Chemical Industry
The chemical industry handles aggressive, corrosive, and hazardous media under stringent safety requirements. Explosion-proof, chemical-resistant instrumentation with long-term stability is essential for safe operations and consistent product quality.
Overview
The chemical industry encompasses a vast range of processes handling aggressive, corrosive, and potentially hazardous media under stringent safety requirements. From batch and continuous processing to storage and logistics, reliable level and pressure measurement is essential for maintaining safe operations and consistent product quality. Explosion protection, chemical resistance, and long-term measurement stability are non-negotiable requirements in this sector. Modern chemical plants demand intelligent instrumentation that integrates into digital process control systems, enabling predictive maintenance and real-time process optimization across diverse applications involving acids, bases, solvents, and reactive intermediates.
Industry Challenges
Key challenges we help address
Monitoring highly corrosive and toxic media safely
Preventing overfill in storage tanks with hazardous chemicals
Maintaining precise reaction conditions for product quality
Detecting leaks in pressurized systems before escalation
Meeting SIL-rated safety instrumented system requirements
Managing foam, agitation, and buildup on level sensors
Handling extreme temperatures in reformers and reactors
Solutions for This Industry
Tracking Solutions
Industrial IoT
Use Cases
Explore specific scenarios and challenges in this industry
Ammonia reactor
Chemical Industry
In the ammonia reactor, nitrogen reacts with hydrogen to form ammonia. The temperature in the reactor can be anywhere up to 500 °C at pressures of 200 bar. To monitor the system pressure, the measurement itself does not take place in the interior of the reactor, but in the cooler inlet pipe of the reactor.
Ammonia separator
Chemical Industry
In the ammonia separator, the reaction gas mixture (ammonia, hydrogen, nitrogen, traces of methane) is cooled to the boiling point of ammonia (-33 °C). This condenses the ammonia gas. A bypass tube is typically used for measuring the level of the condensed ammonia. In addition, a limit switch is also installed directly in the vessel as a redundant measurement.
Ammonia tank
Chemical Industry
The diffusion behaviour of ammonia is extreme, which means it can eventually pass through any conventional process fitting or elastomer seal. To avoid any long term leaks and unwanted outages, gas-tight process sealing and special safety configurations are therefore mandatory, which considerably restricts the choice of instrumentation. The high risk potential and tough environmental restrictions also make reliable control of the level absolutely necessary when handling ammonia.
Bulk storage tanks
Chemical Industry
Dependable storage is not only the basis for reliable production and supply, it also protects against raw material shortages and price volatility. In addition to regulations on the use of overfill protection or safety instrumented systems, large storage tanks are also often subject to hazardous area codes of practice in conjunction with level measurement.
Chlorine storage tank
Chemical Industry
Chlorine production and storage places high demands on the chemical and the diffusion resistance of the materials in the production equipment. Extensive process knowledge and experience is required when selecting the sealing materials. In fact it is decisive for the long-term, safe and profitable operation of the plant. Since the processes can only be interrupted at great expense and plant disruption, the reliability of the instrumentation is a top priority.
Column trays
Chemical Industry
Accurate level control of the distillation unit ensures product quality of the hydrocarbon at the different cuts, but this is made difficult due to hot liquids flashing, buildup and high temperature. Even through process changes reliable level measurement and point level detection are required.
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