Reliable empty alarm in cosmetics tank

Reliable empty alarm in cosmetics tank

Economy and ecology in harmony through automatic monitoring of the filling line – Reliable empty alarm in cosmetics tank with NCS-L-12/18   

For over 60 years, the French brand Yves Rocher has been synonymous with high-quality cosmetics based on vegetable raw materials. The company is strongly committed to ecological issues and biodiversity. Even small factors such as the optimal use of raw materials play a role.

  1. The application

The filling systems for cosmetic creams were previously controlled manually. The filling level in the buffer tank had to be monitored by an employee and the filling process had to be stopped manually at the appropriate moment.

In order to prevent the filling pump from running dry, the process was stopped for safety reasons at an early stage, leaving important quantities of cream in the tank. This residual product was then disposed of, resulting in a significant loss of value.

Application advantages

  • Significantly lower product losses due to optimal emptying of the tank during filling
  • Precise measurement results despite high viscosity of the cream and corresponding adherences to the sensor probe
  • No manual control and monitoring required
  • Fast amortization through reduction of product losses and time savings for employees
  1. The solution

With the NCS-L level sensor, the filling process is automated. Due to its special sensor shape with 18 mm length and its measuring method with an extended measuring range, the NCS-L-12/18 is particularly suitable for low-water, viscous media such as oils, syrups or even cosmetic creams. Due to its inline integration in the outlet pipe of the filling system, the sensor signals safely and reliably as soon as the cream is depleted, thus stopping the filling process automatically.

  1. The result
  • Cream losses are minimized.
  • The quantities of waste to be disposed of (cream remaining in the tank) is reduced.
  • Impurities (splashes due to dry running of the filling pump) are avoided.
  • Maximum process reliability for the personnel operating the filling system
  1. Sensors used in the application

NCS-L-12/18                   NCS-01, NCS-M, NCS-L-31P

       4.1 Point level NCS-L-12/18

 Advantages:

  • Limit level detection even with media with low water content such as syrup, fruit concentrates, alcohols and oils with εr (Dk) ≥ 2
  • Reliable indication even with strongly adhesive media due to capacitive measuring principle
  • Very short response time

4.2 NCS-01, NCS-M, NCS-L-31P

Advantages:

  • Insensitive to foam and adhesions
  • Different sensor lengths for adaptation to all installation situations in pipes and vessels

 

 

 

 

Tailor-made solutions for the textile industry – UWT solution in acetone

 

Tailor-made solutions for the textile industry – UWT solution in acetone

Single-rod probes using the capacitive measuring method are in many cases a clever solution when it comes to level detection. They can be found in overfill protection and as demand or empty detectors in process or storage containers. These limit switches are suitable for almost all bulk materials from different industries, due to high sensitivity, high mechanical load and a variety of probe extensions. But these qualities also make them a suitable solution in the fascinating world of varied liquid applications, be they in food, wood, rubber, plastics, environmental and power plants, building materials, and chemical industries.

Tailor-made solutions - UWT solution in acetone

Capacitive sensor RFnivo® RF8100 for point level measurement

The use of the RFnivo® capacitive rod within the textile production process featuring the aggressive substance of acetone.

Satisfied by a classic solution – The Rotary Paddle Level Switch

A synthetic fibre company producing a wide range of polyester textile yarns, geotextiles and carbon, and heat resistant polypropylene materials, for products such as special protective clothing or packaging solutions in agriculture and construction have successfully installed Rotonivo® devices for different powders and granules in several process vessels. Depending on the requirements, they function as full, demand or empty detectors and, thanks to their simple electromechanical measuring principle, can also be adapted to extreme process conditions, such as high temperatures up to +1,100°C. The RN rotary paddle is mainly used for storage and drying of plastic particles as a full detector as well as in dosing tanks and extruders for demand reporting. During conveying processes, it works as an overfill detector. For protection against temperatures of below -20°C, a heating function was integrated in the electronics.

Level measurement in clean and contaminated acetone within the textile industry: Capacitance solution in acetone tanks for overfill protection and empty detection

As the synthetic fibre manufacturer was satisfied with the rotary paddle detectors, they also required a measuring solution from UWT for their acetone containers.  Preliminary tests in the solvent tanks were conducted.  During synthetic fibre manufacturing, acetone is used to impregnate the fabric. Each fabric to be produced is passed through a bath of clean, pure acetone, where amongst others excess epoxy resin, which is used for bonding the fibres, is washed off. Most of the resin is usually cured after the heat treatment, non-hardened epoxy resin can be removed during this process step. Thereafter, the acetone is considered polluted and enters a separate tank, where it is cleaned in a special mechanical process. Subsequently, the purified solvent is filled in the tank container with so-called regenerated acetone.

Acetone is an extremely aggressive substance that secretes corrosive vapors and quickly corrodes ordinary materials. For the individual tanks with clean, contaminated as well as regenerated acetone the synthetic fibre manufacturer needed a reliable, and at the same time robust, level monitoring system. Tests carried out with a variety of sensors made it clear that the robust RFnivo® probe was the most favorable solution. The RF series consists of single-rod probes that require, due to their design, no temperature-limiting components for media detection and can, therefore, be used in processes of up to 500°C.

They work with the capacitive measuring principle, whereby the capacitance is detected independently of the length of the sensor of the medium between the probe and the container wall.

 

The customer has different tanks measuring from 1.2 to 1.6 meters in diameter. Apart from a reliable measurement, even with frequently occurring pressure fluctuations, it was also essential that the sensor carried a corresponding certificate according to gas explosion protection (Zone1). Firstly, each tank was equipped with an RF probe (standard version) for full signal, that ensured reliable protection against the overfilling of the acetone containers. Secondly, an empty detection system was installed in each container, that switches on time to prevent dry running. As it is common that the sensor probe is exposed to the acetone and the aggressive molecules of the acetone vapour for longer periods of time, especially during the empty detection process – it was realized that an extra robust version of the device was required. The capacitive single rod was thus refined – 1.4404 (316L) stainless steel and PPS isolators were used with a FFKM seal in the product-contacting probe.

The FFKM seal (perfluoroelastomer / perfluoro rubber) has a particularly high chemical resistance against aggressive materials. Perfluoro rubber is considered as the new generation plastic. It is a true high-tech elastomer, which is always used when special demands are placed on resistance to chemicals, temperature, and form. The equipping of the probe seals of the capacitance level indicator with the highly robust polymer made them resistant to the acetone. Clean and regenerated as well as contaminated acetone tanks can be similarly monitored using the capacitive measuring principle.

The Active Shield Technology, which is integrated into the RF probe as standard, also ensures that the measurement result will not be affected by any build-up on the sensor probe. A total of 16 acetone tanks could be fitted with a reliable content monitoring, which meant the optimal support of a smooth and maintenance-free manufacturing process for the synthetic fibre producer.

What is important to the operator?

The RFnivo® calibrated itself after mounting and wiring in the box after power was applied. The operator had to do nothing further but set the signal output in the Quickstart menu after application. If a RFnivo® is used in an application to which the supply voltage has already been applied, only the calibration button needs to be pressed after installation in the container. The probe automatically adjusts to the new application. Thus, the calibration of the RFnivo® is easily performed. For “diehard” RF probe operators, there is also a powerful manual and menu-driven calibration. This ultimately leads to the same result as the automatic calibration. The universal voltage electronics are clearly equipped with a display and 3 control buttons and provide a DPDT signal output for signal evaluation. During operation, the display will always show the capacity measured at that moment. Parameters such as FSH (fail save high) and FSL (fail save low) as well as reaction time of the signal output can be clearly arranged in a quick start menu. A test button allows the manual start of a self-diagnosis of the sensor. If required, an automatic self-diagnosis can be set, which then regularly checks the correct function of the RFnivo® and activates the failsafe in case of error. This self-diagnostic runs in the background without affecting the function of the probe in the application. A simple operating system was integrated into the capacitance limit switch, which can be easily operated.

 

UWT’s Rotary Paddle switch for point level measurement

UWT’s Rotary Paddle switch Rotonivo® RN 3002 with rope extension for point level measurement

Limit detection is required in most silos and containers to avoid overfilling or unnecessary downtime. The sensor needs to deal with an assortment of process conditions within a wide range of industries.

Contingent upon the necessities, the Rotonivo® rotary paddle switch is utilized as a full, demand or empty detector in storage silos or process vessels and is suitable for use in almost all solids. With its simple electromechanical measuring principle, it can also be adjusted for extraordinary process conditions.

A motor-driven shaft causes the vane to rotate. Once the material level reaches the vane, thereby preventing further rotation, this creates a torque, which is converted via a switch to an electric signal. Once the vane is free again of the material, the output signal is reset, and the motor-driven shaft rotates again.

This dependable and maintenance-free limit switch for safe level detection in bulk solids has international approvals for use in gas and dust hazardous areas and is also certified to SIL

The RotoNivo offers a universal voltage power supply, 24VDC to 220VAC. It can be connected to the same unit without any alterations being made and with the absence of additional power supply to the unit, for example in very old plants, is completely nullified. This makes it easy for a processing plant to keep one version in stock that can be used in various applications on different parts of the plant.

UWT suits the unit to your application, to ensure complete reliability and effectiveness.

Features:  Suitable for most bulk solids

  • Reliable, easy to operate and maintenance-free measurement principle.
  • Unaffected by dust, electrostatic charging and caking.
  • Compact, rotatable electronics housing for easy installation.
  • Mechanically stable shaft bearing design with ball bearings.
  • Process seal with radial shaft seal.
  • Robust aluminium die-cast housing.
  • International approvals for use in potentially explosive atmospheres (dust)
  • Varying shaft lengths available.
  • Enclosure IP66 as standard.
  • Wide range of process connections and supply voltages available.
  • RoHS compliant.

Anderson-Negele provides application-specific hygienic Sensor solutions

Morton Controls in partnership with  Anderson-Negele provides application-specific hygienic sensor solutions and support for safe processing in the Food & Beverage and Pharmaceutical markets.

TFP-164

TFP-164 Flush Temperature Sensors – Temperature Measurement in vessels and pipes with flush Hygienic process fitting.

APPLICATIONS:

Applications include monitoring of temperature measurement in vessels with agitators and stirrers and in pipes where an inserted probe is not suitable.

FEATURES:

  • Product contacting materials compliant to FDA
  • Sensor completely made of stainless-steel resp. PEEK (front flush sensor)
  • Conforming to 3-A Sanitary Standard 74-06 for front flush sensors
  • Front flush mounting possible
  • Integrated transmitter optional
  • Different electrical connections available

P41


P41 Pressure Sensors – Pressure transmitter device for hygienic pressure monitoring for various applications in breweries, dairies and food & beverage industries.

APPLICATIONS:

Sanitary pressure measurement in pipes and tanks for process temperatures up to 250 °C for ranges from 0.2 to 40bar.

FEATURES:

  • Hygienic process connection with G1/2″ & G1” CLEANadapt
  • Rapid response time of < 10 ms
  • Vacuum-proof
  • Full stainless-steel body & easy installation
  • Electrical connection with M12 plug connection
  • Available with relative or absolute measurement cell
  • Built-in two-conductor measurement converter 4…20 mA

HM-E

HM-E Turbine Flow Sensors – Measurement of flow rate and volume in hygienic applications.

APPLICATIONS:

Designed for hygienic applications in food-, beverage- and pharmaceutical Industries e.g. Process water, demineralized water, aqueous media such as filtered fruit juice or beer, alcohols, light oils, saline solutions, cleaning agents, and acids.

FEATURES:

  • High quality and hygienic alternative to industrial, non-hygienic turbine, paddle wheel or variable area flowmeters
  • Economical alternative to mass flowmeters in non-conductive, low-viscosity media
  • Cost-effective and compact alternative to magnetic-inductive & Coriolis flowmeters
  • Hygienic design, confirmed by 3-A & FDA certification

NCS-M-12

NCS-M-12 Level Sensors – capacitive limit detection in metallic vessels and pipes with hygienic thread G1/2″ (CLEANadapt)

APPLICATIONS:

Limit detection of fluid also with low or no water content like syrup, fruit concentrates, alcohols and oils with a dielectric constant εr (Dk) ≥ 2

FEATURES:

  • Hygienic process connection with CLEANadapt
  • Conforming to 3-A Sanitary Standard
  • All wetted materials are FDA-conform
  • CIP- / SIP cleaning up to 143 °C / max. 120 minutes
  • Compact installation size
  • Capacitive measuring principle
  • Independent of the medium conductivity
  • Insensitive to foam and adherence
  • Very short response time (< 100 ms)

Save time and money with Quadbeams suspended solids sensor/turbidity meter

Quadbeam Technologies’ Stormwater and Wastewater Sensor, the SWW, is a unique suspended solids sensor/turbidity meter.  The intended use of the S20-SWW and S40-SWW sensors is the continuous monitoring of Suspended Solids concentration in a non-hygienic industrial, stormwater, raw water or wastewater installation.

Quadbeam uses the four beam alternating light ratio-metric system of measurement for its sensors. Suspended Solids Sensors and Turbidity Sensors measure the change in light intensity to produce a relative measure of the solids or turbidity concentration in the liquid being monitored. Other suspended solids sensors and turbidity meters use only a single beam of light. When a single beam of light is used light intensity can be influenced by not only the solids particles suspended in the liquid, but also any solids/contamination that are stuck to the surface of the sensor and variability of the light source and photo diode as they age. It is therefore critical to keep single beam sensors very clean for accurate readings.

Multi-beam sensors measure across multiple light paths allowing them to use mathematical algorithms where the change in ratio of intensity of light is measured. This system automatically compensates for contamination stuck to the surface of the sensor and variation of the light components in the sensor. For this reason, it is common for multi beam sensors to be used in Process Control installations where a repeatable output is very important.

Applications:

The Quadbeam SWW sensors can be used in a wide range of Turbidity and Suspended Solids Monitoring and Control Applications, including;

  • Stormwater Sediment Monitoring and Control
  • Wastewater Suspended Solids Monitoring
  • Flocculant Dosing Control
  • Environment Turbidity Monitoring
  • Raw Water Supply
  • Remote Turbidity Monitoring
  • Irrigation Water Turbidity Monitoring

S40-SWW

S20-SWW

 

CHEMICAL SAVINGS DURING CIP

CIP-cleaning in the food processing industry

CIP-cleaning facilities are primarily used in those installations wherever supreme necessities are demanded for hygiene and product safety, such as dairies, breweries and in food production. Throughout this process the complete production facility, including tanks and conducts, are purged and rinsed with cleaning agents and water in several cycles.  The aim of Cleaning-in-Place (CIP) is to remove product residues and microorganisms from all wetted surfaces inside tanks, pipework and filling machines while not disassembling the plant. To warrant optimum and economical cleaning, all parts in direct contact with the product must be made according to the principles of hygienic design.  Anderson-Negele’s motto “Hygienic by Design” is an expression of commitment that sensors fulfill this superior demand of the food processing industry in an exemplary manner.

Sequences of a CIP-cleaning within the example of a dairy

The CIP cleaning process takes place in several coordinated process steps. In the first step remains of the product in the installation are extruded and adhering particles removed in the pre-rinsing process. In the next steps, organic traces are eliminated with caustic and mineral deposits by use of acid. Subsequently, the facility is rinsed with fresh water and thus prepared for the next production step.

  1. Pre-rinsing (water)
  2. Cleaning (caustic)
  3. Mid-cycle rinse (water)
  4. Cleaning (acid)
  5. Rinsing (freshwater)

 

Optimization of the CIP Process

A CIP cleaning process in commonplace applications lasts between 60 and 90 minutes. The operator of a production facility consequently suffers from downtime in production capacity leading to a loss of products, and from increased cost for the consumption of water, energy and chemicals.

The hygienic design of the complete production facility and automatized processes are key factors for a reduction of the cleaning cycle times and for an increase in the efficiency and productivity of the process itself. Being an experienced specialist for sensor technology in hygienic environments, the sensors and process connections from Anderson-Negele are perfectly adapted to the requirements of the food industry and ensure the safe and economical cleaning of the facility and installations.

Why Morton Controls together with Anderson-Negele’s ILM-4 could help you

 The analysis of the return media is one of the most important steps for an environmentally friendly and cost-efficient process. The ILM-4 inductive conductivity meter plays a central role in precisely determining the phase separation: during the discharge of the liquids at each cleaning stage the media are differentiated with cost-saving accuracy.  Re-usable cleaning agent that flows off after cleaning can thus be returned to the tank to the maximum possible degree. In a separate, internal circulation and for permanent optimum cleaning result, its concentration is adapted to the specified ideal value by re-dosing with detergent and fresh water in the cleaning agent tank. The ILM-4 conductivity meter also ensures the highly precise measurement of conductivity and temperature required here.

Inductive Conductivity Meter ILM-4

The ILM-4 is designed for hygienic applications in food-, beverage- and pharmaceutical industries and controlling of CIP processes (e. g. phase separation detergents/water). The ILM-4 is currently equipped with the IO-Link in parallel.  IO-Link offers important benefits over analog technology when it comes to reliably controlling the entire process technology with a variety of measuring points, control and operating elements.

FEATURES/ADVANTAGES

  • CIP/SIP cleaning up to 150 °C/maximum 60 minutes
  • Wear-free, inductive measurement
  • In contrast to conductive measurement procedures, no problems with electrode deterioration or polarization.
  • Accurate measurement through compensation of temperature influences.
  • High reproducibility of ≤ 1 % of the measurement value.
  • Analog outputs for conductivity and temperature are a standard feature.

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

  • Analog outputs for conductivity, temperature or concentration are freely adjustable.
  • Rapid temperature response time T90 15…60 s
  • Installation in tube diameters from DN 40

 

For more information please contact the Morton Controls team:  0861 000 393, sales@mortoncontrols.co.za, www.mortoncontrols.co.za

 

Anderson-Negele’s NCS-M Capacitive Level Sensor with the MPI-300 programming adapter

 

In combination with theMPI-300 USB programming adapter, the NCS-M sensor can be individually adapted to the application used by the customer. In addition to setting the device to the appropriate medium, switching threshold, hysteresis and time delay can also be individually configured.

 

Application examples of the capacitive level sensor:

  • Limit detection in vessels or pipes
  • Product monitoring in pipes
  • Pump/dry running protection
  • Detection of syrup and fruit concentrate

 

 

 

 MPI-300 USB programming adapter in combination with the NCS-M sensor

  1. NCS-M-12:
  • Version with enhanced measurement range for critical media (e.g. Oil, Fat)
  • No adjustment necessary
  • The switching threshold, hysteresis and time delay parameters can be set for the sensor for complex applications
  • Insensitive to foam and adherence
  • Very short response time (< 100 ms)
  • IP 69K

2. The MPI-300:

Adapter for the universal programming of the NCS-M capacitive level sensor family. Level detection even for media with a low or no water content such as syrup, fruit concentrate, alcohols and oils with a dielectric constant εr (Dk) ≥ 2.

The switching threshold, hysteresis and time delay parameters can be set for the sensor.

How to get the most from your Feed Plant

How to get the most from your Feed Plant

UWT in partnership with Morton Controls have the solutions for the Animal Feed Industry

The process and storage environments within the feed industry sector often have factors such as moisture, vapor and fat to consider which cause the materials to have caking tendencies.  In order to withstand and remain fully operational, UWT devices have special coatings which in turn provides the customer with economically viable solutions.  With years of experience within the feed industry and the continual research and development of measurement technology, UWT sensors offer wide and innovative versatility.

Reliable measurement technology for versatile solutions within the animal feed industry

The production of high-quality animal feed and pet food is an important economic growth sector. As well as livestock feed, this sector also includes pet and sports animal nutrition.

The requirements of animals in terms of nutrition are diverse and so a variety of mixed feed formulations is manufactured. Accordingly, the focus of the measuring technology equipment in the manufacturing plant is on the ability to easily and quickly adapt to the varying processing conditions. The formulation of a compound feed is based on the particular use for which the product is intended. Similarly, the use of appropriate measuring sensors is in accordance with the relevant requirements of the application.

The level sensor is an indispensable element of the technical equipment within a modern feed production plant for the detection and monitoring of levels and limit levels within the different process stages. All UWT devices are designed to allow easy integration into the various processes and are characterized by being completely maintenance free in accordance with the principle of “install and forget “.

  1. UWT Portfolio

UWT provides sensors for the measurement of level and limit level in bulk solids and liquids. Depending on the medium and application, different measurement techniques are used as well as a range of complete systems for level monitoring and visualization. The product lines include not only an economic standard but also particularly high grade, premium versions. UWT devices are completely maintenance-free and, importantly, carry international certificates.  All limit switches are available with universal voltage electronics as standard or as an option.

1.1 Sensors for Level Detection:

Rotary Paddle Level Switch – Rotonivo® Series 3/6

  • Variable extension lengths – either rope or tube
  • Extension and process connection available in stainless steel
  • Adjustable sensitivity
  • EHEDG compliant
  • Suitable for use in high temperatures of up to 1,100°C
  • Modular design
  • Rotonivo® 6000 SIL 2 compliant
  • All-rounder suitable for all applications
  • Wide variety of configuration options

Rotary Paddle Level Switch – Rotonivo® Series 4000

  • Variable extension lengths – either with pendulum shaft or rope extension
  • Version with plastic housing and process connection
  • Various process connections
  • Adjustable sensitivity
  • Modular design
  • The plastic design offers increased corrosion resistance

Vibrating Fork Level Switch – Vibranivo® Series 1/2/5/6

  • Variable extension lengths – either rope or cable extension
  • Extension and process connection available in stainless steel
  • Sensitive to the lightest bulk materials (< 5g/l)
  • EHEDG compliant
  • Version with separate housing available
  • NAMUR-electronics
  • Suitable for interface measurement within sediment tanks/containers

Vibrating Fork Level Switch – Vibranivo® Series 4000

  • Variable extension lengths – either rope or cable extension
  • Extension and process connection available in stainless steel
  • Extension, process connection, and oscillators cast from one mold
  • Sensitivity from 30g/l

 

Vibrating Single Rod Level Switch – Mononivo® Series 4000

  • Variable extension lengths – either rope or cable extension
  • Heavy mechanical loading
  • High-quality material in the process (SS 316L)
  • High surface quality
  • Sensitivity adjustable in 4 settings
  • Temperature range from -40°C to +150°C
  • Robust version
  • Suitable for overpressure up to 16bar
  • Compact Limit switch with threads from 1″

Capacitive Level Switch – RFnivo® Series 3000

  • Variable extension lengths – either rope or cable extension
  • Extension and process connection available in stainless steel (Stainless steel probe material with FDA conformity)

  • Version with plastic coated extension available
  • Can be used in low dielectric values from 1.5 DK
  • EHEDG compliant
  • Suitable for use in high temperatures of up to 500°C
  • Suitable for use in process pressures of up to 25bar
  • “Active Shield Technology” for anti-caking functionality
  • Available as remote version
  • User-friendly parameter setting via display and function buttons with measurement results given also via display
  • Simple automatic calibration at startup

Capacitive Level Switch – Capanivo® Series 4000

  • Variable extension lengths – either rope or cable extension
  • The version available with plastic housing, process connection, and extension
  • Extension FDA compliant
  • Can be used in low dielectric values from 1.6 DK
  • Suitable for use in high temperatures of up to 180°C
  • “Active Shield Technology” for anti-caking functionality
  • Integrated earthing in-process connection
  • No calibration required

1.2 Sensors for Level Control:

Electro-mechanical Plumb Bob Sensors – Nivobob® Series 3000

  • Measuring range up to 50m (silo height)
  • Easy commissioning
  • Rope and tape version
  • Integrated tape cleaner
  • Threaded or flanged process connection
  • Modbus and Profibus interface
  • Reliable measurement results independent of material
  • Suitable for interface measurement within sediment tanks/Containers

Electro-mechanical Plumb Bob Sensors – Nivobob® Series 4000

  • Measuring range up to 30m (silo height)
  • Easy commissioning
  • Rope and tape version
  • Integrated tape cleaner
  • Threaded or flanged process connection
  • Aiming flange for angled installation

Radar sensor – NivoRadar® 3000

  • Measuring range up to 100m (silo height)
  • Aiming flange model
  • Robust stainless-steel housing IP68
  • High sensitivity (DK ≥ 1.6)
  • Temperature solution up to +200°C
  • 78 GHz technology
  • 4° beam angle
  • Lens antenna and mounting flange are flush
  • Integrated lens cleaner
  • Simple, six-step commissioning

Visualization – Nivotec® Series 2/3/4

  • Web-based visualization solution
  • Level monitoring and analysis via ethernet
  • Remote access via internet option
  • Complete system for plug and play
  • Sensor interface for 4-20mA or Modbus RTU
  • Expandable to monitor up to 15 or 30 silos within a plant
  • Full, empty, demand, fault alarm via email option
  • Signal output for silo full alarm
  • Effective silo management

Complete system for:

  • Level indication
  • Trend display
  • Data storage
  • Remote fill level analysis

The main processes involved in the production of feed are storage, weighing and mixing with conditioning, pelletizing, followed by cooling and crushing. There are also other processes such as extrusion, conveying and dosing applications. UWT level technology is used in almost all sectors, for level indication or to control limit levels for all bulk solids.

 

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