Online FT-IR
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Online FT-IR Analyzer
Chemical, pharmaceutical, and materials process development and production demand accurate quantitative analysis of components to ensure product quality and process efficiency. Traditionally, offline laboratory methods such as chromatography, mass spectrometry, and nuclear magnetic resonance spectroscopy are employed. However, these techniques require sample extraction and lengthy analysis times, resulting in low sampling frequency and delayed feedback. This limitation hinders real-time process monitoring and control.
An Online FT-IR Analyzer offers a powerful solution by enabling continuous, real-time monitoring of chemical processes directly in the production line without the need for sample removal. This enhances process understanding, improves quality control, reduces waste, and accelerates decision-making.
Short Description
The Online FT-IR (Fourier Transform Infrared) Analyzer is an advanced Spectroscopy instrument designed for real-time, in-situ quantitative analysis of chemical components in various industrial processes. It continuously monitors process streams by measuring the infrared absorption spectra, providing rapid, accurate, and non-destructive analysis of multiple components simultaneously.
Technical Highlights
- Real-Time Monitoring: Provides continuous, real-time data acquisition for immediate process feedback.
- Multi-Component Quantification: Simultaneously analyzes multiple chemical species in complex mixtures.
- Non-Destructive & Non-Invasive: Measures directly in process streams without altering or consuming samples.
- High Sensitivity & Specificity: Detects low concentration components with high accuracy using characteristic IR absorption bands.
- Robust & Reliable: Designed for harsh industrial environments with minimal maintenance requirements.
- Fast Response Time: Typical analysis time ranges from seconds to a few minutes, enabling high-frequency sampling.
- User-Friendly Software: Equipped with intuitive software for data visualization, calibration, and process integration.
- Flexible Sampling Interfaces: Supports various probe types (transmission, attenuated total reflectance (ATR), fiber optic) for different process conditions.
- Integration Capabilities: Easily integrates with Distributed Control Systems (DCS) and Manufacturing Execution Systems (MES) for automated process control.
Product Specifications
| Specification | Details |
|---|---|
| Spectral Range | 4000 – 650 cm¹ (mid-infrared region) |
| Spectral Resolution | 2 – 8 cm¹ (configurable) |
| Detector Type | DTGS or MCT (Mercury Cadmium Telluride) |
| Sampling Interface | Transmission, ATR, Fiber Optic Probe |
| Measurement Mode | Continuous online, real-time |
| Response Time | 10 seconds to 2 minutes (depending on setup) |
| Data Output | Concentration, spectra, trend graphs |
| Communication Protocols | Modbus, OPC, 4-20 mA, Ethernet |
| Operating Temperature | 0°C to 50°C (probe dependent) |
| Power Supply | 110-240 V AC, 50/60 Hz |
| Dimensions | Compact, bench-top or panel-mounted options |
| Software Features | Calibration, multivariate analysis (PLS, PCR), real-time alerts |
| Calibration | Pre-calibrated models with options for custom calibration |
| Maintenance | Low maintenance, periodic validation recommended |
Summary
The Online FT-IR Analyzer is an indispensable tool for industries requiring rapid and reliable chemical analysis during production. By delivering real-time insights into process chemistry, it empowers manufacturers to optimize operations, ensure product quality, and reduce downtime. Its flexibility, accuracy, and ease of integration make it ideal for chemical, pharmaceutical, polymer, and materials manufacturing environments.
Online FT-IR Analyzer FAQs
How does an online FT-IR analyzer improve real-time process monitoring?
1. Continuous Real-Time Data Acquisition
Unlike traditional offline methods that require sample extraction and lengthy laboratory analysis, an online FT-IR analyzer measures spectra continuously and in real time...
2. Multi-Component Simultaneous Quantification
FT-IR spectroscopy provides rich spectral information that reflects the unique vibrational absorption bands...
3. Rapid and Accurate Analysis
FT-IR analyzers deliver results within seconds to minutes, dramatically reducing the detection time...
4. Non-Destructive and In-Situ Measurement
Online FT-IR probes can be inserted directly into process streams...
5. Process Optimization and Control
The rich, real-time data from FT-IR analyzers can be integrated with process control systems...
6. Enhanced Traceability and Compliance
Continuous online monitoring supports stringent regulatory requirements...
7. Cost Efficiency and Return on Investment
Although initial investment in FT-IR spectrometers and calibration development is required...
Product Specification Variations by Industry?
1. Chemical and Pharmaceutical Industries
- Spectral Range & Resolution: Mid-infrared range (4000–650 cm⁻¹), high spectral resolution (2–8 cm⁻¹)
- Sampling Interface: ATR, Transmission
- Calibration & Software: Advanced multivariate calibration models (PLS, PCR)
- Environmental Control: Instruments with temperature control and inert gas purging
- Integration: MES and DCS integration
2. Environmental and Emission Monitoring
- Gas Analysis Capability: Multiple gases such as SO2, NOx, CO, CO2, etc.
- Sampling System: Long optical path gas cells and robust probes
- Portability & Durability: Portable analyzers with low power consumption
- Data Handling: Real-time data output with compensation algorithms
- Communication: Industrial protocols like Modbus and OPC
3. Materials and Polymers
- Sampling Techniques: ATR-FTIR for solid polymers, coatings, films
- Spectral Sensitivity: For detecting functional groups and additives
- Robustness: Handles variable sample thickness
- Performance Qualification: Includes calibration routines
4. Industrial Process Control
- Response Time: Fast analysis (seconds to minutes)
- Probe Design: Customized for harsh process environments
- Maintenance: Low maintenance with self-diagnostics
- Software: Real-time alerts and trend analysis.
Summary Table of Specification Variations by Industry
| Specification Aspect | Chemical/Pharmaceutical | Environmental/Emission Monitoring | Materials/Polymers | Industrial Process Control |
|---|---|---|---|---|
| Spectral Range | Mid-IR (4000–650 cm⁻¹) | Mid-IR with gas focus | Mid-IR with polymer-specific | Mid-IR with fast scanning |
| Sampling Interface | ATR, Transmission | Gas cells | ATR (single/multi-reflection) | Customized for harsh conditions |
| Detection Limits | ppm to low ppm | ppb to ppm | ppm for additives | ppm, fast response |
| Robustness | Lab or pilot plant | Portable, rugged | Lab/production compatible | Industrial-grade |
| Calibration | Multivariate, compliant | Compensation for interferences | Polymer-specific | Process-specific |
| Integration | MES, DCS | Monitoring networks | QC systems | Real-time process systems |