Petrochemicals

Petrochemical plants require continuous monitoring of process stream compositions to detect deviations faster and stabilize product quality. Spectrally supports inline monitoring, reduces raw material losses, and enables more efficient operational decisions.

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Petrochemistry – Most Common Challenges

Here are the most common challenges we observe in your industry:

Variability in raw material and fraction composition
Fluctuations in feedstock quality and fraction ratios can affect the process course and the stability of final product parameters.
Delayed information on deviations
Relying solely on laboratory analyses for control extends reaction time and hinders real-time process correction.
Raw material and energy losses
Lack of real-time monitoring of stream composition increases the risk of off-spec batches, process adjustments, and unnecessary operational losses.

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Petrochemistry – Which compounds do we measure?

Example chemical compounds we can monitor in your process

benzenetoluenexylenesliquid ethyleneliquid propylenearomatic compoundsalkenesalkynesthiolsethers

We tailor the hardware configuration to the process and medium. Most often, we measure components critical to quality, raw materials, intermediate products, and contamination markers. Below are example analyte groups – the final list is always refined during the feasibility stage.

Check all chemical compounds

Our products

In-line, At-line/Lab, and Portable

Spectrally™ X1 INLINE

Real-time quality control, directly in the process

Measurement without sampling and without downtime

Designed for 24/7 operation, even in demanding conditions

Integration of results with control systems / QA reports

Spectrally™ X1 LAB / LAB+

The bridge between the laboratory and production

Rapid verification of batch composition without tedious sample preparation

Support for scaling formulations from R&D to production

Real-time data visualization and analysis

Spectrally™ X1 PORTABLE

Mobile raw material identification and incoming quality control (IQC)

Fast PASS/FAIL, even without opening the packaging (for transparent packaging)

A tool for raw material control at warehouse intake and in the field

Non-destructive measurement with results in seconds

Spectrally™ OS

Dedicated software with proprietary analytical models

Analyte signal converted into a user-readable result

Rapid development and deployment of models in response to specific process issues

Real data for automating and optimizing the production process

Learn more about our solutions

What does the implementation of the Spectrally™ analyzer look like?

Identification of critical points and risks
We jointly analyze where the greatest losses, quality deviations, and downtime risks occur in the process. Based on this, we select measurement points in specific processes that will yield the fastest return on investment.
Feasibility study – testing process samples
We test samples from your process to confirm whether the measurement technology and algorithms meet the requirements. You will receive a clear report on the implementation potential.
Architecture recommendation, technology selection, and ROI report
We design the measurement configuration (in-line / at-line / mobile), measurement points, integrations, and results reporting method. We present an implementation plan and a return calculation based on process data.
Implementation and service support
We install the system, launch models, and train your team so that the results immediately support production and quality decisions. We provide service support, updates, and model development as the process evolves.

Petrochemistry - See use cases of Spectrally™ analyzers

Check case studies from other industries

Linia mieszania ciągłego ciekłego nawozu azotowego RSM

Concentration of urea and ammonium nitrate in urea-ammonium nitrate fertilizer (UAN): inline composition control

The plant produces UAN 28, 30, or 32 to customer order on a single continuous mixing line. Hitting the specification window for the selected grade and reaching it quickly during grade changes determine the amount of transitional material and the nitrogen above declaration. We demonstrate how to control composition directly in the mixing line.

Reaktory polimeryzacji emulsyjnej w produkcji dyspersji akrylowych

Monomer conversion and copolymer profile in acrylic dispersions and resins: inline measurement

In acrylic dispersions and resins, the copolymer composition and its homogeneity determine the glass transition temperature (Tg) and coating properties, while residual monomer is subject to customer regulations. We demonstrate how to monitor monomer conversion and copolymer composition directly in the reactor.

Stanowisko rozładunku cysterny z koncentratem UFC

Verification of the F/U ratio and formaldehyde concentration in UFC concentrate upon receipt

The molar F/U ratio in UF resin is a fundamental parameter determining formaldehyde emissions from the finished board, and it directly results from the composition of the received UFC concentrate. We demonstrate how to verify the F/U ratio and formaldehyde content in UFC upon delivery – within 1–2 minutes and without reagents.

Write to us and learn more

Aleksandra Łukasiewicz

Head of International Sales

+48 512 554 952 · +1 (804) 593-0282
a.lukasiewicz@gekkophotonics.com

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