A large variety of processes, few of which are exactly alike, typical unit operations share many commonalities. One of these is the requirement for accurate process analytics in order to help maximize product quality and yield and to minimize costs. Measurement of pH, ORP, conductivity, DO or turbidity may seem like small parts of a total industrial process, but these parameters can be the cause of frustration, downtime and substantial expenditure unless they are properly understood and adequately controlled.
How can plant managers and engineers ensure measuring parameters will help processes run smoothly and efficiently, and exploit the availability of process machinery? Fortunately, advanced process analytics solutions exist that not only are accurate and reliable – even in the harshest of process conditions – but that also minimize the maintenance burden by actually predicting when maintenance of a measuring point is required.
This white paper reviews issues that can occur in chemical plants when some of the above mentioned parameters are not held within desired ranges, and how cutting-edge process analytics can help avoid the problems and achieve greater plant efficiency.
Water preparationBoiler tube failures continue to be the single largest source of forced outages in industrial-type steam generators. In most cases, corrosion occurs under deposits and scale which builds up on the boiler tubes. In addition to contributing to the corrosion process, the buildup of scale on the tubes by itself reduces heat transfer and therefore increases the overall fuel costs required to produce a given quantity of steam. Corrosion and scale buildup can be controlled by maintaining proper water chemistry.
Accurate pH control of the inlet water of the reverse osmosis unit protects membranes from damage. In the operation of ion exchangers, pH monitoring is required to ensure that no excess regeneration acids or bases contaminate the boiler water. In boiler feedwater, pH measurement is a significant challenge but essential for corrosion prevention.