How to monitor online the conversion rate of liquid-phase materials and the degree of polymerization in chemical production

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Process industries are often accompanied by physical and chemical reactions, biochemical reactions, phase transition processes, as well as the transfer of matter and energy. They represent highly complex industrial systems that inherently involve numerous uncertainties and nonlinear factors. It is difficult for existing technologies to accurately determine whether the set parameters match the actual values; therefore, production must be guided by offline laboratory analyses, which can affect product quality and cause significant economic losses for enterprises. This technology enables real-time detection online of data that cannot be measured by conventional instruments; it automatically or semi-automatically adjusts the parameter settings so that the actual values match the required values for production. This helps to reduce the rate of defective products, improve product quality, ensure production safety, and lower energy consumption. This system makes use of the existing signals at the production site (temperature, pressure, flow rate, etc.), and adds several measurement points at appropriate locations depending on the specific project (by purchasing mature hardware devices from domestic and international manufacturers such as Rosemount or Henghe). The signals required for detection are fed into intelligent instruments for model calculations, while the test results of samples on-site are used to adjust the parameters. We do not produce any hardware ourselves; our main technical approach involves developing additional functions for existing hardware, conducting mechanistic modeling using physical and chemical methods, designing a model that is specifically suitable for the customer’s actual processes, and utilizing a database platform to enable the accurate measurement of the values of interest. The core technical advantage lies in the fact that the products are entirely developed through independent research. By taking into account the nature of various testing objects, the manufacturing processes, and the surrounding environment, corresponding models are established, and design solutions are developed to ensure that the products fully meet the actual requirements of production.