The Process Technology Blog
The Process Technology Blog provides educational and product information for the industrial process control and factory automation markets. Posts will include application information, new product announcements, How-To's, and process control education. This blog is sponsored by Process Technology, Inc. Contact PTI by calling 801-264-1114 or visiting their website at https://process-tech.com.
Process Weighing: The Foundation of Industrial Precision
The Role of Industrial Flare Stacks and the Need for Advanced Flare Management
Industrial plants that process oil, gas, and chemicals depend on flare stacks as essential safety devices. When excess hydrocarbons build up in a process, facilities need a reliable way to dispose of them. The flare stack provides that safeguard. By burning off gases under controlled conditions, flare stacks prevent dangerous pressure buildups and uncontrolled releases that could lead to explosions, fires, or toxic leaks. In short, flares protect workers, equipment, and surrounding communities.
The operating principle is straightforward yet crucial. Excess gases travel through a flare system to a tall stack where a continuous pilot flame ignites them. The combustion process breaks down volatile organic compounds into less harmful byproducts such as carbon dioxide and water vapor. Steam or air assist systems often mix with the gas stream to ensure complete combustion and minimize smoke. While flaring is never the first choice, it remains a necessary last line of defense in industrial operations.
That said, flaring carries environmental concerns. Even when properly managed, flare stacks emit greenhouse gases and, if not optimized, can produce soot and unburned hydrocarbons. Regulators, investors, and communities demand that operators minimize flaring, prove high combustion efficiency, and show commitment to sustainability. For plants, the challenge lies in achieving both safety and environmental compliance while keeping operating costs in check.
This is where technology has begun to transform flare management. Baker Hughes, through its Panametrics division, has developed the flare.IQ flare management control system, a solution designed specifically to address inefficiencies in traditional flare operations. Historically, operators had little real-time visibility into flare combustion efficiency. Adjustments to steam or air assist often relied on manual estimates, leading to wasted energy and suboptimal destruction efficiency.
Flare.IQ closes that gap with advanced monitoring and automated control. The system continuously measures flow, temperature, and gas composition, then applies real-time algorithms to calculate combustion efficiency. With those insights, flare.IQ automatically adjusts steam or air assist to maintain ideal conditions. This not only ensures regulatory compliance and higher destruction efficiency but also reduces unnecessary steam consumption, delivering significant energy and cost savings.
Plants that implement flare.IQ reports greater confidence in meeting environmental requirements, improved reliability, and lower operating costs. Instead of treating flare systems as a compliance burden, operators can now view them as optimized, intelligent assets that support both safety and sustainability.
For companies in the Mountain West, Front Range, and Southwest regions, having a local partner to implement and support this advanced technology makes all the difference. Process Technology, Inc. of Salt Lake City stands as the trusted resource in the region for Baker Hughes Panametrics solutions, including flare.IQ. With deep technical expertise, hands-on support, and a commitment to customer success, Process Technology, Inc. helps industrial operators integrate smarter flare management into their facilities. By partnering with Process Technology, Inc., plants not only meet safety and environmental demands but also unlock new levels of efficiency and performance.
Ensuring Water Purity in Semiconductor Fabs with the Mettler Toledo UPW UniCond Sensor
In the high-stakes world of semiconductor manufacturing, purity is everything. Even the slightest contamination can lead to product defects, costly downtime, or failed production runs. Ultra pure water (UPW) plays a vital role in this process, acting as a cleaning and rinsing agent for wafers at multiple stages. Maintaining the integrity of UPW systems requires precise monitoring and control, especially when it comes to conductivity. One of the most trusted and advanced solutions for this critical application is the Mettler Toledo UPW UniCond conductivity sensor.
The UPW UniCond represents a breakthrough in measuring ultra-low conductivity in semiconductor-grade water systems. Traditional conductivity sensors often struggle with accuracy at such low levels, especially below one microsiemens per centimeter. However, the UPW UniCond delivers highly stable and reliable measurements down to 0.055 μS/cm, which aligns precisely with the theoretical conductivity of pure water at 25°C. This precision makes the sensor ideal for the stringent demands of semiconductor water systems, where even parts-per-billion levels of ionic contamination must be detected and controlled.
One of the most impressive aspects of the Mettler Toledo UPW UniCond is its intelligent sensor design. Each UniCond integrates a built-in microprocessor that stores calibration data and sensor identity. This functionality allows for plug-and-measure convenience, reducing the risk of operator error and minimizing installation time. Technicians can perform calibrations in a controlled environment, then install the sensor with confidence that it will perform accurately in situ. This capability becomes especially valuable during shutdowns or tool qualification, where every minute of uptime counts.
The UPW UniCond works seamlessly with Mettler Toledo's Thornton transmitters, including the M800 series, enabling multiparameter analysis and flexible integration into process control systems. The transmitter-sensor pairing ensures fast response times, excellent signal stability, and easy configuration. The sensor's compact design and high-pressure compatibility make it suitable for a wide range of installation points, including water polishing loops, point-of-use systems, and makeup water units.
The semiconductor industry faces growing challenges as chip designs become smaller and more complex. As process nodes shrink to single-digit nanometers, the tolerance for contamination approaches zero. This trend places even greater emphasis on the need for advanced analytical technologies like the UPW UniCond. Leading fabs and ultrapure water system designers count on this sensor to ensure that water quality remains within spec—continuously and without compromise.
Moreover, environmental and economic factors add further pressure to reduce water waste and optimize system performance. By providing real-time, accurate conductivity data, the UPW UniCond supports predictive maintenance strategies and enables more efficient use of resins and filtration media. Over time, these benefits can lead to measurable reductions in operational costs while ensuring regulatory compliance and product quality.
In the southwestern United States, where the semiconductor industry continues to expand and water resources remain limited, the demand for reliable ultrapure water monitoring tools continues to grow. Facilities across the region rely on expert support to ensure successful installation, calibration, and operation of conductivity measurement systems.
Process Technology, Inc. proudly sells and supports Mettler Toledo Process Analytics products, including the UPW UniCond, across Utah, Western Wyoming, Idaho, Northern Nevada, Arizona, New Mexico, and Colorado. With deep technical expertise and a strong commitment to customer service, Process Technology, Inc. helps semiconductor manufacturers and system integrators maintain the highest standards of water quality and process reliability.
PFAS Groundwater Contamination: A Growing Crisis and a Smart Solution
Across the United States and around the world, communities are waking up to the danger of PFAS—per- and polyfluoroalkyl substances—polluting their groundwater. These synthetic chemicals, often referred to as "forever chemicals," resist degradation in the environment. Manufacturers have used them since the 1940s in non-stick cookware, waterproof fabrics, firefighting foams, food packaging, and countless other applications. Over time, PFAS leached into soil, rivers, and aquifers, contaminating the drinking water supplies of millions silently.
The health risks associated with PFAS exposure are serious and well-documented. Long-term exposure, even at low levels, can increase the risk of kidney and testicular cancers, liver damage, hormone disruption, immune system suppression, and developmental issues in children. Unlike bacteria or some organic compounds, PFAS don't degrade naturally. Once these chemicals seep into groundwater, they travel long distances and remain intact for decades, making them especially difficult to remove.
Regulators now recognize the urgency. The U.S. Environmental Protection Agency recently set maximum contaminant levels (MCLs) for certain PFAS compounds at just a few parts per trillion (ppt)—a microscopic threshold that underscores their toxicity. Meeting these new limits has proven challenging and costly for municipalities, military bases, industrial facilities, and airports, all of which face legacy contamination and heightened public scrutiny.
Traditional filtration methods, such as granular activated carbon (GAC) and ion-exchange resins, often struggle to meet these new standards consistently. These systems typically require high pressure, frequent maintenance, and significant energy input. Worse, many allow PFAS breakthrough before full media saturation, creating uncertainty in performance and cost.
This is where Smart Sponge Quanta™, developed by Abtech Industries, changes the game.
Smart Sponge Quanta™ offers a new generation of filtration technology specifically engineered to remove PFAS and other persistent contaminants from water. It combines a polymer matrix with an enhanced biochar core to create a porous, chemically selective filter media. Unlike GAC or ion exchange resins, Quanta™ doesn't just trap PFAS on the surface—it absorbs and permanently sequesters them inside its structure. Independent tests show that even when fully saturated, Smart Sponge Quanta™ does not leach PFAS back into the environment.
What sets this technology apart is its efficiency and simplicity. Quanta™ can reduce PFAS concentrations from over 4,000 ppt to less than five ppt in under two minutes. It supports flow rates of up to 40 gallons per minute per square foot, five times faster than traditional systems, all while operating at minimal back pressure—often less than one psi. It works equally well under gravity-fed systems and low-pressure applications, which eliminates the need for complex pump setups or energy-intensive processes.
Cost matters, too. Quanta™ delivers roughly 50% lower capital costs and up to 35% lower lifecycle costs than GAC or resin systems. It easily integrates into existing filtration infrastructure with minimal retrofitting, and its long lifespan reduces maintenance and media change-out schedules. When the media reaches capacity, users can safely dispose of it through waste-to-energy facilities, cement kilns, or approved landfills—thanks to its non-leaching design.
Beyond PFAS, Smart Sponge Quanta™ also captures heavy metals, hydrocarbons, phosphorus, and bacteria, making it ideal for complex sites where multiple contaminants coexist. Municipal utilities, industrial operators, and environmental engineers now use this technology in stormwater systems, groundwater remediation projects, and treatment of landfill leachate and construction dewatering.
The PFAS crisis demands innovation that's fast, scalable, and proven. Smart Sponge Quanta™ answers that call. It gives communities and industries a powerful tool to protect public health and the environment without breaking budgets or requiring high-tech overhauls. As regulators tighten standards and contamination hotspots emerge, this innovative, adaptable solution offers a way forward—clean water delivered safely and sustainably.
Let's not wait another decade to solve a problem we can tackle today. With Smart Sponge Quanta™, the path to PFAS-free water starts now.
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