Automation in operational analytics

A total of approximately 32,000 samples from the various Salzgitter Flachstahl GmbH facilities, plants and systems are analyzed each year in the chemical laboratories. The resulting analytical data is used to monitor many aggregates and material flows along the entire production route. The majority of the samples are analyzed in the specialist "Water" department area. In addition to a wide variety of process water types, including cooling water, condensates and degreasing solutions, all indirect wastewater streams and the wastewater itself are also examined. Particular importance is also attached to tests for the analysis of drinking water. In addition to supplying the company’s industrial area itself, public consumers are also supplied with drinking water. In total, around 18,000 samples per year are analyzed in the water department, tested for their parameters and finally included in the results reports.
 
The focus is always on achieving the highest possible degree of automation in the analytical methods employed in order to be able to process samples faster and more effectively. Various autosamplers are firmly in place on analytical devices, allowing large sample series to be prepared and processed stand-alone by the corresponding device without the need for direct human intervention. In the past, for example, gas chromatic analysis, ICP and combustion analysis methods have been optimized in this respect.

Consequently, as shown on the following photos, a "SP2000" robot system was procured for water analyses. Given the corresponding specifications, the robot is able to process the samples independently. All the sample preparation steps required for the analysis, such as opening and closing the tubes, diluting, pipetting and filtering, are also included. The system was designed closely in line with the relevant specific requirements and can hold up to 90 water samples. Using fixed and pre-programmed racks, the sample containers coming from the plants and systems only need to be sorted and positioned on the device before starting the analysis. The robot is used to test a comprehensive range of parameters such as pH value, conductivity, chloride content, acid and base capacity, turbidness and coloration in water samples, including filtration and the sequential determination of biochemical oxygen demands.

A laboratory information and management system (LIMS) is used to calculate and store some of the final measured values and make them available for facility, plant and system controlling and management at any time. All the tests utilized are carried out in accordance with standards.