Anderson Negele’s ILM-4 conductivity sensor with IO-Link

Conductivity sensor with IO-Link

The ILM-4 conductivity sensor with IO-Link is a big step to industry 4.0 in hygienic process technology.

Proven industry standard now also for hygienic and aseptic applications

IO-Link offers advantages in process control and monitoring. The ILM-4 conductivity sensor, the first of a whole range of measuring instruments to be equipped with an additional IO-Link interface, is a well-known and proven conductivity sensor on the market. This will be followed in due course by the sensors ITM-51 for turbidity, NSL-F for level, L3 for pressure and D3 for differential pressure and volume, all based on the modular platform with fail-safe plug-and-play technology with standard cable for time-and-cost-saving installation and set-up.

The (R)evolution of conductivity measurement

IO-Link offers significant advantages over analogue technology when it comes to reliably controlling the entire process technology with many measuring points, control and operating elements. Set-up and installation are easy and cost-effective. A three-pole standard cable is sufficient for the signal transmission and power supply itself. In practice, point-to-point connections are made at field level from various sensors to collection points, so-called IO-Link masters, and from there via Fieldbus system to the control centre.

 

Simple data transfer becomes intelligent communication

With IO-Link, data streams in the opposite direction towards the sensors are now also possible. In this way, the status of the sensor can be checked and specifically queried at any time. This makes it possible to detect potential faults, signs of wear or an increased risk of failure at an early stage and helps to avoid production downtimes.

“Plug-and-play” takes on a whole new meaning

Sensor replacement of the ILM-4 with IO-Link becomes easier and safer than ever before and can be carried out independently, at any time and by any employee without any programming effort. The device configuration of each connected sensor can be stored in the IO-Link Master. Immediately when plugged in, the new sensor is automatically recognized, configured and parameterized by the IO-Link Master.

The new dimension in hygienic measuring technology is digital and analogue, compact or remote. It is: modular

ILM-4 conductivity transmitter with IO-Link creates planning security and flexibility for status control and sensor diagnostics for preventative maintenance avoids production downtime.  The combination with the modular platform, with the separation of sensor and electronic unit in the optional remote version, creates a unique constellation of hardware and software that is unparalleled in flexibility, simplicity and system compatibility.

PETROCHEMISTRY: CHLORINE-ALKALI ELECTROLYSIS

PETROCHEMISTRY 

 CHLORINE-ALKALI ELECTROLYSIS

The chlorine-alkali electrolysis is an important procedure in the chemical industry. The products chlorine, hydrogen, hydrochloric acid and caustic soda are generated from sodium chloride. There are three manufacturing methods: the diaphragm, the membrane and the amalgam process.

The LiquiSonic® analyzer provides an advantageous utilization in the varied process steps of the three methods. Foremost, the customer gains the advantages of a reduction in raw material and energy consumption, as well as an increase in the yield.

 

LiquiSonic® measuring points in the processes of the diaphragm method of the chlorine-alkali electrolysis

 

Preparation of end products

1.1  Caustic soda concentration

The market ready caustic soda (NaOH) typically has a concentration between 45 wt% and 50 wt%. Since NaOH gained from electrolyzer cells only yields a concentration range between 12 wt% and 33 wt%, it is concentrated in cascade evaporators.

If together with NaOH the solution contains NaCl (diaphragm method), the excess salt in the caustic soda precipitates in a crystal form during the evaporation. This way, the NaOH-concentration is elevated to 45 wt% and 50 wt%.

The LiquiSonic® analyzer continuously determines the concentration of caustic soda at any time after evaporation. A subsequent dilution of the caustic soda to a customer specific product concentration, can also be monitored.

ADVANTAGES:

  • Continuous concentration monitoring of the caustic soda
  • Reduction in the energy costs during the evaporation process

1.2 Chlorine gas drying

Water content needs to be removed from the chlorine gas before it is further processed as its corrosives elevate at a moisture content of over 30 ppm. For the drying, the chlorine gas is routed into the absorption towers, where the water content in the chlorine gas is absorbed with highly concentrated sulfuric acid (80 – 99 wt% H2SO4).

The effectiveness of this drying process significantly influences the productivity and quality of the gas. Therefore, a reliable measurement of the H2SO4 concentration is vital. The LiquiSonic® analyzer offers a continuous and safe monitoring of the H2SO4-concentration, in opposition to conductivity and density measurement.

ADVANTAGES:

  • Elimination of labour intensive sampling
  • Continuous monitoring of H2SO4-concentration
  • Clear concentration determination signal between 80 wt% and 100 wt% H2SO4
  • Ensuring the desired Cl2 dryness to avoid corrosion in the system

1.3  Hydrochloric acid production

The chlorine gas that is generated on the anode of the electrolyzer with the added hydrogen form the base materials for the synthesis of hydrochloric acid. Both gases are fed into a burner and react to form hydrogen chloride. Subsequently, the formed HCI-gas streams from the burning chamber into the integrated isothermic falling-film-absorber. Here, the gas is absorbed with the help of water or diluted acid, whereby concentrated hydrochloric acid (37 wt% HCI) is formed.

Using the LiquiSonic® analyzer, a continuous monitoring of the hydrochloric acid concentration is possible. This allows for deviations to be recognized from the target concentration and to react accordingly.

ADVANTAGES:

  • Continuous concentration monitoring of hydrochloric acid (20-40 wt% HCl)
  • Ensuring an extremely precise target concentration

Advantage of sonic velocity as compared to conductivity and density

 

 

Efficient silo management for smooth process flow

Efficient silo management for smooth process flow

The electromechanical Lot system Nivobob® 4000 is equipped with a Modbus function which allows easy connection to visualization systems, thus providing an economic silo management solution.

 

Multifunctional unit for discontinuous level monitoring in bulk goods

 

The electromechanical measurement device is an invaluable instrument in the field of inventory management due to its advanced electronics technology. The reliable electromechanical lot system Nivobob® with its robust mechanical design has for that reason become the choice of many plant operators across the globe faced with demanding conditions. The Nivobob® series of plumb bob sensors is used for continuous level measurement within bulk storage silos and for interface measurement. The simple electromechanical measurement principle is a truly reliable all-rounder in most bulk materials.

 

Nivobob® 4000 with Modbus function

The electromechanical Lot system Nivobob® 4000 is equipped with a Modbus function which allows easy connection to visualization systems, providing an economical silo management solution.

UWT GmbH has developed an economical and practical solution in terms of centralized content level monitoring; especially suited for the storage processes within industrial plants. The maintenance-free electromechanical lot system Nivobob® is mounted on each silo within the plant for continuous level monitoring. The plumb bob systems of the economical Nivobob® 4000 series come standard with a Modbus interface which allows for quick and easy connection of the units to the visualization system.

Parameters such as content level, operating time, pending replacement intervals, sensor status are available to the operator. For level control, diagnostics etc. the license-free visualization software Nivotec® is used: The information is sent from the electromechanical lot sensors to the visualization system via Modbus. The operator can access the required information from any PC 24h a day. The software with its data storage and trend analysis function enables the operator to perfectly plan material disposition and any logistics required. The outcome is efficient silo management resulting in cost saving due to planning security. With this new development UWT has responded to the demands for an affordable solution which combines reliable level monitoring with live-data visualization for effective silo management.

 ADVANTAGES:

  • Communication between Nivotec® visualization software and Nivobob® 4000 lot systems can be    conveniently controlled directly from your PC
  • Modbus RTU interface reduces the installation time by using Daisy-Chain-Wiring
  • Silo full detector can be wired directly to the Modbus RTU interface of the Nivobob® 4000

For more information on UWT products contact Morton Controls today.

The Mining Industry is Booming!

If you are not using quality components in the mining industry, then you are going to miss out.

Quadbeam’s sensors are top drawer and here is why:

Quadbeam Technologies Sensors are products that can be relied on, due to its accurate, rugged construction, and repeatable signal.

It’s excellent performance means you have control of Suspended Solids and Turbidity in the Mining Processes.

What are the S Series bodies manufactured from?

Polypropylene or PVDF are the main ingredients, and they give excellent chemical resistance for challenging chemical environments, often found in mining applications.

Their Application usage for the mining industry is broad-

  • Raw Water intake monitoring
  • Water Treatment processes
  • Control of flocculate dosing
  • Clarifier overflow monitoring
  • Filter breakthrough monitoring
  • Tank Profile monitoring

The Key Benefits are-

  • Provides excellent chemical resistance
  • Repeatable, reliable and accurate signal
  • Long lasting

The Products to look out for are:

The S10-IMM, S20-IMM and T30-IMM

Quadbeam S20-IMM

We have a nice story from the mining industry for you.  Quadbeam, based in New Zealand, had a client, situated in one of the largest rock quarries, who had a problem in their sand and aggregate washing plant.  The problem was with the recycled waste water.

Following a very painful manual process, and umpteenth errors, where the waste water was being fed back to the sand washing plant, they had a Quadbeam S20 suspended solids sensor installed in a vertical section of the  pipe.  This measured, on a continuous basis, the suspended solids in the recycled water.

 

 

Quadbeam S10-IMMThe flow and suspended solids measurements were sent to a PLC, where it calculated the mass flow of the solids and adjusted the dosing pump so that the correct level of chemical addition was achieved.

 

After the flocculation process, the solids settle out in 3 large cone clarifiers.  Then, the clean recycled water is sent back to the plant.

For the last 2 years, the plant has produced consistently clear recycled water, with minimal maintenance involved.

Should this be a situation you wish to rectify, please contact us for more info on Quadbeam’s sensors.

Quadbeam T30-IMM

TELEPHONE: 0861 000 393

EMAIL:  sales@mortoncontrols.co.za / ian@mortcon.co.za

cip system

The CIP System – Within the F&B Industry

In food manufacturing, cleaning-in-place or the CIP system is a standard component for ensuring reliable and efficient adherence to quality standards. The requirements placed on sensors, used for process control, are particularly high in the food and beverage industry.  They are tailored solutions for optimizing the CIP process, using turbidity and conductivity sensors.

What is involved?

The CIP system consists of numerous interlinked steps. Plant operators need to take into account more than just the downtime of the system. Costs also arise from the consumption of water, chemicals and energy, as well as product loss.

The sequence of the individual cleaning cycles is often still time-controlled. These fixed cleaning intervals will guarantee that the system is always cleaned properly.  However, more water, and cleaning solution and time, may be consumed than would actually be necessary for the medium being processed.

What is the solution?

The solution is to automate control of the CIP system using turbidity and conductivity sensors. The average water consumption, depending on the product, is 1.5 to 3 liters per processed liter of product.  Half of this water is used for cleaning the system.

Are there disadvantages?

A disadvantage of cleaning processes with fixed time intervals is that the maximum required cleaning duration must be used for each cleaning cycle. For example, the removal time for pasty media is considerably longer than for less viscous products. Therefore, when performing CIP cleaning after producing media with less viscosity, more water is used than is necessary.

This, however, can be remedied through automated process control using the turbidity and conductivity sensors. Water consumption at large F&B manufacturing plants can be lowered from an average of 6,500 to 2,500 liters per cleaning cycle simply by deploying an intelligent phase detection system. This will result in savings of water and wastewater costs.

In addition, shorter cleaning cycles lead to a lower consumption of acids and bases.  The use of chemicals can be precisely controlled by measuring their concentrations using the conductivity sensor, allowing their consumption to be further optimized.

What are the production-related stats?

Experience has shown that production-related losses reach 0.5% in large operations and 2.5% in small operations. It is particularly the plants with low levels of automation that experience significant losses in product.

The precise and rapid detection of water-to-product phases using the turbidity sensor lead to reductions in product losses of 5–10% in customer field projects. A CIP system usually takes 60–90 minutes. A hygienic design of the entire system is therefore an important contributor to shortening the cleaning cycles and increasing the efficiency and productivity of the process.

How can Morton Controls help?

As a specialist for sensor systems in hygienic processes, we, at Morton Controls, have sensors and process connections that are optimally designed for the demanding requirements of the F&B industry and that ensure reliable and efficient cleaning of the system.

 

 

 

 


 

History Around Coal Mining

We love a little bit of history, and coal mining has an interesting tale to be told.

One of the largest mining industries, mining for coal started out in the 18th century and boomed all the way to the 1950’s.  Although maybe not as huge as some other mined commodities, coal is still a valuable form of energy for open-pit extraction.

Interestingly, tunnelling into the earth to pull the coal was the initial method, but had to be stopped due to the perilous vapours that were emitted (carbon monoxide, carbon dioxide, and hydrogen sulphite) deadly to say the least.

The sensors now used in the coal mining process have helped with detecting these harmful vapours and have progressed from the mining’s canary method.

What is the Miners Canary?

If you know mining, you would have heard of this amazing story.  Very simply, miners would take a canary in a cage down with them as they descended. Canaries were known to be very sensitive to odourless vapours, such as carbon monoxide, and they would show effects of distress, rocking from side to side, before falling off their perches.

While not a very animal safe procedure, it was known to have saved many human lives.  After a time, the canary method of detection was stopped as it proved not to be as effective as they assumed it was.

In steps the Pellistor

The Pellistor was introduced as a catalytic sensor and was able to detect a very wide range of toxic vapours and flammable gases.

Due to limitations, such as malfunction when exposed to chemicals with chlorine, sulphur, halogen, and any metals containing silicon or lead; as well as high costs to maintain the pellistor, this method was withdrawn.

Infrared LED-based Gas Sensor

The more modern and more effective method is the infrared LED – based Gas Sensor.

The advantages of this method are:

  • A wider measurement range
  • A rapid response rate
  • Background gases do not affect the gas sensor, as it did with the Pellistor
  • Each gas can be detected and measured separately