Polymerization processes play a key role in many industries. In these processes, precise control is essential to ensure high product quality and minimize waste and costs. However, traditional methods of polymerization control are often inaccurate and rely on infrequent lab tests.ak często nieprecyzyjne i polegają na rzadkich testach laboratoryjnych. The solution to these problems is to use modern real-time monitoring technologies, such as the Spectrally X1 fiber-optic probe device.
Problems of traditional methods
Current methods of controlling polymerization processes are indirect and imprecise. They rely on rare laboratory tests that focus on atoms rather than chemical bonds, making them unable to accurately distinguish monomers from polymers. In addition, these methods often require problematic chemical preparations and have high error rates due to the measurement of reaction byproducts.
Spectrally solution
To address these challenges, our solution uses the Spectrally X1 fiber-optic probe device to collect process signals in real time. Unlike traditional methods, our approach focuses on chemical bonds, which allows us to accurately distinguish monomers from polymers and monitor polymerization directly and automatically. Our solution eliminates the need for specialized personnel or intensive research and development.
Stages of solution implementation
Customer needs analysis: The first step was to understand the customer’s needs. We offer personalized measurement solutions, so we conducted an on-site assessment to get a local perspective.
Feasibility study and bid: We then determined whether inline, online, offline monitoring or a combination of these would be the best solution. We conducted tests on customer samples and prepared an implementation plan that culminates in a bid proposal.
Implementation: This includes system development, on-site testing and calibration, staff training, and ongoing system supervision.
Benefits to the company of real-time monitoring of polymerization processes
Optimization of the polymerization process:
Process monitoring allows continuous evaluation of polymer and monomer content in solution. Our solution makes it possible to measure these substances in powders, liquids, bulk materials and even in aqueous solutions. Analysis of the measurement data can identify areas of the process that need to be optimized or improved, leading to increased efficiency and productivity.
Waste reduction:
By responding quickly to a malfunctioning process, waste can be minimized, saving raw materials and resources. Nowadays, according to the BAT directive, waste disposal is very expensive, and every kilogram less is a real savings for an industrial plant.
Improving product quality:
Constant monitoring of the process ensures stable production conditions, which translates into consistent product quality. Eliminating fluctuations in process parameters, such as chemical composition, leads to the production of more uniform and expected products, which increases the company’s competitiveness.
Increase profitability and earnings:
The ability to monitor the amount of monomers and polymers in real time allows for a shorter production process, which increases efficiency or savings in the consumption of raw materials, energy and the involvement of specialized personnel. Reducing production costs and minimizing losses contribute to increased operating profitability, which leads to increased company profits.
Measurable benefits
We provided measurable customer benefits that improved many aspects of production processes:
Reduction in material loss: 10%
Energy consumption optimization: 15%
Increase in production efficiency: 15%
Reduction in production time: 20%
Relief of labs: 60%
Emission reduction: 15%
The implementation of advanced real-time polymerization process monitoring technologies, such as the Spectrally X1 fiber-optic probe device, brings numerous benefits to the industry. Optimizing processes, reducing waste, improving product quality and increasing profitability are just some of the advantages of our solution. With precise and continuous monitoring, it is possible to significantly increase operational efficiency and competitiveness in the market.