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Measuring Phosgene: How Applied Analytics’ Remote Sample Systems Ensure Superior Safety and Accuracy
 

Introduction

Phosgene (COClâ‚‚) is a vital industrial chemical that plays a significant role in the production of numerous everyday products, such as polycarbonate plastics, polyurethane foams, agricultural chemicals, and more. Despite its widespread use, phosgene’s highly toxic nature and corrosive behavior make its measurement and analysis a complex challenge. Ensuring safety while maintaining precise measurements is crucial in industries that handle this hazardous compound.

 

The Challenges of Measuring Phosgene

Phosgene is a colorless, highly toxic gas with a suffocating odor reminiscent of freshly cut hay. Its dangerous properties demand careful monitoring to protect workers, the environment, and production processes. Some key considerations when measuring phosgene include:

  1. Sample Line Length: Systems with internal sampling pumps may have limitations regarding the length of sample lines, potentially affecting performance.

  2. Dust Interference: Dust particles can cause false readings, particularly in paper tape-based analyzers.

  3. Filters: Filters at sample collection points are necessary to ensure accurate analysis by removing contaminants.

  4. Tubing Leaks: Leaks in the inlet or outlet tubing can compromise sample quality and lead to inaccurate measurements.

The presence of corrosive substances like chlorine (Clâ‚‚) and hydrochloric acid (HCl) in phosgene sample streams adds another layer of complexity, as these compounds can damage equipment and lead to analyzer downtime.

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Applied Analytics OMA 300 can measure Phosgene, Carbon Monoxide, and Chlorine simultaneously

 

Applied Analytics’ Solution for Phosgene Monitoring

Applied Analytics offers a robust solution for measuring phosgene through its innovative remote sample systems. These systems address the challenges of monitoring toxic and corrosive gases with a two-fold approach:

 

1. Analyzer Design: Complete Isolation from Process Fluids

Our analyzers are engineered to ensure complete isolation of process fluids from the electronics enclosure. By using fiber optic cables to connect the analyzer to the flow cell, process fluids never come into contact with the analyzer’s internal components. This design enhances safety and enables routine maintenance without the need for isolating the analyzer from the process fluid.

 

2. Custom Sample Conditioning Systems

Applied Analytics collaborates with clients to design and build tailored sample conditioning systems that:

  • Improve measurement accuracy.

  • Increase analyzer uptime by reducing the impact of poor sample quality.

With over 30 years of expertise, we specialize in creating systems that meet the unique requirements of hazardous and corrosive services. For phosgene analysis, we utilize specialty materials like Hastelloy and corrosion-resistant fluoropolymers to ensure durability and reliability. These materials withstand the harsh conditions of phosgene sample streams, providing long-term operational stability.

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Remote IR cell to measure Carbon Monoxide remotely

Why Choose Applied Analytics?

Phosgene’s toxic and corrosive nature makes it imperative to use monitoring systems that prioritize safety, reliability, and precision. Applied Analytics stands out by:

  • Minimizing the risk of exposure to toxic chemicals.

  • Offering unmatched expertise in designing systems for challenging applications.

  • Providing solutions that enhance both safety and operational efficiency.

     

Conclusion

Effective phosgene monitoring requires advanced technology and meticulous system design. Applied Analytics’ remote sample systems provide a safer and more reliable alternative to conventional continuous online analyzers. By isolating analyzers from process fluids and employing custom conditioning systems, we deliver unparalleled performance and peace of mind.

If you’re looking to upgrade your current analyzer or install a new system for phosgene service, reach out to our experts today. Let Applied Analytics give you a window into your process while ensuring the highest safety standards.

 

Please contact Bobby Singh (Louisiana) or Greg Brumfield (Texas) for more information!

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©2025 by Kaizen Controls and Automation. 

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