Process Analysis for Hydrocarbon and Hydrogen.pdf

As the energy landscape and industrial processing continues to change, real-time, accurate monitoring of hydrocarbon and hydrogen streams is necessary. The forefront of this action is Modcon Systems and its online photonics-based process analyzers to provide operational efficiencies, safety, and sustainability in high risk and adverse environments.
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1. Process Analysis for Hydrocarbon and
Hydrogen









As the energy landscape and industrial processing continues to change, real-
time, accurate monitoring of hydrocarbon and hydrogen streams is necessary.
The forefront of this action is Modcon Systems and its online photonics-based
process analyzers to provide operational efficiencies, safety, and sustainability
in high risk and adverse environments.
Hydrocarbon Gas: Real -Time, Robust Analysis
The MOD-1022 Hydrocarbon Gas Analyzer is an unprecedented op tion for
monitoring hydrocarbon gases in stream monitoring applications. It employs a
photonics-based platform to provide real-time measured compositional
information on typical refinery and LNG gases (C₁-C₆ alkanes). Key features
include:
• Live, continuous analysis in real-time with negligible drift (<0.2% per
month)
• No exogenous carrier or fuel gases (lower infrastructure)
• Small, rugged design compliant to NEMA4X/IP66, outdoor/portable
applications.

These capabilities will allow for accurate, continuous control of hydrocarbon
processes which is vital for measuring Heating Value, ensuring product quality
and sustaining energy-efficiency.

2. Hydrogen: Precision in a High -Stakes Arena
Hydrogen, because of its instability and importance in clean energy transitions,
requires detailed and reliable monitoring. Modcon provides just that with
several premium analyzers:
MOD-1060 Hydrogen Analyzer — An inline thermal-conductivity (TCD)
instrument that has:
• Measurement from low ppm levels to 100% hydrogen
• A very fast response time — less than 30 milliseconds
• An explosion-proof design (Ex d), ATEX/IECEx certified and SIL2-ready
• Outstanding ability to withstand moisture, up to 200 bar pressure and
harsh environments.
MOD-5330 Intrinsically Safe Hydrogen Analyzer — A completely maintenance-
free hydrogen monitoring hero. Built on solid-state sensing technology, it
provides:
• Up to 10 years of continuous, calibration-free operation
• No consumables or calibration gases required
• Complete immunity to cross-gas interference and contaminant tolerance
• Compact design with digital and analog outputs for easy integration.
Together, both analyzers equip hydrogen facilities to assure purity, identify
leaks early, and work safely throughout the production cycle, from
electrolyzers to fuel cells.
The Bigger Picture: Safety, Purity, and Energy Transition
Accurate gas analysis is more than a technical convenience, and frequently a
safety necessity. In hydrogen processing, even a related trace amount of
oxygen or leaked hydrogen creates explosion risk. Ongoing monitoring of H₂
and O₂ is crucial for early warning and process integrity.
Modcon has the MOD-1040 Oxygen Analyzer, specifically for high-pressure pipe
applications. Using accepted optical sensing technology and certified SIL2 rated
safety for analysis, it allows for oxygen measurement through in-situ
monitoring. This means there is no need to extract any samples, reducing or
eliminating the explosive zone classification.
In the 2025 industry overview, one area discussed was how Modcon's
analyzers in combination with AI driven reinforcement learning, will
substantially improve hydrogen production. By observing purity and reacting to
process variations, production operators can reduce energy consumption, lower
system wear and tear, and reduce total operational costs.

3. Beyond Hydrocarbon & Hydrogen: A Unified Approach
Modcon's analysis suite is not restricted to gas species. The Beacon-3000 NIR
Analyzer is a versatile fiber optic option for real-time liquid hydrocarbon
monitoring. It allows for non-contact, multi-channel measurement of both
chemical composition and physical characteristics, with minimal maintenance
or sheltering requirements.
Underneath these products is Modcon's core philosophy: fiber optic,
intrinsically safe sensing with AI-enabled data compensation, integrated
sample conditioning inside the sample cell, and completely customized turnkey
installations.

Conclusion: Driving Smarter, Safer Process Control
For industries such as oil refining, LNG, hydrogen production, petrochemicals
etc. - there is a heavy burden because being safety responsible and
sustainable are no longer luxuries, they are necessities. Modcon Systems takes
a shot directly at this burden with analyzers built for purpose designed to give
fast, accurate, and reliable process analysis in hydrocarbon and hydrogen
spaces.
• Hydrocarbons: Real time, drift resistant speciation with very little
infrastructure.
• Hydrogen: Fast, explosion proof, low maintenance purity monitoring.
• Oxygen: High pressure, inline analysis for safety and control.
• Liquid applications: NIR based and contactless monitoring of complex
streams.
• AI integration: Autonomous optimization with dynamic analysis and learning.
As the global push for decarbonization and cleaner energy solutions continue,
understanding the mutual dependencies of the gas composition is paramount.
Modcon's analyzers empower industry leaders with the tools to monitor, adapt
and thrive—leading the energy transition with intelligence, accountability and
ambition.