Metrohm 2060HI Online Process Analysis Platform

Overview

The Metrohm 2060HI Online Process Analysis Platform is an engineered, modular industrial analyzer system designed for continuous, real-time monitoring of critical chemical parameters across demanding production environments. Built on a robust, field-proven architecture, the platform implements multiple analytical techniques—including potentiometric, photometric, thermometric wet chemical analysis, ion chromatography (IC), near-infrared (NIR) spectroscopy, and Raman spectroscopy—within a unified, scalable hardware and software framework. Unlike traditional single-technique analyzers, the 2060HI operates as a configurable process analytics infrastructure: it supports up to four interconnected cabinets, enabling parallel multi-stream sampling, multi-parameter measurement, and simultaneous deployment of heterogeneous analytical modules. Its core function is to deliver traceable, repeatable, and auditable chemical data directly to distributed control systems (DCS), programmable logic controllers (PLC), or enterprise-level MES/SCADA platforms—ensuring closed-loop process control, predictive maintenance, and regulatory compliance in continuous manufacturing operations.

Key Features

• Modular cabinet architecture supporting up to four physically separate but logically integrated units for maximum scalability and redundancy.
• Native integration of multiple analytical technologies: wet chemical (potentiometric/photometric/thermometric), ion chromatography, NIR, and Raman—each with dedicated, application-optimized modules.
• Real-time bidirectional communication via industry-standard protocols including Modbus TCP/RTU, discrete I/O, OPC UA, and Ethernet/IP—ensuring seamless DCS/PLC interoperability.
• Pre-engineered sample handling solutions: from compact inline sample conditioning modules to full turnkey analyzer shelters with temperature-controlled enclosures, pressure regulation, filtration, dilution, and reagent management.
• Time-based programming interface with graphical timeline visualization for method scheduling, calibration cycles, cleaning sequences, and alarm triggering.
• Fail-safe operation design: automatic leak detection, flow verification, reagent level monitoring, and diagnostic logging compliant with IEC 61508 functional safety principles.

Sample Compatibility & Compliance

The 2060HI accommodates a broad range of process streams—including aggressive aqueous effluents (e.g., boiler feedwater, flue gas desulfurization scrubber liquor), electroplating baths, semiconductor CMP slurries, pharmaceutical buffer solutions, and petrochemical refinery sidestreams. Sample matrices may contain suspended solids, particulates, high salinity, oxidizing agents, or volatile organics—addressed via optional pre-treatment modules (e.g., ultrasonic homogenizers, ceramic membrane filters, PTFE-lined peristaltic pumps). The platform meets international regulatory expectations for process analytical technology (PAT) deployments: hardware design adheres to EN 61326-1 (EMC), EN 60529 (IP65/NEMA 4X enclosure rating), and ATEX/IECEx Zone 2 certification for hazardous areas. Software modules—including tiamo™, MagIC Net™, OMNIS™, and Vision™—support 21 CFR Part 11-compliant electronic records and signatures, audit trail functionality, role-based access control, and GLP/GMP-aligned validation documentation packages.

Software & Data Management

Each analytical module is managed by its respective domain-specific software suite, all unified under a centralized configuration and monitoring layer. tiamo™ provides validated workflows for wet chemical titration and photometry; MagIC Net™ delivers IC-specific peak integration, baseline correction, and eluent generation control; OMNIS™ enables chemometric model development and spectral preprocessing for NIR; Vision™ supports multivariate calibration, spectral library management, and real-time Raman band quantification. All software components generate timestamped, metadata-enriched datasets stored in SQL-based relational databases with configurable retention policies. Data export supports CSV, XML, and OPC-HDA formats. Integrated alarm management allows threshold-based notifications (email/SMS/SNMP), event-driven DCS setpoint adjustment, and automated report generation aligned with ISO/IEC 17025 reporting requirements.

Applications

• Power generation: Continuous monitoring of Cl⁻, SO₄²⁻, NH₄⁺, and SiO₂ in boiler feedwater to prevent turbine erosion and membrane fouling.
• Surface finishing: Real-time control of Ni²⁺, Cu²⁺, Zn²⁺, H⁺, and complexing agent concentrations in electroplating baths to minimize reagent overfeed and defect rates.
• Chemical manufacturing: In-line quantification of reaction intermediates and residual catalysts during batch or continuous synthesis—enabling endpoint determination and yield optimization.
• Water & wastewater treatment: Simultaneous measurement of NO₃⁻, PO₄³⁻, F⁻, and total alkalinity for dynamic dosing control of coagulants and pH adjusters.
• Pharmaceutical manufacturing: PAT-compliant monitoring of buffer composition, conductivity, and redox potential in bioreactor feeds and purification skids.

FAQ

What analytical techniques does the 2060HI platform support?
The platform natively integrates wet chemical analysis (potentiometric, photometric, thermometric), ion chromatography, near-infrared (NIR) spectroscopy, and Raman spectroscopy—each implemented as plug-in modules with dedicated detectors, fluidics, and software.
Can the 2060HI operate in hazardous area environments?
Yes—certified variants are available for ATEX Zone 2 and IECEx Zone 2 applications, featuring intrinsically safe electronics, explosion-proof enclosures, and non-sparking sample handling components.
How is calibration and maintenance managed remotely?
Calibration schedules, standard additions, blank corrections, and cleaning cycles are programmable via the time-based GUI; remote diagnostics, firmware updates, and log file retrieval are supported over secure HTTPS or VPN connections.
Is the system compatible with existing DCS/PLC infrastructure?
Yes—the 2060HI includes native Modbus TCP/RTU, discrete I/O, and OPC UA drivers; custom protocol adapters can be developed for legacy systems upon request.
What validation support is provided for regulated industries?
Metrohm provides IQ/OQ documentation templates, URS alignment checklists, and 21 CFR Part 11–compliant software validation packages—including test scripts, traceability matrices, and change control logs—for GxP and ISO 13485 environments.