PETROCHEMISTRY: CHLORINE-ALKALI ELECTROLYSIS

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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

 

 

sensors

Precise Measurement with Sensotech’s Liquisonic Sensors

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For a more precise and quicker measurement of concentration and density, look no further than the Sensotech Liquisonic Sensors.

 

In particular Sensotech have had much success in the many sectors from chemical to the  brewing industry. While they use a standard system, there is also fine-tuning to customise the solution to the specific food industry specifications and hygienic requirements.

 

INSTALL AND FORGET

It is rare in an industry, where keeping tabs is the norm, to find a company that promotes walking away and letting the system manage the process alone. And that really is the case here! Sensotech’s Liquisonic sensors are that in tune, that once they have been set up correctly, they will monitor continuously.

 

Multiple signals are sent out every second and combined into one compensated signal. The temperature of the medium and the drifts are taken into account during single measurements. No matter what is happening with the conductivity and colour of the medium, the measurements continue. They are also resistant to pressure shocks.

 

The Liquisonic sensors are manufactured to be maintenance and drift-free for a period of 15-20 years. If you were concerned about drift in measurement before, no need to with SenorTech.

 

WHAT IS THE UNIQUE CONCEPT BEHIND THESE SENSORS?

sensors

The fast reaction time of these sensors using absolute sonic velocity as a well-defined and retraceable physical value means phase separation is quicker than before, with more accuracy. You are getting a reproducible physical signal that is quite unique handling temperature rangers of  up to 180 °C or 200 °C and can be use in explosion areas as well.  Solid rugged sensors for a precise and fast density and concentration measurement using absolute sonic velocity as a well-defined and retraceable physical value.

The positioning of the Liquisonic sensors is key in the application, be it in the main vessel or piping. The sensors are available to suit your process connections, such as tri-clamps, varivents or flanged.

The electronics can be housed inside a enclosures form polyester to stainless steel casing (IP 69) or in an existing cabinet.

 

THE STORAGE OF DATA

 

The Sensotech  controller can have up to four sensors connected for management of up to 32 (optional 99) products with an output of concentration and temperature, trend chart for a fast process course overview with  simple parameterization, e.g. of periphery analog and digital outputs, fieldbus, and Ethernet. It has a automatic self-monitoring function with a simple installation und intuitive operation for recording of events, e.g. exceeding of thresholds or change of product plus long-term memory of measuring results and user management with authorization levels. Remote operation via browser (PC, tablet, etc.)standard is to provide data storage that is situated internally as well as a card slot this way you can store the measurements for longer periods of time.

 

LET’S TALK APPLICATIONS

 

There are many variations and applications where the Liquisonic sensors can be applied. Namely:

 

Phase Interface Detection

Gas Scrubber Control

Concentration & Density Measurement

Refrigeration Cycle Monitoring

Evaporator

Neutralization

Incoming Goods Control

Bath Monitoring

Polymerization Monitoring

Solids control in pulp and paper (green, red and black liquor)

 

sensotech emergency vent scrubber

The Emergency Vent Scrubber – why it’s important to monitor

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WHY THE EMERGENCY VENT SCRUBBER

Within the chemical industry, it is important to get rid of environmentally hazardous or toxic gases and vapours.  And, this is where the Emergency Vent Scrubber comes into play.

Typical gasses and vapours that are removed are chlorine, bromine, phosgene, sulfur dioxide, NOx, HF and ammonia.

emergency vent scrubber

HOW DOES IT WORK?

The scrubbing liquid of an emergency vent scrubber circulates and is continually in contact with the gas stream to be cleaned. If toxic or environmentally hazardous chemicals are included in this stream, they will be absorbed.

SensoTech inline analyzers are often used to moni­tor the scrubbing liquid, which improves the system stability and quality.

The LiquiSonic® 40 analyzer allows the concentration measurement of 3-components-liquids (normally the scrubbing liquid, the concentration of NaOH and salts (NaCl and Na2CO3).  This is due to the parallel detection of two physical quantities, such as sonic velocity and conductivity.  The process is very sensitive.  If the NaOH content is under limit, it must be re-dosed. In case of too high salt content, the salt must be removed from the circulation stream, to prevent crystallization in the system and blocked nozzles.

emergency vent scrubber

WHAT IS THE CUSTOMER VALUE COMPONENT?

Because Sensotech’s LiquiSonic® analyzer provides a precise inline concentration measurement with real-time monitoring, they are able to provide true accuracy.

In addition, because of the automatic control, a sufficient level of scrubbing liquid is kept, which then keeps the scrubber at its perfect absorption efficiency.

There is a substantial reduction in labour costs, time saving of at least 1 day, and of course a saving on material use.

 

INSTALLATION PROCESS?

Installation is a breeze.

The LiquiSonic® immersion sensor is easily installed directly into pipelines. A typical installation point, combined with a conductivity meter, are DN 80 pipe­lines from the scrubber to the regeneration tank.

The robust sensor construction and the optional spe­cial materials, like HC2000, promote long process life.

The LiquiSonic® controller 40 is connected to the LiquiSonic® ultrasonic sensor as well as the device for the second physical value (conductivity meter). The cont­roller displays NaOH concentration and salt content.

 

For more on the Emergency Vent Scrubbers from #Sensotech, please make contact with us.

 

 

metal industry

The Metal Industry & Sensotech

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The metal industry offers its own set of challenges.  Sensotech has the know-how and solutions. 

The Applications

The analyzer LiquiSonic® has many applications in the metal industry:

  • concentration measurement in pickling baths
  • concentration measurement of rolling and cutting oil emulsions
  • acid regeneration
  • electrolytic galvanizing
  • roller chrome plating

SensoTech analyzers are ideal instruments for the rugged process conditions encountered in the metal and mining industries. The sensors allow precise control and accurate measurements, despite extreme temperatures, pressure and other harsh environments.

 

Unbeatable Utilization Rates

Where accuracy is critical, or where high pressure, high temperatures or sensitive processing environments make sampling impractical or impossible, SensoTech analyzers are ideal for monitoring inline processes.

LiquiSonic® sensors are engineered for tough industrial processes including Class I Division 1 Hazardous Area installations.

A rugged housing is crucial for protection and high mechanical stability, especially needed in the metal industry. Depending on the sensor type, our housings are able to withstand temperatures up to 200 °C or 392 °F, rated pressures up to 500 bar or 7,250 psi and are resistant to lye, acids and solvents. LiquiSonic allows you to automate manual operations and achieve a new level of productivity and process control.

The fundamentals for this quality are the high-grade materials used such as stainless steel, PTFE and PFA, alloy steels or tantalum. The sensor design consists of one homogenous body and requires no gaskets.

 

Well Connected
Our sensors may be equipped with all common process adapters and fittings and can be used under the most complex application conditions that the metal industry offers.

By changing immersion lengths or process adapters, our sensors fit into tanks and vessels of almost every design as well as directly in any size tube.

Because the measuring technology is not dependent on color, turbidity or other optical attributes, the user will have no limitations, even under the most challenging application conditions.

Products and Process may change
Every LiquiSonic® system can be easily adapted as various process conditions are modified. The Controller software manages up to 256 various product characteristics. Depending on the user access rights, these characteristics may be activated after the sensor is replaced or after the process conditions change.

This concept ensures the return of your investment and decreases your response time on changing boundary conditions. For new applications, you can create a new calculation model using process reference values together with our highly sophisticated SonicWork software.

Individual Interfaces
SensoTech is able to offer all current and emerging standards of signal processing. For continuous concentration and density measurement, 4-20 mA in 2-wire loop power (or 4-wire technology), Profibus PA or Foundation Fieldbus are available. For alarm level detection and switching a non-contact output or a relay can be configured. SensoTech analyzers can always conform to your installation needs.

Sensotech

Sensotech Immersion Sensor 40-40 Ex

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Measuring can be so simple: Sensotech’s sensors have no moving parts that can wear out or age, they are completely maintenance-free and feature a robust and completely enclosed design that does not require gaskets, moveable parts or “optical windows” to the process.  The Sensotech Immersion Sensor 40-40 covers all these bases.

Sensotech do not compromise on materials: the standard version of their sensors are made of stainless steel DIN 1.4571 (SS 316Ti). Sensotech also offer special alloys, such as Hastelloy, Titanium and Tantalum or various plastic coatings for chemically aggressive substances that require corrosion protection measures.  Sensotech’s Immersion Sensor 40-40 is available for different applications.

The measuring method is independent of conductivity, colour and transparency of the liquid and has excellent reliability. The user achieves an accuracy between 0.05 % and 0.1 % by weight. In addition to the sonic velocity measurement, all LiquiSonic® sensors have an integrated temperature measurement.

Sensotech 4040

Typical applications are:

The Sensotech Immersion Sensor 40-40 Ex is perfect for all applications in hazardous areas.

Here are the features:

  • Can withstand temperatures between -20 °C to 120 °C
    with an option up to 150 °C
  • The pressure level is standard from 16 bar up to an optional 500 bar
  • The material is made from stainless steel or hastelloy, but can be purchased in titanium, tantalum, zirconium, monel and others
  • The standard process connection is the flange DN 50 or the ANSI 2”
  • The process housing is the IP65
  • The diameter of the sensor head & bar is 40 mm
  • The standard immersion length is 92 mm, but can be increased to between 150 mm and 2000 mm
  • Sensotech’s Immersion Sensor 40-40 Ex is explosion proof

Contact Morton Controls to order:

TELEPHONE: 0861 000 393

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

Morton Control’s Product Brief – Sensotech –  LiquiSonic® Plato

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For use in the beverage industry, the LiquiSonic® Plato inline analytical technology works well with wort boilers, wort coolers, filtration, blending, filler and mixed and soft drinks processes.

The LiquiSonic® Plato system is an inline analytical system based on most advanced technologies. By the precise and temperature-compensated measurement of the absolute sonic velocity the concentration of different liquids, e.g. original gravity, extract or alcohol, can be detected.

Depending on the specific application, LiquiSonic® Plato consists of one or more intelligent sensors and one controller linked by a bus cable with each other. Investment costs are comparatively low, in particular, for a maximum of four sensors combined with only one controller suited for almost any distance between the individual measuring points.

Advanced production and calibration processes do not only enable highly accurate measurement results, but also the extremely comfortable operability of the system.

Using the latest digital signal processing technology ensures a highly accurate and fail-safe measurement of the absolute sonic velocity and concentration.

In addition, integrated temperature sensors, a sophisticated sensor design and the know-how resulting from numerous series of measurements and many applications guarantee a high reliability

of the system with a long lifetime and minimum maintenance efforts. 

MORTON CONTROLS FOR MORE INFO:

TELEPHONE: 0861 000 393

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

Sensotech – Steel and Rolling Mills

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In the steel production, Sensotech uses the LiquiSonic® measuring technology, which optimizes operations.  The reason, briefly, for using this technology is because of the possibility of saving chemicals, such as acids and cooling lubricants, without influencing the surface finish negatively.

We will explain the following processes in this blog: Pickling and Acid Regeneration.

To catch up with us on the other processes, namely, Cold Rolling, Electrogalvinizing, and Roller Chrome Plating, tune in for another blog coming soon.

Pickling

Pickling baths are used downstream of the hot rolling process, and also in many other fields in the metal-working industry, to remove, passivate, modify, and clean surfaces in a defined manner.

And so, pickling solutions are employed, which consist mainly of a mixture of mineral acids.  The concentration of these acids decreases during the pickling process, however the portion of distributing components, such as contaminations and carry-over increases.

The LiquiSonic® Measuring technology provides a solution for online measurements of pickling bath concentrations facilitating redosing of the required quantity of fresh acid.  This ensures a continuous optimum pickling bath quality.  Delays in time as a result of sampling and lab analyses are avoided.

These are the successful pickling bath applications where LiquiSonic® has been used:

  • Sulturic acid (H2SO4)
  • Phosphoric acid (H3FO4)
  • Hydrochloric acid (HCI)
  • Nitric acid (HNO3)
  • Hydrofluoric acid (HF)

Acid Regeneration

In this process, the acid is refreshed and removed of all contaminations, such as iron salt.  The most popular procedure used is the crystallisation for the recovery of sulturic acid.  In addition, the spray roasting or buttering-floating procedure is used, for the recovery of hydrochloric acid.

Before the used pickling acids are cleaned, they are evaporated to concentrate the acid.  The acid is then separated, and the cleaned acid is added to the pickling process.  The resulting metal oxides are used as valuable raw materials in other industry sectors.

After evaporation, the LiquiSonic® 40 system is used to determine the acid and the metal salt apart from each other.  The last part of the process is when the LiquiSonic® 30 system is used to detect the acid concentration solely, as the metal salts have been removed before.

MORTON CONTROLS FOR MORE INFO:

TELEPHONE: 0861 000 393

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