Chemical Industry Use Cases
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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.
Coupling vessel
Chemical Industry
The main reaction in colour pigment production takes place in the ‘coupling’ vessel. So named as a type of coupling reaction occurs here to form a synthetic ‘azo dye’, which is then converted into different colour pigments in subsequent process steps. An agitator in the tank ensures constant mixing of the azo dye. Additionally, ice is added for cooling, as otherwise the individual components of the reaction would decompose. Level measurement is required to ensure a smooth process flow.
Diazotization vessel
Chemical Industry
In the diazotization process, the individual raw materials for colour pigment production are prepared so that they will react to become diazonium compounds ready for the subsequent ‘coupling’ vessel where they form the final crude pigment or ‘azo dye’. The basic starting materials for these compounds are hydrochloric acid, water, sodium nitrite and the diazo component (usually aniline). To preserve the material quality during formulation, the mixture is kept cool by adding ice or via a cooling jacket. During this process, the level must be carefully monitored and kept constant.
Discharge chute of the belt dryer
Chemical Industry
The final, still wet pigment cake is heated on a belt dryer. At the end of the belt dryer, the dried coarse pigment powder is discharged into a silo ready for final milling and grinding into a fine powder. The feed through the belt dryer is controlled both by the flow through the chute and level in the silo.
Dissolving tank
Chemical Industry
The precursors for the manufacture of colour pigments are dissolved in the dissolving tank. These precursors are mainly Naphtha based, and, depending on the formulation, water and sodium hydroxide solution are added as solvents for the production of the basic pigment solution. An agitator ensures uniform mixing of substances as they are added. The level measuring system is needed to ensure reliable values that are delivered to the control system.
Distillation column
Chemical Industry
The process temperatures in a distillation column place high demands on the measurement technologies deployed. The boiling point of the distillate frequently exceeds 400 °C. The aim is to achieve the highest possible product throughput for cost-effective operation of the plant. This means the raw material replenishments need to be optimally controlled by level and process pressure measurement in the column.
Filling silo for colour pigment
Chemical Industry
In the last production step, the finished pigment powders are pneumatically conveyed into packing silos. The conveying system generates very high dust levels and air movement inside the silos. To control the filling process, the levels in the silos need continuous monitoring. A high level detection switch is used for safety shutdown in case of overfilling. The pigment powder is then filled into sacks via the bottom outlet.
Flare knockout drum
Chemical Industry
The unrecoverable residues of oil and gas production are collected in the flare knockout drum and liquefied at high pressure. The recovered liquid, the condensate, collects at the bottom of the vessel and is disposed of. The non-liquefied gases are decompressed and burned in the flare system. To ensure efficient and safe operation of the vessel, the level inside must be very reliably measured.
Gas scrubber
Chemical Industry
Carbon dioxide is separated from a gas mixture via two scrubbing columns. The gas mixture consisting of nitrogen, hydrogen and carbon dioxide passes through a gas pipeline into the first stage gas scrubber. An added solvent, usually aniline, binds with the carbon dioxide, which is then forwarded in liquid form to a gas scrubber or ‘desorber’ where it is “washed” out of the liquid. The process pressure is monitored during the absorption process, which takes place at high pressure and low temperature. The actual separation of the carbon dioxide from the liquid, however, is carried out under low pressure and high temperature, where the level of the liquid needs to be kept as constant as possible.
Heat recovery boiler
Chemical Industry
In the heat recovery boiler, hot process gas is passed through heating pipes. This means the gas is cooled and the necessary process heat for the plant recovered to be reused. To prevent the heat recovery boiler from running dry and thus overheating, reliable monitoring of the water level in the boiler is required. For maximum safety, the measurement is carried out redundantly with diverse instrument technology.
IBC-Tank (metallic)
Chemical Industry
In many of the production processes in the chemical industry, small quantities of various chemicals are needed in order to improve the characteristics of certain products. The media are often provided directly to the production areas in small, transport containers. Accurate level measurement ensures a continuous supply of materials for production.
IBC-Tank (plastic)
Chemical Industry
In many of the production processes in the chemical industry, small quantities of various chemicals are needed in order to improve the characteristics of certain products. The media are often provided directly to the production areas in small, transport containers. Accurate level measurement ensures a continuous supply of materials for production.
Medium-sized silos for bulk solids
Chemical Industry
Many different kinds of bulk solids are produced or used as raw materials in the chemical industry. To ensure reliable measurement of the silo contents, several factors must be considered: different bulk densities, abrasive properties, dust generation and the requirements of explosion protection. Application of the right level sensors ensures optimal production planning and reliable logistics for the finished products.
Pool condenser
Chemical Industry
In a pool condenser, ammonium carbamate is produced from a mixture of carbon dioxide and ammonia under high pressure. The ammonium carbamate, in turn, is the starting material for the subsequent main reaction in the production of urea. To ensure safe operation of this high-pressure application, a continuous, dependable level measurement solution is needed.
Preflash drum
Chemical Industry
In the preflash drum, the medium is heated before it is fed into the distillation column. Accurate and reliable level control is a critical factor in ensuring efficient operation of the distillation column. Reliable measurement of the level prevents overfilling of the vessel and also keeps the pumps from running dry.
Primary reformer
Chemical Industry
In the primary reformer, methane gas and water vapour react into hydrogen, oxygen, carbon monoxide and carbon dioxide at a pressure of around 30 bar and a temperature of 870 °C. Since the temperature in the reformer is very high, pressure is measured at the inlet via a temperature adapter. The temperature also needs to be measured in order to regulate the process.
Propane storage in bullets and spheres
Chemical Industry
Propane, a flammable, colourless and odourless gas, is one of the many types of liquefied petroleum gases (LPG) that exist. It is produced from natural gas via a special refining process. Propane is compressed, liquefied and stored in pressure vessels so that it does not return to a gaseous state. To ensure optimal storage, reliable level measurement is required.
Reaction vessel
Chemical Industry
Changing media, as well as process pressures and temperatures, characterize the typical reaction processes in a reaction vessel. This is a big engineering challenge, because any sensors used to control the process need to deliver reliable measurements under these conditions. To meet the diverse conditions found in reaction vessels, level measurement and point level detection instrumentation must cover a broad spectrum of applications.
Reactor
Chemical Industry
High temperatures, pressures and vacuums are techniques usually employed to make reaction processes more efficient and economical. This is a big challenge for engineering, because the sensors used have to deliver reliable measurements under these conditions. To be able to meet the diverse requirements of reaction vessels, sensors for level measurement have to meet a very wide range of application conditions.
Reboiler
Chemical Industry
Evaporators are heat exchangers that are deployed at the bottom of distillation columns. In the evaporator, the residue is boiled up from the sump and fed back into the distillation process. Precise control of the level in the evaporator ensures efficient operation of the plant. A reliable measurement also ensures that the heating coils are always covered with liquid, to prevent any overheating incidents.
Reflux accumulator drum
Chemical Industry
The efficiency of a distillation column is increased with the help of return flow. The return flow in this case is that portion of the condensed liquid head product that is fed back to the upper part of the column. Reliable level measurement in the reflux tank is required to ensure that the return flow is accurate and continuous.
Separation vessel
Chemical Industry
These processes often involve the separation of water-based media from hydrocarbons. In most applications, the upper, lighter medium is electrically non-conductive. Guided radar level measurement makes use of the effect that non-conductive media allow some of the radar energy to pass through, thus enabling a measurement of the interface between the water-based lower medium and the hydrocarbons.
Silos for bulk solids
Chemical Industry
In the chemical industry, many different kinds of bulk solids are produced or used as raw materials. To ensure reliable measurement of silo contents, many factors must be considered: different bulk densities, abrasive properties, dust generation and the requirements of explosion protection. Implementation of the most suitable level sensors ensures optimal production planning and reliable logistics for the finished products.
Steam boiler
Chemical Industry
High process pressures and a highly compressed vapour phase are the normal operating conditions inside boilers. The size of the steam generator is what determines the quantity of saturated steam that can be fed into a heat exchanger. Reliable control of the water level and limitation of high and low water levels are therefore extremely important. In power plants boilers are governed by the steam pressure and the process temperature.
Storage and buffer tanks
Chemical Industry
Storage and buffer tanks enable a reliable material supply for various ongoing processes. The plant operators need to have exact level data from these tanks at all times to ensure timely replenishment and facilitate continuous production. In addition, the measured values form the basis of the statistical consumption analysis for validation and quality monitoring.
Storage tank
Chemical Industry
In the production of pigments, aggressive raw materials such as chlorobenzene, hydrochloric acid and sodium hydroxide are used. They are stored in horizontal cylindrical tanks and filled through a dip pipe to reduce splashing and fume generation. A reliable level measurement ensures safe handling and continuous material availability for optimum productivity.
Storage tanks for highly toxic liquids
Chemical Industry
For extremely toxic substances such as phosgene, absolute control over the process is a necessity. In industrial applications, these products are only used in hermetically closed circuits. To minimize the inherent risks, independent protection devices form an integral part of the tank equipment. Moreover, it is important to keep the number of tank openings as small as possible. An external level measuring system that includes point level detection is ideal for such situations.
Storage tanks for toxic liquids
Chemical Industry
Some chemical processes generate extremely toxic intermediates that have to be stored under the most stringent security measures. In order to be used in this application, the measurement technology must meet specific requirements in terms of design and functional reliability. A redundant sealing concept, an optional glass feedthrough (Second Line of Defense) and highly resistant materials provide the necessary security for the storage and processing of toxic media.
Stripper
Chemical Industry
Impurities are separated from urea in a special process tank, the so-called stripper. The unwanted substances are removed from the urea by means of a counter current of carbon dioxide to the flow from the urea solution leaving the reactor. The urea itself collects at the bottom of the stripper. The filling height in the urea sump must be monitored and kept constant.
Tanks for solvents
Chemical Industry
Low viscosity solvents can degrade many types of plastics. This places increased demands on the process instrumentation. A separate level detection system is required for protection against overfilling. It increases plant safety and ensures protection of human health and the environment.
Urea reactor
Chemical Industry
In a Urea reactor, ammonium carbonate is decomposed into urea and water. Nearly pure urea is discharged from the reactor via the long pipe, which projects into the upper part of the vessel from the bottom. During the reaction process, the level in the reactor must be kept as constant as possible to maximise the purity and productivity of the process.
Urea reboiler
Chemical Industry
In the production of urea from ammonia, high process temperatures and the urea itself limit any sensor material selection considerably. The thick container walls further complicate the installation of measurement technology. A reliable monitoring of the level is essential to enable the cost-effective production of urea.
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