The application areas for BON’s intelligent process analyzers are not limited by specific industries, but can rather be categorized as analysis of materials and chemical compounds in manufacturing processes based on solids, liquids and gases.
Examples for measuring applications within those categories are:
Moisture in powders, homogeneity of powder blends, API distribution and concentration in pharmaceutical products, protein content in agricultural products like grain milk, milk powder, meat and sausage production, color and turbidity measurement, crude oil traces in refined products, refinery gases (Methan, Ethan, Propane, Butane), Hydrogen Sulfide (H2S) in liquids or gases, biogase, Isocyanate during the production of Polyurethane, Ammonia (NH3) in processing of cosmetics and many more.
Water is one of the strongest absorbing compounds in the NIR spectral region and can therefore be measured at very low concentrations. NIR spectroscopy is an efficient alternative to traditional analytical methods such as Karl Fisher (KF) titration for quantifying moisture concentrations. Blue Ocean Nova's moisture sensors are measuring moisture via diffuse reflectance from the powder blend in real-time. The targeted concentration range determines the optical technology in the moisture sensor. In the pharmaceutical industry, the moisture content affects the flow, caking, compaction and strength properties and is usually above 1%. In the chemical industry concentrations of well below 1% are required to maintain the optimal chemical, physical and microbial product properties. Dependent on the target concentration, the sensor utilizes NIR techniques for concentrations down to 1% with +/- 0.3% accuracy, or MIR for concentrations below 1%.
Due to the FDA’s PAT initiative, NIR spectroscopy has become the most utilized spectroscopy technique for pharmaceutical manufacturing processes, next to UV and fluorescence based techniques. The applications range from various processing operations of powder mixes, such as blend monitoring for homogeneous mixing of APIs and excipients, drying and granulation, to tablet pressing and measuring of content uniformity of the API in the final tablet. NIR spectroscopy is also used for validation of drug authenticity and verification of dosage concentration. UV spectroscopy is mostly used for cleaning validation (CIP) across virtually all manufacturing industries.
Blue Ocean Nova’s products are compliant with all regulatory (FDA) requirements (cGMP, 21CFR part 11).
Industrially processed food products, animal feed, fertilizer, chemicals, pharmaceutical and cosmetic products are passing through several unit operations in their respective production cycles, requiring a variety of analytical technologies to control the relevant process parameters. Inline analysis using NIR technology is providing the optimal solution to precisely determine the fat and protein content in realtime. TRITON and TELLUS products are the ideal process sensor types to analyze fats and proteins during production as well as during quality control of the final product.
The validation of a cleaning process is mandated in virtually any manufacturing process to prevent carryover of material above a predefined acceptable level from one product to another. Typically, samples of the rinse solution, chlorine, caustic clips or acids used for cleaning must be removed from the system and taken to the laboratory for analysis of the residual material in the rinsate. This greatly slows the cleaning process while adding to the laboratory test burden and significant cost increase due to excessive use of solvents.
BON's TRITON products enable the user to detemine in real-time, when the concentration of the analyte reaches this predefined acceptable level and can actively stop the cleaning process, thereby saving signifcant expenses on solvents and increasing the efficiency of the manufacturing equipment.
Color measurements are playing an important role in many industrial processes. Whether it is the color analysis of food products, the detection of crude oil in refined products during distillation, verification of color accuracy during paint production or the color measurement of materials in the chemical industry, the precise determination of color or the absence thereof, are routine requirements in many manufacturing processes.
BON’s color analyzers are grouped into two categories, the TRITON model, based on transmittance measurement technology for color analysis in liquids and the TELLUS model, using reflectance probes or flow cells for color in solids such as powders or surfaces.
Hydrogen sulfide (H2S) is a crucial process parameter in the processing of oil, natural gas, waste and sewage treatment. As it is poisonous, corrosive and explosive, it is of paramount importance and mandated by regulatory bodies to monitor the concentration levels in real-time during any process.
Blue Ocean Nova's H2S sensor families for liquids (TRITON) and gases (BOREAS) are able to analyze H2S concentrations in water as well as gases in concentrations in the single digit ppm range, using multivariate analysis in the UV and MIR spectral range, combined with patented measurement interfaces to withstand the corrosive nature of the analyte.
A common problem in refineries occurs during the process of fractional distillation when traces of crude oil occasionally spill over into the refined products with adverse consequences for downstream processing equipment. These spillovers manifest in subtle changes in color and turbidity of the refined products and byproducts. The BON Triton product series has been purposely built for process applications like this, including the certifications for hazardous areas.
Many refining processes require constant monitoring of exhaust gases, such as Ammonia (NH3) and total Nitrogen (NOx) to ensure compliance with legal environmental emission limits. The operating temperatures of these catalytic reduction processes are usually reaching up to 400°C and higher. BON’s BOREAS product series is equipped with the process interfaces and optical components specifically designed to be deployed in conditions like these. All products are available with enclosures compliant with the respective design regulations for explosion-proof equipment.
Without available and appropriate measurement techniques, biogas plants are often run below capacity, in order to avoid instabilities in the fermentation process.
BON’s sensors for biogas are matching the rugged requirements for analytical measurement equipment for inline deployment with regards to gaskets, window material and the robustness of the stainless steel blend used for the probe shafts, which are for ease of maintenance, easily interchangeable.