PECM Issue 23 2016 - Page 84

Improving Process Accuracy with Metrohm Process Analytics Metrohm Process Analytics offers a range of off the shelf and bespoke Process Analysers that automatically sample and analyse direct from your process. M etrohm Process Analytics offers a range of off the shelf and bespoke Process Analysers that automatically sample and analyse direct from your process. Many processes operate within tightly defined limits for parameters such as weight, temperature, pH, or more unique parameters; as examples, Acid concentration in an etching solution, Nickel concentration in a plating bath, moisture levels in reactive drawing oils… Often control of these parameters is critical to maintain product and process specifications to achieve optimal product quality and consistency. Deviation of these parameters from target can negatively impact on product quality and/or lead to excessive operating costs, e.g excess chemical consumption, reduced throughput, lower yield….. Processes that rely on any analytical measurement to maintain the process near to an operating target and within an operating window will be accurate dependant on: The analytical instrument employed SEP Error of sampling from the process and any manual manipulations of the sample Frequency of analysis Process variation error Moving from the laboratory to a process analyser allows you to run production much closer to your operating target giving increased yield, improved final product quality and consistency. All this leads to increased profit margins and less out of conformance product. Also by reducing the process/product variation can mean product specification can be tightened giving a competitive advantage and/or higher value product versus the competition. Because process analysers remove the manual sampling from a process, there is a clear safety advantage. Moving to a process analyser fully removes the risk associated with taking samples that are: under pressure, at elevated temperature, toxic, corrosive, sensitising, noxious, carcinogenic, harmful, and unpleasant. Metrohm Process Analytics has experience designing and integrating Process analysers for many industries and applications. Metrohm Process Analysers operate on the methods of Titration, Liquid Chromatography, Photometry, near-infrared spectroscopy, voltammetry and TOC. Figure 1. Process Accuracy depends on multiple sources of error Normal laboratory analysis “off-line can have detrimental impact on process accuracy by introducing sampling error and limiting analysis frequency due to manual limitations and differences between analysts. Introducing “on-line process analysers reduces the sampling error and increases the sampling frequency as well as improving the prediction error for the analysis. Improving all these steps leads to significant improvements in process accuracy narrowing the normal operating window to ensure the process is operating at its most efficient. Figure 3. Difference in Process Accuracy for laboratory analysis (1) and continuous analysis (2) , highlighting how the process can be shifted closer to specification (3) to increase profit. Figure 2. Operating window for continuous process analysis versus “at-line” laboratory analysis is significantly improved Figure 4. Metrohm Analysers have major application in the surface finishing industry. .FUSPIN1SPDFTT"OBMZUJDTIBT FYQFSJFODFEFTJHOJOHBOEJOUFHSBUJOH 1SPDFTTBOBMZTFSTGPSNBOZ JOEVTUSJFTBOEBQQMJDBUJPOT