Summary
In partnership with Endress+Hauser, Evonik has successfully integrated Raman spectroscopy as a powerful process analysis technology (PAT) from the laboratory to pilot plants, right through to production. This technology delivers real-time data, increases efficiency, reduces costs, and improves product quality. Its flexibility, scalability, and safety make it the key to new savings potential in chemical process development. Customers can benefit directly from this acquired expertise to optimize their own development and production processes in a sustainable manner.
The results: Greater efficiency, safety, and quality
16
installed Raman Rxn2 analyzers
50+
measuring points with Raman Rxn probes
Raman spectroscopy from Endress+Hauser has established itself as a key PAT tool at Evonik. It enables significant efficiency gains, cost reductions, and faster market launch of new products.
Results include:
- End-to-end process analysis from the laboratory to production
- Real-time measurements possible at several measuring points at the same time
- Inline measurements replace manual sampling
- Suitability for pilot plants with low volumes
- Reliable operation even under difficult conditions (e.g., ATEX zones)
- Reduction in the time to market
- Cost reduction through elimination of laboratory evaluations and reduced personnel costs
- Increased safety
- Internal acceptance and acquisition of expertise
"With Raman spectra, you might be able to assign isolated peaks to individual substances in the mixture. This significantly reduces the calibration effort and quickly leads to quantitative results."
The challenge: Find a versatile, real-time lab-to-process solution
Back in 2016, Evonik launched its company-wide “lab to process” strategy with the aim of embedding PAT technologies early on in process development. Evonik was looking for a process analysis technology that would efficiently support the entire development and optimization process while also helping to reduce costs. The goal was to find a solution that not only provides accurate real-time data but is also versatile enough to be used in a wide variety of process environments – from the laboratory to production.
The technology should:
- be universally applicable for a wide range of chemicals, states of matter and process conditions
- be flexible and scalable from the R&D lab to large-scale production facilities
- be quick to integrate in order to shorten development times and reduce time to market
- improve product quality through continuous inline measurements
- function reliably even under demanding conditions such as ATEX zones
Our solution: A scalable PAT Endress+Hauser Raman spectroscopy system
Endress+Hauser provided Evonik with a customized solution based on Raman spectroscopy – a technology that meets all of the requirements outlined. The systems are characterized by their exceptional modularity and versatility. Thanks to optical fibers and various probe types, they can be easily integrated into a wide variety of installation situations. Up to four independent channels enable simultaneous monitoring of multiple measuring points – a clear advantage for complex processes.
The chemometric suitability of the spectra offers particular added value – due to compatibility with all common chemometric programs, these can be analyzed directly on the spectrometer in a way that is versatile, intuitive, and achieved in real time. This allows qualitative and quantitative data to be recorded and interpreted immediately during the process – without any time-consuming manual sampling.
Raman spectroscopy was successfully used for the first time in a pilot plant for the development of hydrogenation processes. The probe was integrated into a 6 mm pipe – significantly smaller than in production facilities. Instead of daily NMR sampling, the technology now enables inline measurements to be taken every single minute, and the process continuously monitored.
This process is efficient, precise, and safe. In pilot plants with low volumes in particular, the system composition remains unchanged because no samples need to be taken. This not only saves time and money but also increases safety for both personnel and plant.
Hazardous area use
Thanks to its standardized and certified components, the Raman system can even be used in ATEX zones at a cost that is reasonable. For use in potentially explosive atmospheres, Evonik also uses the Liquiphant Vibronic level switch. This ensures that no flammable gas mixture can form in the laser beam of the Raman probe – a decisive contribution to process safety.
Testimonial
“The requirements for PAT measurement systems are particularly high, especially in the harsh environment of process plants and the need to comply with ATEX regulations. Raman spectroscopy has established itself as a robust and reliable tool in this area.” - Dr. Roland Peschke, PAT expert at Evonik Oxeno
Global roll out
This system has enabled Evonik not only to increase efficiency and quality in process development, but also to successfully transfer technology from the laboratory to production – a real key to new savings potential. Following successful implementation in Germany, Raman technology is now being rolled out internationally in Evonik’s first production plants – supported by the global expertise of Endress+Hauser.
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