What is Process Analytics?
23 July 2025
Understanding the role of gas and liquid analysis in optimising industrial performance.
In the world of industrial operations—whether it’s petrochemicals, pharmaceuticals, food and beverage, or energy production—minute variations in the composition of gases or liquids can have outsized impacts on quality, efficiency and compliance.
Process analytics refers to the real-time measurement and interpretation of chemical and physical properties in a process stream—most commonly gases or liquids—to control and optimise industrial processes. Unlike laboratory analysis, which is typically retrospective, process analytics delivers continuous, on-the-spot data from within the production line itself.
At its core, it involves the use of sophisticated instrumentation—such as gas chromatographs, spectrometers, and sensors—integrated with automation systems to monitor parameters like concentration, flow, pressure, pH, and more.
When applied to gases and liquids, process analytics can answer critical questions such as:
- What is the chemical composition of this process stream?
- Are we maintaining the correct mixture ratios?
- Is contamination or deviation occurring?
- Are emissions within regulatory limits?
These insights are not just academic—they directly impact the profitability, safety, and sustainability of operations.
Why It Matters
While the technology may seem highly technical, the business benefits are clear and measurable. Process analytics is an enabler of informed decision-making, process control, and regulatory compliance, with direct implications for operational performance.
Improved Efficiency and Yield
Real-time monitoring allows operators to quickly identify inefficiencies, optimise reaction conditions, and fine-tune inputs, leading to better yields and reduced waste. In gas processing, for instance, inline analysers help maintain ideal gas ratios, ensuring minimal losses and optimal combustion.
Enhanced Product Quality
Consistency is key in sectors like pharmaceuticals or food production. Deviations in the chemical profile of a liquid ingredient can compromise product quality or safety. Continuous analysis safeguards quality by enabling immediate corrective actions.
Regulatory Compliance and Safety
Environmental and safety regulations require accurate monitoring and reporting of emissions and discharges. Process analytics systems offer the data integrity and traceability necessary for compliance with standards such as ISO, EPA, or ATEX.
Predictive Maintenance and Downtime Reduction
With real-time data, businesses can identify equipment fouling, leaks, or abnormal behaviours before they escalate. This predictive capability reduces unplanned downtime and extends asset lifespans.
Data-Driven Optimisation
Beyond compliance and control, the insights gained from process analytics feed into broader digital transformation efforts—from process simulation and modelling to AI-driven decision support systems.
A Strategic Asset, Not Just a Technical Tool
Traditionally the domain of plant engineers and chemists, process analytics is increasingly recognised at the executive level as a strategic asset. It bridges the gap between operational technology (OT) and information technology (IT), aligning frontline activities with business objectives like cost reduction, sustainability, and competitive agility.
For organisations aiming to digitise and decarbonise their operations, investing in modern process analytics is no longer optional—it’s fundamental.
In summary, process analytics for gas and liquid analysis isn’t just about measuring things—it’s about mastering your process. When implemented effectively, it provides the real-time intelligence that businesses need to run safer, smarter and more sustainably.
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