News. Chemical. Seamless Process Monitoring at Nalco with ISM Technology. Perspectives in Liquid Process Analytics INGOLD

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1 Chemical Perspectives in Liquid Process Analytics 17 News INGOLD Leading Process Analytics Seamless Process Monitoring at Nalco with ISM Technology For the world s leading water treatment and conditioning company, process analytical systems are vital for ensuring product quality remains high and manufacturing effluent meets regulatory requirements. Intelligent Sensor Management provides the assurance they require and makes maintenance easier. Background Nalco was founded in Chicago in 1928 as the National Aluminate Corporation. It formed from the merger of the Chicago Chemical Company and Aluminate Sales Corporation, two companies whose main business was selling sodium aluminate for water treatment. Chicago Chemical Company sold primarily to municipal utilities and industrial plants for boiler feedwater treatment. Aluminate Sales Corporation made most of its sales to railways for processing the water needed for steam generation. Today, Nalco is the world s leading supplier of chemicals for water treatment and conditioning, with 70,000 customers in 130 countries. Nalco has been active in Germany since 1958 as Nalco Deutschland GmbH. Their Biebesheim plant, built in 1974, also focuses on water treatment. With 110 employees, the facility produces an annual volume of 50,000 metric tons of exclusively liquid products. It supplies a wide range of additives for corrosion protection, protection against micro-organisms, polymers for water treatment in sewage plants, and polymers for water treatment over the full spectrum of industrial applications. Exhaust gas treatment The exhaust gases generated during the production of water additives are treated in several stages at the Biebesheim plant. They are first passed through a sulfuric acid scrubber and are then neutralized by sodium hydroxide in a second scrubber. Following this, they are fed through an active carbon filter.

2 Publisher / Production Mettler-Toledo AG Process Analytics Im Hackacker 15 CH-8902 Urdorf Switzerland Illustrations Mettler-Toledo AG Procter & Gamble Jklune, Dvkorn, Angelogila Dreamstime.com Subject to technical changes. Mettler-Toledo AG 12/10 Printed in Switzerland. Two METTLER TOLEDO InPro 4260 i ph electrodes, each with an M700 transmitter and InTrac retractable housing, are installed in the exhaust gas treatment system. Thanks to the retractable housing, the sensor can be withdrawn from the process stream whenever desired without requiring process shutdown. The InPro 4260 i electrodes are members of the Intelligent Sensor Management (ISM) family of sensors and transmitters. Convenient calibration The most important aspect of the ISM concept is full integration of sensor diagnostics in the sensor. This makes probe maintenance easy and flexible. All important sensor information, such as the most recent calibration data, is stored on an integrated microprocessor, so sensor calibration at the measurement system is not necessary. Using isense Asset Suite software, ISM sensors can be calibrated in a lab or office and stored until they are required. Nalco uses the InPro 4260 i electrodes to help control alkali and acid dosing in the scrubber circuits, which varies depending on the contamination level of the exhaust. The main reason for using ISM sensors here is that they can be pre-calibrated in the lab and installed in the measurement system as necessary. At Nalco, this means that pre-calibrated ph electrodes are always available in the lab. If the electrodes in the process equipment need calibration, they are simply replaced with calibrated electrodes. As a result, interruption to process monitoring is significantly shorter than if in situ calibration were necessary. The replaced electrodes are subsequently recalibrated in the lab using the isense software and then put back into service at the next exchange event. Monitoring raw materials One of the raw materials used to produce polymers for water treatment is acrylamide. Nalco uses biological acrylamide, which means that it is prepared by the enzymatic hydrolysis of acrylonitrile. The biological acrylamide is stored in solution in a tank while waiting further processing. Measures must be taken to avoid autopolymerization during storage. Autopolymerization poses a threat because a lot of heat is released by this form of polymerization, and furthermore, acrylamide is of no use to Nalco after it has been polymerized. If polymerization begins in the tank, the ph value of the solution will shift, so to provide instant warning of this, an InPro 4260i ph electrode with an InTrac retractable housing is also mounted on this tank. If this electrode needs calibration, it is also replaced by a pre-calibrated electrode from the lab. Further plans for ISM at Nalco There are plans for using ISM sensors in other measurement systems in the future, such as determining the oxygen level during inertization. An oxygen sensor with ISM technology has already been purchased for this purpose, and it is intended to be put into service soon. Find out how intelligent sensors can help your processes, at: ph electrode InPro 4260 i 2 METTLER TOLEDO Chemical News 17

3 M800 Transmitter Reduce Maintenance with a New Transmitter! Lower your operating costs through proactive maintenance. With its unique imonitor feature, the new M800 transmitter provides all the information you need to prevent unnecessary and unanticipated maintenance of your process analytics sensors. One instrument When our customers speak, we listen. Two years of development work have gone in to making our latest transmitter not only the finest in our portfolio, but possibly the most user-friendly analyzer on the market. Advanced on-screen diagnostics provide real-time monitoring of sensor condition for proactive maintenance. Touchscreen technology and the intuitive user interface offer incomparable ease of use. And for the first time, you are able to use both Ingold and Thornton sensors on the same platform. All major parameters METTLER TOLEDO offers a highly versatile family of sensors for applications in process analytics and water treatment. The new M800 transmitter platform covers all major measurement parameters in one instrument: ph/orp, oxygen (amperometric and optical), ozone, conductivity and flow monitoring are all possible in conjunction with our Intelligent Sensor Management (ISM) sensors, and other parameters will follow. Up to four analytical sensors plus two flow inputs can be connected to one M800. With this multi-channel multi-parameter ability, most applications in the chemical industry that are today covered by different transmitters can now be equipped with the same instrument platform. imonitor the key to efficient maintenance Most scheduled maintenance work is unnecessary. Proactive maintenance allows higher efficiency and hence cost savings in daily operations, by informing operators in advance as to when maintenance will be required. With the imonitor, the M800 transmitter provides a tool for optimizing your sensor maintenance tasks. At a glance, the current performance of each connected sensor can be ascertained. Color-coded bars for all ISM diagnostic data provide real-time determination of measuring result quality. Alerting operators proactively to maintenance requirements helps prevent unanticipated, costly process downtime and ensures easy and efficient maintenance management. Complete control at a touch The M800 s large, high-resolution, color touchscreen simplifies all transmitter operations. The freely programmable display of up to eight measurement values or diagnostics data provides all vital information on one screen, or up to eight screens, to suit your requirements. Fully tailorable wizard set-up allows you to reach any menu function in only three touches. This concept helps reduce training effort and configuration failures to an absolute minimum. M800 transmitter quick overview j Intelligent Sensor Management j Color touchscreen/imonitor j Measures ph/orp, conductivity, DO (amperometric and optical), DO 3, O 2 gas, flow j 2- and 4- channel versions j Logbook j User management Find out more about the M800, at: METTLER TOLEDO Chemical News 17 3

4 ph in Hypochlorite Production Reliable ph Measurement in Difficult Conditions Means Improved Product Quality for P&G For Procter & Gamble (P&G) in Italy, the quality of ph measurement equipment is very important. A METTLER TOLEDO ISM ph system provides precise determination and high repeatability, resulting in an increase in process analysis quality. Procter & Gamble is the world s largest producer of consumer goods, with annual revenues of over $ 70 billion. Their Campochiaro (Campobasso) manufacturing plant in Italy is the bleach production base for their Ace brand. Flavio Di Salvatore works in the hypochlorite production module, where a METTLER TOLEDO ph measurement system with Intelligent Sensor Management (ISM) technology was recently installed. The system comprises an InPro 2000 i ph electrode, M420 transmitter and InFlow 764 housing. We asked Mr Salvatore to describe the process and explain why P&G chooses METTLER TOLEDO. Flavio Di Salvatore with InPro 2000 i ph electrode and In Flow 764 housing MT: Mr Di Salvatore, would you please give a brief description of the production process you re involved with. FDS: We have a vessel containing a chloride brine, the ph of which is regulated by adding doses of hydrochloric acid since part of this solution will be used to fuel the electrolysis process. MT: And during this phase of production, which analytical parameter is most critical in terms of safety, quality and productivity? FDS: ph measurement, considering the difficult conditions, is one of the most critical. Lack of control in this area could produce very negative consequences for the electrolyzer. MT: So it would affect productivity and possibly system safety as well. FDS: Yes, it certainly would. MT: Before installing the METTLER TOLEDO system that you are currently using, what were your most frequently occurring analytical problems? FDS: Previously, the quality of ph measurement was influenced by many factors. These caused difficulties in reproducing and repeating measurements and values. MT: You mean between the process itself and analysis conducted by the lab? FDS: Yes, exactly. MT: What kind of improvements did you expect to obtain? FDS: Given the system s issues, the objective was an increase in the reliability and quality of the analysis. MT: What benefits have you noticed since installing the METTLER TOLEDO ISM system you are using? FDS: The greatest benefit is that we have significantly increased the reliability and accuracy of the ph values. InPro 2000 i ph electrode 4 METTLER TOLEDO Chemical News 17

5 Another important achieved objective is that we can now control, over the medium period, the consistence and the solidity of this improvement, and results confirm that the improvement is constant. MT: So the main benefit is regarding the accuracy and repeatability of analysis during measurement. FDS: That s exactly right. MT: Are there economic benefits as well? FDS: We have seen real gains in terms of precision, reliability and maintenance. This has produced an increase in quality and productivity. These results confirm without hesitation that investing in an ISM system was a good decision. P&G is so satisfied with the performance of METTLER TOLEDO s ph measurement solution that they are planning on purchasing additional systems to cover all of their production at Campochiaro. If accurate, reliable ph measurement is important to you, go to: More Accurate Process Control Leads to Superior Zinc Production Precise control of sulfuric acid concentration is vital for efficient leaching of zinc calcine. But lab titration consumes too much time and resources. The answer? In-line conductivity measurement. Conductivity Demand for zinc Zinc s uses are broad and varied: from galvanizing steel to a white pigment in paints, from a primary metal in coins to a fire retardant. Such is the need for zinc that over 11 million tons of the metal are produced annually worldwide. Binani Zinc Ltd. in Binanipuram, Kerala, India has been producing zinc since In the 1980s the company began manufacture of special high-grade ingots with % purity. The plant has a current capacity of 38,000 tpa and is planning to expand this to 50,000 tpa to meet increasing demand. In an ongoing process to raise efficiency, the company has streamlined and de-bottlenecked many of its systems and is constantly looking at process improvements. Binani Zinc were not satisfied with the efficiency of their zinc leaching procedure and believed far greater productivity could be achieved. Zinc leaching The first step of the plant s zinc extraction process involves roasting zincblende to convert the zinc sulfide in the ore into zinc oxide. A by-product of the calcination is sulfur dioxide, which is subsequently converted to sulfuric acid and used later in the zinc extraction process. Leaching of zinc from zinc calcine is carried out in a two-stage countercurrent process. Firstly, finely ground calcine is leached in a dilute sulfuric acid solution taken from the second leaching stage to produce a first stage leach solution containing a high zinc concentration. This contains low iron and sulfuric acid concentrations. After suitable purification treatment, zinc is recovered from this solution by conventional electrowinning. The residue from the first stage, which still contains a certain amount of zinc, is leached further in a separate tank with electrolyte from the electrowinning operation. The liquid from this second stage becomes the solution used for the first leaching. Crucial to obtaining high zinc yield from the entire process is the control of sulfuric acid concentration. METTLER TOLEDO Chemical News 17 5

6 During the two leaching stages, sufficient but not excessive sulfuric acid must enter the leaching circuit to ensure that the solution drawn from the first leaching stage will contain enough dissolved zinc (approx gpl) to make it suitable for zinc recovery by electrolysis. Also, the quantity of oxides entering the first stage leach must be in excess of the quantity required to react with all available acid in the solution recycled from the second leaching stage. Requirements Binani Zinc had been using sample based lab analysis for acid concentration measurement. However, they found that effective process control was not possible because of the time taken to perform measurements and their infrequency. As part of their philosophy of continuous improvement, Binani Zinc looked for a reliable system for determining acid concentration, with high repeatability, very low maintenance, a reasonable cost of ownership, and an ability to withstand the process conditions. After discussions with METTLER TOLEDO engineers, it was agreed that indirect acid concentration measurement by determining conductivity in the process medium would be the best solution. Binani Zinc purchased seven identical systems, comprising InPro 7250 PEEK conductivity sensors, M700 transmitters and InDip 550 PVDF housings. Concentration and conductivity Before using the METTLER TOLEDO systems, a few steps had to be taken. Firstly, lab titration to determine acid concentration of the leaching solutions was correlated with conductivity levels measured in-line with InPro 7250 sensors. The data was then entered into the M700 transmitter s Concentration Table function. Further testing of the conductivity level as it altered during the process, was measured against levels determined in the lab. After some final adjustments to the Concentration Table, the engineers had sufficient confidence in the measurement system that lab testing was no longer required. Process improvement Before installation of the METTLER TOLEDO systems, acid concentration fluctuated from gpl. Thanks to the InPro 7250 and M700, that range is now held to a much more satisfactory gpl, leading to the better process control and improved productivity Binani Zinc were looking for. In addition, plant engineers appreciate the robustness and maintenance-free operation of the InPro The sensor s PEEK body is resistant to acids and has no electrodes in contact with the process medium that could become fouled. In combination with the M700 transmitter, engineers find the whole system simple in use and operation. Find out how you can benefit from the InPro 7250 in your processes, at: Conductivity sensor InPro 7250 PEEK 6 METTLER TOLEDO Chemical News 17

7 Intelligent Remote Operation Reliable, Simple, Convenient Measurement with a Temporary Data Logger Temporary data logging in many applications is needed for process optimization, quality assurance or troubleshooting purposes. The new temporary data logger, iro, from METTLER TOLEDO offers a unique solution providing easy installation and commissioning thanks to ISM technology. Easy to install, simple to use The iro data logger is the ideal tool in combination with METTLER TOLEDO Intelligent Sensor Management (ISM) systems, for temporary in-line analytical measurement. iro (which stands for intelligent remote operation ) records iro with sensor real-time in-line measurements without the need for time consuming installation, as no wiring for power supply or data acquisition is required. Plug and Measure functionality, a feature of our ISM technology, ensures error-free commissioning. While Bluetooth communication for data read out and system configuration sets a new standard in ease of use. Here, we look at three uses for iro that will save you both time and money. Process optimization During process development and optimization of production processes, in-line measurement of analytical parameters such as ph, oxygen concentration or conductivity is often vital. To find the most suitable installation points for analytical instruments can be time consuming and complex if complete measuring systems have to be installed temporarily. The iro data logger is easy to commission as it needs no wiring and thus simplifies short-term data acquisition. Measurements from up to two sensors can be logged for several months, and data read out with a computer over a Bluetooth connection can be performed within a minute. The data can be stored in a format that can be easily imported into Excel for processing and analysis. Each measurement data set contains the measurement value, date and time, and important sensor information such as serial number and diagnostics information. Quality assurance Quality managers need information. The traceability of process parameters at different measurement positions is required for guaranteeing the reproducibility of a production process and compliance with validation requirements. The iro temporary data logger is able to provide additional information to the existing measurement points without the need for complicated installation. Troubleshooting In processes like filtration, separation or filling of oxygen sensitive products, oxygen contamination can significantly reduce the yield or quality of the final product. To find the source of the contamination, oxygen measurement at various points is necessary. Installation of a complete measurement system needs wiring and connection to the control system. iro is the perfect tool for these situations. No wiring is needed and the data can be read out at any time. Data acquisition over weeks or months is simply achieved. Discover more reasons to use iro, at: METTLER TOLEDO Chemical News 17 7

8 Comprehensive Website The Information you Want is at The new-look METTLER TOLEDO Process Analytics website contains a vast amount of up-to-date information on all our products and services. Content is localized for your country and tailored to suit your selections. The home page has been designed to get you quickly to the products and news you are interested in Simple layout allows you to quickly find the information and features you are looking for. j Learn about our most recent product developments j Register for free webinars j Request further information on products and services j Obtain a quote quickly and easily j Download our latest white papers j Read case studies relevant to your industry j Access buffer and electrolyte solution certificates j and more... 8 METTLER TOLEDO Chemical News 17

9 Product pages provide a product overview and quick access to all important details and documentation Application pages help guide you to the products that are right for your processes j Read the latest product news j Access our newsletter archive j Find out when our next trade show or exhibition is in your area j Register for free webinars presented by our industry experts j Download our white papers METTLER TOLEDO Chemical News 17 9

10 Explore ISM The Universe of Intelligent Sensor Management Intelligent, Predictive, Tailorable, Adaptive Intelligent Sensor Management (ISM) is an innovative new concept for process analytical measurement solutions that simplifies sensor handling, enhances reliability and reduces sensor lifecycle costs through a groundbreaking new maintenance concept. Intelligent n The ISM universe offers unique and comprehensive solutions for all major analytical parameters. n Digital sensor technology offers easy handling with pre-calibrated sensors, enhanced sensor performance and built-in diagnostics. n An exclusive set of tools allows management and optimized service of sensors over their lifetime. Tailorable ISM offers industry specific solutions tailored to respective needs. n In Pharmaceutical and Biotech, accurate calibration and comprehensive electronic documentation offer full traceability. n In Chemical and Petrochemical industries, pre-calibration in a maintenance shop and optimized sensor management improve process reliability and reduce operating costs. n In Breweries, pre-calibrated optical DO sensors offer more reliable measurement and less maintenance. 10 METTLER TOLEDO Chemical News 17

11 Predictive n Avoid unscheduled maintenance with the Dynamic Lifetime Indicator; a unique, predictive, real-time diagnostic function. n Manage the lifecycle of your sensors with the isense Asset Suite PC-based sensor management software. n Optimize maintenance schedules to reduce costs and avoid unplanned shutdowns. Adaptive n ISM allows seamless integration of on-line diagnostics information into process control systems via Profibus PA and Foundation fieldbus transmitters or Ethernet. n Low-power concept offers wireless installations and Bluetooth-based temporary loggers. n Direct integration into analog controllers via 4 20 ma converter cables offers the best of both worlds, ISM based maintenance with isense and local diagnostics, with robust analog signal integration. METTLER TOLEDO Chemical News 17 11

12 Get in-line with METTLER TOLEDO Take the Hassle out of Oxygen Measurement More than 98 % of installed O 2 gas measurement systems require gas conditioning equipment: gas cooler, gas filter, acid filter, etc. The cost of maintaining all these additional parts can be substantial, and the probability of system failure is high. Also, the response time from extracting a gas sample to providing a measurement can be several minutes. METTLER TOLEDO offers a different solution involving only a sensor and a transmitter. Our amperometric sensors are installed directly in the process vessel and begin measuring immediately. Reliable, continuous, real-time data is sent to the transmitter for instant readout or connection to your process control system. Further, ISM technology in our O 2 systems reduces the installation, maintenance and calibration effort to a minimum. Mettler-Toledo AG Process Analytics Im Hackacker 15 CH-8902 Urdorf Switzerland Visit for more information