Case Study

Air quality monitoring at a chemical plant in Ludwigshafen (Germany)

BASF SE
Sector:

Need

Air quality monitoring is a crucial component of environmental management in the chemical industry to ensure both regulatory compliance and community well-being.

Due to the high costs and high maintenance needs of traditional type-approved measuring devices, air quality monitoring at large industrial areas is usually limited to only a few strategically positioned measurement stations.

Kunak’s advanced air monitoring technology enables users in the chemical industry to scale their measurement network and provide a comprehensive real-time monitoring of the industrial area.

With an area of 10 km2 the headquarter of BASF SE in Ludwigshafen is the largest integrated chemical complex in the world. Many thousands of products for customers from almost all industries are manufactured in the 200 production plants at the site in a highly integrated Verbund starting from organic base chemicals to highly specialized chemical products.

Due to the proximity of the site to residential areas, BASF operates five air quality stations employing traditional type-approved measuring devices and continuously screens the air quality at the site and its surroundings with a fleet of measuring vans.

BASF explored the potential of Kunak’s sensor-based solutions to evolve its current measurement approach into a denser, resource-efficient, real-time monitoring network.

FOCUS AREAS

  • Performance at monitoring VOCs: With many petrochemical facilities at the site this is a crucial prerequisite.
  • Real-time data with high availability: This is needed to detect emissions and act timely in case of increased concentrations.
  • Consistency of data and time-series with existing type-approved measurement devices: This is a prerequisite to ensure that authorities accept the data.
  • Integration with existing systems: Any new monitoring technology had to seamlessly integrate with BASF’s internal environmental management platform.
Kunak’s technology provides real-time insights that enhance compliance and environmental management at BASF's facility.
Air quality monitoring at BASF's chemical plant in Ludwigshafen (Germany) - KunakAir quality monitoring at BASF's chemical plant in Ludwigshafen (Germany) - KunakAir quality monitoring at BASF's chemical plant in Ludwigshafen (Germany) - KunakAir quality monitoring at BASF's chemical plant in Ludwigshafen (Germany) - KunakAir quality monitoring at BASF's chemical plant in Ludwigshafen (Germany) - Kunak

Solution

  • Strategic placement: Kunak AIR Pro units were strategically deployed at various key locations within BASF’s Ludwigshafen site to cover differing background conditions and emission profiles.
  • Remote management & analytics: Data was transmitted to the Kunak Cloud platform, facilitating continuous remote monitoring and analysis.
  • Laboratory comparison: Multiple laboratory experiments were conducted to evaluate the performance of Kunak AIR Pro equipped with VOC and methane sensors for detecting various hydrocarbons.
  • Comparative validation: Field measurements were complemented by parallel measurements using traditional type-approved methods, demonstrating a strong overall correlation.
This network allows for better emission control, quicker response to anomalies, and long-term environmental stewardship.

Results

  • Enhanced real-time air quality monitoring: The study affirmed the value of a denser, real-time air monitoring system utilizing Kunak’s sensor-based solutions.
  • Performance and competitiveness: The study demonstrated a strong correlation between Kunak’s sensor-based solutions and traditional type-approved methods in a complex industrial environment.
  • Scalability and long-term strategy: Following the successful study, Kunak’s sensor-based solutions were integrated into the site’s environmental monitoring strategy, starting with the long-term deployment of Kunak AIR stations.

CONCLUSION

The deployment of Kunak’s sensor-based solutions at BASF Ludwigshafen demonstrates the significant advantages of expanding traditional air quality networks with cost-effective, high-performance monitoring technology. Kunak AIR Pro enables a denser network of sensors, offering reliable & real-time data, remote management, and seam-less integration with existing systems—all with strong correlation to type-approved devices.

This approach not only improves early detection of emissions but also strengthens compliance and enhances public trust. For industrial sites, especially those close to residential areas, implementing a flexible, scalable, and reliable monitoring network like Kunak’s is a strategic move. Investing in such networks is no longer optional—it’s essential for sustainable industrial operations.

Project details

Customer: BASF SE

User: BASF SE

Location: Ludwigshafen, Germany

Sector:

Year: 2025

Parameters:

  • Carbon monoxide (CO)
  • Nitric oxide (NO)
  • Nitrogen dioxide (NO2)
  • Ozone (O3)
  • Sulphur dioxide (SO2)
  • Volatile organic compounds
  • Methane (CH4)
  • Particulate Matter (PM1, PM2.5 and PM10)
  • Temperature, relative humidity and atmospheric pressure

Solutions

  • AIR ProProfessional air quality monitoring station
    Air quality monitor

    AIR Pro

    The most accurate air quality monitoring station

    SENSOR-BASED | BEST AVAILABLE ACCURACY

    Benefits

    • Multi-pollutant
    • Smart cartridge system
    • Fully autonomous
    • Real-time data
    • Proven accuracy
    See more
  • AIR CloudAir quality software
    Air quality software - Kunak AIR Cloud

    AIR Cloud

    Multipurpose air quality software for professionals

    REAL-TIME DATA | ALWAYS UPDATED

    Benefits

    • Secure and condifential
    • Air quality reporting
    • Advanced data analysis and visualisation
    • Reliable data guaranteed
    • Data sharing and integration
    See more
  • Carbon monoxideReliable real-time data on CO
    Carbon-monoxide

    Carbon monoxide

    Reliable information about carbon monoxide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Electrochemical
    • R2 >0.85
    • Range: 0-12,000 ppb (Type A) | 0-500 ppm (Type B)
    • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
    • 24 months of operating life
    See more
  • Nitric oxideReliable real-time data on NO
    Nitric_oxide_cartucho

    Nitric oxide

    Reliable information about nitric oxide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Electrochemical
    • R2 >0.9
    • Range: 0-5,000 ppb
    • Resolution: 1 ppb
    • 24 months of operating life
    See more
  • Nitrogen dioxideReliable real-time data on NO2
    Nitreogen_dioxide

    Nitrogen dioxide

    Reliable information about nitrogen dioxide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Electrochemical
    • R2 >0.85
    • Range: 0-12,000 ppb (Type A) | 0-500 ppm (Type B)
    • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
    • 24 months of operating life
    See more
  • Ozone
  • Sulphur dioxideReliable real-time data on SO2
    Sulphur_dioxide

    Sulphur dioxide

    Reliable information about sulphur dioxide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Electrochemical
    • R2 >0.7
    • Range: 0-10,000 ppb
    • Resolution: 1 ppb
    • 24 months of operating life
    See more
  • Volatile organic compoundsReliable real-time data on VOCs
    Volatile_organic_compounds

    Volatile organic compounds

    Reliable information about volatile organic compounds

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Photoionization detector
    • R2 >0.99
    • Range: 0-3,000 ppb (Type A) | 0-40 ppm (Type B)
    • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
    • 10,000 hours of operating life
    See more
  • MethaneReliable real-time data on CH4

    Methane

    Reliable information about sulphur dioxide

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • NDIR
    • Typical accuracy (MAE): ±3 % F.S.
    • Range: 0-50,000 ppm
    • Resolution: 500 ppm
    • > 7 years of operating life
    See more
  • Particulate MatterReliable real-time data on suspended particles

    Particulate Matter

    Reliable information about particulate matter

    GASPLUG TECHNOLOGY | PATENTED DESIGN

    Specs

    • Optical particle counter
    • Up to R2 >0.9
    • Range: 0-1,000 | 0-2,000 | 0-10,000 ppb
    • Resolution: 1 μg/m3
    • 24 months of operating life
    See more
Air quality monitor

AIR Pro

The most accurate air quality monitoring station

SENSOR-BASED | BEST AVAILABLE ACCURACY

Benefits

  • Multi-pollutant
  • Smart cartridge system
  • Fully autonomous
  • Real-time data
  • Proven accuracy
See more
Air quality software - Kunak AIR Cloud

AIR Cloud

Multipurpose air quality software for professionals

REAL-TIME DATA | ALWAYS UPDATED

Benefits

  • Secure and condifential
  • Air quality reporting
  • Advanced data analysis and visualisation
  • Reliable data guaranteed
  • Data sharing and integration
See more
Carbon-monoxide

Carbon monoxide

Reliable information about carbon monoxide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Electrochemical
  • R2 >0.85
  • Range: 0-12,000 ppb (Type A) | 0-500 ppm (Type B)
  • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
  • 24 months of operating life
See more
Nitric_oxide_cartucho

Nitric oxide

Reliable information about nitric oxide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Electrochemical
  • R2 >0.9
  • Range: 0-5,000 ppb
  • Resolution: 1 ppb
  • 24 months of operating life
See more
Nitreogen_dioxide

Nitrogen dioxide

Reliable information about nitrogen dioxide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Electrochemical
  • R2 >0.85
  • Range: 0-12,000 ppb (Type A) | 0-500 ppm (Type B)
  • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
  • 24 months of operating life
See more
Sulphur_dioxide

Sulphur dioxide

Reliable information about sulphur dioxide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Electrochemical
  • R2 >0.7
  • Range: 0-10,000 ppb
  • Resolution: 1 ppb
  • 24 months of operating life
See more
Volatile_organic_compounds

Volatile organic compounds

Reliable information about volatile organic compounds

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Photoionization detector
  • R2 >0.99
  • Range: 0-3,000 ppb (Type A) | 0-40 ppm (Type B)
  • Resolution: 1 ppb (Type A) | 0.01 ppm (Type B)
  • 10,000 hours of operating life
See more

Methane

Reliable information about sulphur dioxide

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • NDIR
  • Typical accuracy (MAE): ±3 % F.S.
  • Range: 0-50,000 ppm
  • Resolution: 500 ppm
  • > 7 years of operating life
See more

Particulate Matter

Reliable information about particulate matter

GASPLUG TECHNOLOGY | PATENTED DESIGN

Specs

  • Optical particle counter
  • Up to R2 >0.9
  • Range: 0-1,000 | 0-2,000 | 0-10,000 ppb
  • Resolution: 1 μg/m3
  • 24 months of operating life
See more