On-line determination and control of the water content in a continuous conversion reactor using NIR spectroscopy

On-line near infrared spectroscopy was used to determine the water content in a continuous conversion reactor. The NIR predictions were incorporated into the distributed control system (DCS) which then controlled the addition of water to the reactor. The conversion reaction utilizes methanol, water, sodium carbonate and a reactant. Control of the water content is important for a number of reasons. At elevated water levels, a competing hydrolysis reaction increases along with the product solubility in the mother liquor leading to product losses. At reduced water levels, the product becomes anhydrous and the reaction mixture becomes gelatinous, necessitating a shutdown of the reactor for cleaning. The previous procedure for monitoring water was to remove a sample once per hour, transfer the sample to the laboratory, and run a Karl Fisher assay. Upon obtaining results from the lab, an operator would manually adjust the water inlet valve to the reactor. NIR spectroscopy in an on-line mode allows spectra to be collected every 200 s markedly increasing the frequency of results. A partial least squares model was constructed, validated and successfully implemented to predict the water content of the reactor. Further, by feeding the results to the process DCS, water additions to the reactor were fully automated. The increased frequency of sampling by NIR led to an improvement in the control of the water content and decreased the normal amount of equipment downtime. These factors improved process stability and recovery thereby generating an estimated $500,000 in savings over the course of the campaign.