Gas & Liquid Analyzers

Instrumentation Used:

• Chemiluminescent gas analyzers (NOx)

• UV-based ozone analyzers (SO₂, O₃)

• Gas filter correlation analyzers (CO, CO₂)

• Paramagnetic oxygen analyzers

Application:
Monitoring flue gas composition at the stack to comply with environmental emissions regulations.

Value:
Ensures regulatory compliance with air quality standards (e.g., EPA, CARB) and enables real-time combustion control. Accurate emissions data supports permitting, reporting, and optimization of air pollution control equipment such as SCR and FGD systems.

Instrumentation Used:

• TDL analyzers (O₂, CO, CH₄)

• Paramagnetic oxygen analyzers

• Thermal conductivity analyzers

Application:
Monitoring excess oxygen and flue gas composition in fossil fuel and biomass-fired boilers, gas turbines, and combined cycle plants.

Value:
Improves combustion efficiency, reduces fuel consumption, and minimizes emissions. Enables fine-tuning of burner performance to prevent incomplete combustion, slagging, and fouling.

Instrumentation Used:

• Thermal conductivity analyzers

• TDL analyzers

• Moisture analyzers (for H₂ dew point)

Application:
Monitoring hydrogen purity in cooling systems for large generators or in hydrogen production and storage for clean energy applications.

Value:
Ensures gas purity for generator cooling efficiency and safety, or for maintaining quality in hydrogen fuel streams. Contaminant detection prevents electrical arcing, corrosion, and premature component failure.

Instrumentation Used:

• Conductivity analyzers (cation, degassed, and specific conductivity)

• pH analyzers

• Silica and sodium analyzers

• Microwave and optical analyzers (chemical concentration)

Application:
Continuous monitoring of boiler feedwater, condensate, and cooling tower systems.

Value:
Prevents corrosion, scaling, and carryover in high-pressure steam systems. Supports chemistry programs (e.g., AVT, phosphate, all-volatile treatment) and maximizes asset longevity while avoiding unplanned downtime.

Instrumentation Used:

• Gas analyzers (ammonia, ozone, VOCs)

• Particulate analyzers

• Humidity sensors

Application:
Monitoring air quality at gas turbine inlets to protect compressor blades and combustion dynamics.

Value:
Reduces risk of fouling, corrosion, and flame instability. Improves turbine performance and extends maintenance intervals.

Instrumentation Used:

• Thermal conductivity analyzers (CH₄/CO₂ ratio)

• TDL analyzers (moisture, H₂S)

• Electrochemical gas analyzers

Application:
Measuring gas composition in biogas engines or anaerobic digester systems to optimize engine combustion and gas upgrading.

Value:
Improves biogas energy yield and engine protection, while ensuring compliance with pipeline injection standards or flare regulations. Enables safe handling of corrosive gases like H₂S.

Instrumentation Used:

• pH analyzers

• Conductivity analyzers

• BOD/COD sensors

• Turbidity and TSS analyzers

• Optical UV analyzers (for organics and nitrates)

Application:
Continuous monitoring of water entering and exiting treatment facilities to track pollutant load and verify compliance with discharge permits.

Value:
Ensures that influent characteristics are suitable for process design and that effluent meets regulatory standards. Early detection of load spikes allows proactive treatment adjustments, while real-time monitoring supports accurate reporting and permits optimization of chemical usage.

Instrumentation Used:

• Dissolved oxygen (DO) analyzers

• Ammonium, nitrate, and phosphate analyzers

• pH and temperature sensors

Application:
Controlling oxygen supply and nutrient levels in activated sludge, MBR, and other biological treatment systems.

Value:
Maintains optimal microbial activity, reduces energy consumption from over-aeration, and ensures complete nutrient removal. Supports nitrification/denitrification processes critical to reducing ammonia and total nitrogen in effluent.

Instrumentation Used:

• Inline particle size analyzers

• TSS and turbidity analyzers

• pH analyzers

Application:
Monitoring solids concentration in sludge to improve thickening and dewatering efficiency.

Value:
Improves polymer dosing control, reduces sludge disposal costs, and enhances performance of centrifuges or belt filter presses. Stable solids handling improves downstream equipment life and reliability.

Instrumentation Used:

• pH and ORP analyzers

• Chlorine (free and total), ozone, and UV analyzers

• Microwave or electrochemical analyzers for chemical concentration

Application:
Automated monitoring and control of chemicals for pH adjustment, coagulation, oxidation, and final disinfection.

Value:
Maintains proper residual disinfectant levels for pathogen control, minimizes chemical overuse, and prevents corrosion or formation of disinfection byproducts. Enables precision dosing for regulatory compliance and process efficiency.

Instrumentation Used:

• Methane, hydrogen sulfide (H₂S), ammonia, and VOC gas analyzers

• TDL or electrochemical gas sensors

• Oxygen deficiency monitors in confined spaces

Application:
Detecting toxic or combustible gases in anaerobic digesters, grit chambers, or storage areas where hazardous gases may accumulate.

Value:
Protects worker safety and facility infrastructure by enabling early leak detection or overpressure conditions. Supports biogas capture efficiency and flare system compliance.

Instrumentation Used:

• pH and ORP analyzers

• Chlorine residual analyzers

• Conductivity analyzers

Application:
Monitoring treated water chemistry in storage tanks and distribution networks to minimize pipe corrosion and maintain disinfection residuals.

Value:
Prevents lead and copper leaching in distribution systems and ensures customer tap water meets regulatory safety standards. Stabilizing water chemistry also reduces maintenance and pipe failure.

Instrumentation Used:

• BOD/COD analyzers

• Ammonia, phosphorus, and nitrate analyzers

• Gas-phase analyzers for odor control (e.g., H₂S, VOCs)

Application:
Continuous environmental monitoring for effluent discharge, air quality, and nutrient loads in sensitive watershed areas.

Value:
Enables data-driven compliance reporting, protects local ecosystems, and reduces risk of fines or violations. Supports sustainability initiatives and transparency with regulators and the public.

Instrumentation Used:

• Dissolved oxygen (DO) analyzers

• pH analyzers (glass or ISFET)

• Optical and electrochemical analyzers for CO₂ and nutrient levels

Application:
Monitoring and controlling the biochemical environment inside fermenters and bioreactors for cell culture, enzyme production, and microbial synthesis.

Value:
Maintains optimal growth conditions to maximize yield and product consistency. Enables precise control of gas flow rates, nutrient dosing, and metabolic byproduct removal, supporting GMP and PAT (Process Analytical Technology) compliance.

Instrumentation Used:

• Conductivity analyzers

• pH analyzers

• TOC (Total Organic Carbon) analyzers

Application:
Monitoring water purity and verifying cleaning cycle effectiveness in WFI systems and CIP/SIP operations.

Value:
Ensures cleaning processes meet regulatory standards (e.g., USP <643>, <645>, <645>) without leaving behind contaminants that could compromise sterile production. Reduces downtime by allowing real-time validation of cleaning efficacy and water quality.

Instrumentation Used:

• Gas analyzers for VOCs, ammonia, and oxidizing agents

• Particulate and microbial monitoring systems

• Humidity and temperature sensors

Application:
Continuous monitoring of air quality in manufacturing suites, isolators, and fill/finish lines.

Value:
Protects sterile environments from microbial contamination and chemical intrusion. Enables rapid response to contamination events and supports documentation for FDA and EU Annex 1 compliance.

Instrumentation Used:

• TDL gas analyzers (O₂, CO₂, CH₄)

• Infrared or mass-based gas analyzers

Application:
Measuring gas composition in exhaust streams from fermenters or bioreactors.

Value:
Provides real-time insight into cell respiration and metabolic activity. Enables non-invasive monitoring that enhances batch control, improves reproducibility, and supports scale-up strategies.

Instrumentation Used:

• Conductivity analyzers

• pH analyzers

• Optical or microwave concentration analyzers

Application:
Controlling the quality and consistency of buffer solutions and media used in upstream and downstream processing.

Value:
Ensures batch-to-batch consistency of critical process fluids, reducing variability and supporting process validation. Accurate pH and ionic strength are critical to protein folding, binding, and separation performance.

Instrumentation Used:

• Oxygen deficiency monitors

• Hydrogen and solvent vapor analyzers

• Thermal conductivity or electrochemical gas detectors

Application:
Monitoring bulk gas supply systems (e.g., nitrogen, oxygen, CO₂) and lab-scale solvent storage for safety and quality control.

Value:
Ensures safety in confined spaces and production zones by detecting leaks and oxygen depletion. Also protects gas supply integrity for critical process steps requiring high-purity gases.

Instrumentation Used:

• BOD/COD analyzers

• pH and conductivity analyzers

• Optical analyzers for solvents and active pharmaceutical ingredients (APIs)

Application:
Monitoring chemical and biological waste streams from production and cleaning processes.

Value:
Supports environmental compliance and waste minimization. Early detection of solvent breakthrough or high organic loads allows for corrective action before violations occur.

Instrumentation Used:

• pH and conductivity analyzers

• Optical analyzers (e.g., UV-VIS, IR) for concentration verification

• Particle size analyzers for suspension or emulsion products

Application:
Verifying that final formulations meet specifications before packaging and release.

Value:
Enables in-process quality checks that reduce rework and batch rejection. Enhances traceability and supports regulatory documentation for product release under cGMP.

Instrumentation Used:

• pH analyzers

• Conductivity analyzers

• Turbidity sensors

• TOC (Total Organic Carbon) analyzers

Application:
Monitoring the quality of incoming and process water used in cleaning, cooking, mixing, and ingredient preparation.

Value:
Ensures that water meets food-grade quality standards. Prevents contamination that could affect product taste, safety, or microbial stability. Reduces risk of product recalls and improves compliance with regulatory standards like FDA and HACCP.

Instrumentation Used:

• Conductivity analyzers

• pH analyzers

• Chemical concentration sensors (optical or microwave)

• Temperature sensors (often integrated)

Application:
Real-time monitoring of CIP cycles to validate that cleaning agents are properly dosed and rinsed from production equipment.

Value:
Reduces downtime between batches, ensures complete cleaning without chemical residue, and avoids microbial contamination. Supports automated cleaning protocols and documentation for audit readiness.

Instrumentation Used:

• Dissolved oxygen (DO) analyzers

• pH analyzers

• CO₂ and ethanol gas analyzers

• Temperature and turbidity sensors

Application:
Controlling fermentation environments in the production of beer, dairy, kombucha, and other cultured foods.

Value:
Optimizes flavor development, alcohol content, and consistency. Enables real-time adjustments to temperature, oxygen supply, or ingredient feed, improving batch yield and reducing waste.

Instrumentation Used:

• Gas analyzers for O₂, CO₂, and N₂

• TDL or electrochemical gas sensors

Application:
Monitoring the gas composition inside Modified Atmosphere Packaging (MAP) or beverage containers to ensure shelf-life and product safety.

Value:
Verifies that the correct gas mix is present to inhibit spoilage and oxidation. Protects product freshness in meats, dairy, baked goods, and carbonated drinks. Reduces packaging rework and improves brand reputation.

Instrumentation Used:

• Microwave or refractometric concentration analyzers

• Conductivity analyzers

• Inline particle size analyzers

Application:
Measuring sugar, salt, or solids concentration in high-viscosity products like sauces, syrups, and dairy concentrates.

Value:
Ensures consistent flavor and viscosity across batches. Reduces overuse of costly ingredients and supports automated blending systems. Improves yield and reduces off-spec production.

Instrumentation Used:

• BOD and COD analyzers

• pH and turbidity analyzers

• Conductivity analyzers

• Nutrient analyzers (ammonia, phosphate)

Application:
Monitoring wastewater and discharge streams for compliance with local environmental regulations.

Value:
Reduces risk of fines and environmental damage. Optimizes wastewater treatment systems and supports sustainability goals by identifying opportunities for water reuse and nutrient recovery.

Instrumentation Used:

• Ammonia gas detectors

• CO₂ gas analyzers

• Oxygen deficiency monitors (in CO₂-enriched storage)

Application:
Detecting leaks in refrigerated storage, ripening chambers, or CO₂-injected cold rooms.

Value:
Protects worker safety and prevents costly product loss due to spoilage. Ensures compliance with occupational health regulations and helps maintain safe ambient conditions in controlled environments.

Instrumentation Used:

• Optical analyzers (UV/VIS or NIR)

• pH and conductivity sensors

• Density or refractive index sensors

Application:
Verifying composition of blended products such as juices, soft drinks, and flavorings during processing.

Value:
Improves batch uniformity and reduces need for manual sampling or lab analysis. Supports closed-loop automation for real-time correction and less product waste.