Real-time Measurement Solutions for Process Analysis

Diablo Analytical designs and builds custom systems for real-time process analysis. Our focus is on developing technology that can be used to enable flexible and quantitative process analysis measurements.
	Our systems are typically used in pilot-plant and R&D environments where the emphasis is on quick implementation, ease-of-use, and fast turn-around of results for many different experiments and process streams.

Mass Spectrometry Solutions

Diablo has used many different kinds of mass spectrometer systems for process analysis applications over the years ranging form low-end Residual Gas Analyzers (RGAs) to very complex laboratory MS instruments adapted for process use. Although there are intriguing new technologies on the horizon, we currently recommend using modern quadrupole-based MS systems for a variety of important reasons, including commercial availability and support, as well as performance characteristics like sensitivity and stability.

Additional Information

Additional background information on process mass spectrometers.

Process MS based on the Agilent 5973N MSD

This small quadrupole MS instrument is the industry standard for bench-top laboratory GC-MS. It has proven to be reliable, sensitive and easy to use for laboratory applications. Diablo Analytical, Inc. has modified these systems for many years for certain kinds of process applications. The stand-alone MS system is similar in size to an RGA unit and can be interfaced directly to the process with an appropriate interface and transfer line.

The Agilent 5000A Real-Time Gas Analyzer

Agilent Technologies has commercialized this approach as the 5000A Real-Time Gas Analyzer. This instrument uses Diablo's MS Sensor process analysis software and a specially-designed transfer line and sampling system interface to enable the 5973 MSD to be used for process analysis applications.

Process Sampling Systems for MS

One of the most important considerations for any process analysis system is the interface between the process and the analyzer. This is particularly true with process MS applications because the analyzer operates at high vacuum, while the process is often pressurized. A variety of sampling system configurations allow direct interface to a wide range of process samples. For example:

Process dryers at high temperatures with condensable samples
Catalyst screening for trace contaminants
Reactor headspace monitoring
Sub-ambient pressure locations
Multi-stream gas sampling
Air sample concentration for trace analysis.

Diablo Analytical, Inc. has developed and implemented many sampling systems for direct MS applications. Pressure, temperature, composition and detection limits are some of the important considerations. Sampling system design, materials of construction and control must match the application.

Calibration for Direct MS Applications

Many direct MS or RGA applications only require qualitative information. Although this is still a useful "eye" into the process, sometimes it is important to make quantitative measurements. The lack of quantitative work in process mass spectrometry is due in part to instrument performance, calibration difficulties, and pressure control problems. Direct MS experiments can be performed in a quantitative fashion with the correct sampling system design, and selection of the proper MS instrument. Calibration mixes can be introduced into a correctly- designed direct MS interface and sampling system to produce successful quantitative results.

Gas Mixing and Dilution Systems

Diablo Analytical has designed very high quality gas mixing systems that interact with analytical instrumentation. These systems allow dynamic mixing for sample conditioning or calibration use.

Portable Gas Chromatography Solutions

The Agilent Technologies MicroGC Systems

This technology was commercialized by Microsensor Technologies, Inc (MTI), and is now available through Agilent Technologies. These portable GC systems combine unique silicon micro-machined injection valves and thermal conductivity detectors with modern capillary GC columns to perform rapid gas analysis in the field. Diablo has many years of experience implementing MicroGCs for both laboratory and process applications. In addition, Diablo has developed a number of custom automation and software solutions for the MicroGC platform.

Other Process Analyzer Systems

Diablo also has experience with a wide range of "traditional" process analyzers including,

Trace oxygen analyzers for semiconductor processing.
Process x-ray fluorescence analyzers for sulfur detection in fuels.
Non-dispersive Infrared (NDIR) analyzers for CO analysis in combustion streams.
Pulsed-fluorescence SO2 analyzers for certification of calibration standards.

Our involvement with these analyzers has ranged from specification and implementation to performance validation to development of custom data logging and automation packages.

Custom Automation and Software Solutions

The programmers at Diablo Analytical have been creating custom software solutions for chemical measurement and process analysis applications for more than a decade. A few example projects that we have completed are listed below.

MS Sensor Process Analysis Software

Diablo Analytical originally developed the MS Sensor software to enable the Agilent Technologies 5973 MSD to be used for real-time process analysis. Agilent Technologies has now licensed the MS Sensor software for its 5000A Real-Time Gas Analyzer. The MS Sensor software can also acquire data from a number of other instruments and sensors. Diablo can also develop custom instrument drivers to collect data from other instruments and sensors. Please refer to the MS Sensor web page for detailed information about this software product.

EZPlot Real-time Plotting Software for Micro GC Systems

Diablo Analytical developed “EZPlot” for the MTI/Agilent Micro GC systems running the EZChrom data system. EZPlot allows the Micro GC to plot analyte concentrations on a real-time trend-plot. Since the micro GCs typically generate results in less than one minute, the trend plot is updated frequently. This allows process stream composition to be tracked visually with time. See our EZPlot product page for more information about this software application. We can also create custom versions of EZPlot to address specific client requirements.

EZ Analog Output Software for Micro GC Systems

Diablo's EZ Analog Output software uses a National Instruments multi-channel analog output board to enable the Agilent EZChrom Data System to output analysis results from a MicroGC to 4-20mA analog output channels.

Multi-Position Valve Control Software

Diablo's MPValve software can be used to automate one or more VICI (Valco) multi-position valves for applications like stream and column selection. MPValve has been used to add multi-position valve control to a number of different data systems.

BTU Database

Diablo developed a custom BTU database application that is designed to process the results of Agilent MicroGC natural gas analyses in the field. The application performs extensive QA/QC tests that give the operator immediate feedback on sample and data quality. Upon return from the field, the application allows results to be uploaded easily to a mainframe database.

Quotation and Purchasing Information

Please contact Diablo Analytical to discuss your specific application requirements and to receive a project quotation.

Diablo Analytical, Inc.
5141 Lone Tree Way
Antioch, CA 94531

Phone: (925) 755-1005
Fax: (925) 755-1007

E-Mail: info@diabloanalytical.com