results disrupt process control
Laboratory testing requires sampling, packaging, transport and analysis, so operators can wait 1.5–2 hours for each result while raw-material concentrations continue to change.
Read background
The source case describes free-alkali concentration changing by 1–2% within 30 minutes. In one batch, concentration fell below the acceptance limit an hour after sampling, but production continued at the previous settings while the team waited for the result. The source reports that 2 tonnes of raw material were rejected because the concentration did not meet specification.
How it works
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.
What changed
Reduced exposure during sampling
In this installation, automated sampling reduced the need for operators to handle raw materials or open sampling ports. The source case reports a reduction in contact risk of more than 98% and no sampling-related safety incidents at the adopting company during the year described. Sampling-protection topics accounted for 10% of its safety training, down from 30%.
Faster response to concentration changes
Operators received online concentration readings and alerts to support production adjustments. In the configuration described, free alkali below 8% triggered an alarm and a prompt to add concentrated alkali solution; available chlorine above 12% prompted a reduction in reaction temperature. The source case reports that the time to identify a concentration anomaly fell from 1.5 hours to within 10 seconds, describing a 540-fold improvement in response speed.
Lower rework and raw-material waste
The source case reports a fall in rework attributed to concentration anomalies from 12% to 2%, a 15-minute reduction in batch production time, and concentration variation narrowing from ±1.5% to ±0.3%. It also reports an 80% improvement in production stability and annual raw-material waste savings of more than CNY 150,000.
Reported results describe this project and its operating conditions. Suitability for your application requires evaluation of your sample and installation.
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