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Measure acetic acid concentration inline
from diluted solution to glacial acetic acid


LiquiSonic® determines the acid content where it is created: in the pipeline, in the stirred tank, in the column reflux. No sampling, no titration on shift intervals, no waiting for the lab result.

Entrained gas is handled much better by the ultrasonic method than by density-based or refractometric measurements - an advantage wherever pressure is released, heating occurs, or aeration is used.

Real-time measurement

Continuous monitoring without delay

Maintenance-free

No moving parts or wear components

Maximum accuracy

Precise measurement even under difficult conditions

Reduced operating costs

Cost-efficient solution with a short payback period

The concentration of acetic acid can be determined inline via the speed of sound. A LiquiSonic®sensor measures how long an ultrasonic pulse takes to travel a known distance through the acid and factors out the influence of temperature. This yields the mass fraction of CH₃COOH in water. Because the density of aqueous acetic acid responds only weakly and not consistently unambiguously to concentration over wide ranges, acoustic measurement goes further here than density or refractometer measurements. We determine together with you which concentration range can be evaluated in your process.


Why the acid content is often known too late in practice

Acetic acid is used in almost every concentration: as glacial acetic acid in tank storage, as 60% or 80% technical acid in dosing, heavily diluted in pickling and cleaning solutions, and as an acidulant in food production. Between these stages are dilution stations, distillation columns, and recovery loops, and in each of these steps the concentration changes. This is usually noticed only when the previous day's lab sample has been analyzed.

Where the concentration shifts

  • Dilution of glacial acetic acid to the target concentration
  • Fluctuating return flows from distillation and solvent recovery
  • Rinse water and CIP residues that dilute a batch unnoticed
  • Concentration increase due to evaporation in heated tanks
  • Increasing acid content during vinegar fermentation

What this costs in operation

  • Batches outside specification, rework, or scrap
  • Overdosed acid in neutralization and the wastewater stream
  • Yield losses in recovery, unnecessary purchase of fresh acid
  • Corrosion where concentration and temperature both get out of control
  • Gaps in documentation between two lab values

Limits of conventional methods

  • Titration: reliable reference, but spot-based and personnel-dependent
  • Density measurement: the density of aqueous acetic acid passes through a maximum, so one value can correspond to two concentrations
  • Conductivity: acetic acid is a weak acid, so the signal is influenced more by salts and acetate
  • pH value: buffered and not very meaningful for concentration
  • Refractometer: viewing windows become fouled, and color and turbidity interfere

The solution: LiquiSonic® right in the acid flow

The sensor extends directly into the acid. There is a fixed measurement path between transmitter and receiver; the transit time of the ultrasonic pulse determines the speed of sound and, from that, the temperature-compensated concentration.

No optics, no mechanics in the process
There is no viewing window that can become coated and no vibrating tube that can clog. Discolored or cloudy acid does not affect the measured value.

Temperature is measured too, not estimated
Each sensor records the process temperature with high precision and factors out its influence on the speed of sound.

High tolerance to gas bubbles
The ultrasonic measurement tolerates entrained bubbles much better than density-based methods. The sensor also outputs an unusually high gas content as an interference signal.

Materials for concentrated and hot acid
Stainless steel for dilute, cold media; Hastelloy as well as PFA, ETFE, or Halar coatings where acetic acid is hot and highly concentrated.

The measured value at the process

The LiquiSonic® controller displays the concentration directly at the system - even when no one is currently watching the control system.

Target range instead of a column of numbers
The bars on the left show at a glance whether concentration and temperature are within the approved limits.

Limit values can be output externally
Upper and lower limit violations can be assigned to digital outputs and used there directly for dosing or switching.

Trend history for batch documentation
Trend recording provides seamless proof of the concentration at which a batch was actually run.

Technical background

Speed of sound as the measured variable

Water and acetic acid differ clearly in acoustic terms: an ultrasonic pulse travels noticeably faster through water than through pure acid. The sensor evaluates exactly this difference. The measurement path is mechanically fixed, the temperature is measured as well, and the value is absolute and does not drift.

As with many aqueous systems, the relationship is not unambiguous over the entire range from 0 to 100 wt%. Therefore, the evaluable section is defined specifically for the application and an appropriate product data set is stored. This also applies to mixtures in which, in addition to acetic acid, other components such as acetates or anhydrides are present.

Gas bubbles as an interfering factor

Gas in the medium is an everyday occurrence in acetic acid plants: pressure release downstream of pumps and valves, outgassing in heated tanks, intensive aeration in the vinegar fermenter, and column return flows shortly after the condenser.

Bubbles change not only the transit time but the entire shape of the received signal. This allows ultrasonic measurement to remain stable over a wide range where density-based methods have long since started to fluctuate. The sensor outputs an unusually high gas content as an interference signal - an additional indication of outgassing or air ingress in the piping system.

How this pays off

Less lab work
  • Titration only for verification, not for process control
  • No sampling of hot, concentrated acid
  • Releases proceed without waiting for the lab result
Less acid in waste
  • Dilution hits the target range instead of overshooting it to be safe
  • Higher yield in distillation and recovery
  • Neutralizing agent is dosed as needed, not based on assumptions
Greater operational safety
  • Continuous documentation for each batch instead of spot sampling
  • Alarm as soon as the concentration leaves the approved range
  • Indication of outgassing and air ingress in the piping system

Configuration for your acid

Installation

  • Installation lengths from 92 mm to 3,000 mm
  • All common flanges, threads, and process connections
  • Adapter for small cross sections and bypass lines
  • Hygienic designs for food applications
  • Sensor versions for Ex requirements

Materials
Diluted, cold acetic acid can be controlled with stainless steel. As the concentration and temperature increase, the selection becomes critical: Hastelloy as well as coatings made of PFA, ETFE or Halar are available. We will clarify which combination is suitable based on your operating data.

OEM and special designs
We also produce customer-specific designs, connections and interfaces in small quantities. Talk to us about your requirements.

Quick overview
Measuring range, accuracy, temperature and pressure limits as well as materials depend on the design and influence each other. We therefore design the sensor together with you and provide the reliable values ​​for your process.

  • Measuring principle: Ultrasonic transit time measurement, temperature compensated, inline
  • Measured variables: Acetic acid concentration, process temperature, disturbance detection (e.g. gas bubbles)
  • Installation: pipeline, container or bypass; Length and connection depending on application
  • Interfaces: Analogue outputs, digital outputs for limit values, Modbus, Profibus, Profinet, EtherNet/IP
  • Maintenance: Maintenance-free, one-time factory calibration

Where acetic acid is measured

Production and processing

Distillation and dehydration in acetic acid production, solvent recovery in plants for cellulose acetate, vinyl acetate, or terephthalic acid. Overhead and bottom streams are monitored continuously instead of being sampled through lab tests.

Dilution and filling

Glacial acetic acid is adjusted to technical concentrations and filled. The inline measurement closes the control loop for water addition and verifies for each batch what concentration actually reached the container.

Vinegar and acidulants

In vinegar production, the acid content rises continuously in the aerated fermenter, then it is blended to commercial strength. Hygienic designs allow installation in direct product contact.

Pickling, cleaning, neutralizing

Acidic cleaning and treatment baths lose active substance with every batch. Continuous measurement shows when replenishment is needed and how much alkali is actually required for neutralization afterward.

Specialized in concentration measurement for over 35 years

SensoTech develops and manufactures inline analytical measurement technology in Magdeburg-Barleben. LiquiSonic® Systems are used worldwide in acid and caustic applications, in chemicals, food production, and semiconductor manufacturing.


35+

Years of experience

50+

Countries worldwide

ISO 9001

Quality certified


Describe your application - we will get back to you for technical coordination!
Together, we clarify boundary conditions and possible solution approaches.

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Details

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Frequently asked questions

Does inline measurement replace titration?

For process control, yes: you operate based on the current measured value instead of the last sample. As an analytical reference, titration still has its place. Some users continue to use it to check and document the inline value at longer intervals.

Isn't that the same as density measurement?

No. What is measured is the speed of sound, not density. This makes a difference especially with acetic acid: the density of the aqueous mixture reaches a maximum in the upper concentration range, so one density value can correspond to two different concentrations. The acoustic variable behaves differently and is also less sensitive to gas bubbles. If you work with density values in your plant, we can convert the measured value into density and output it that way if needed.

How does the measurement behave with gas bubbles in the pipe?

Significantly more tolerant than density- or refractometer-based methods. A moderate amount of bubbles does not noticeably affect the measured value. However, there is a limit: if the gas content rises further, the evaluation becomes unreliable. The sensor detects this condition to a certain extent and outputs it as a fault signal. If there is consistently a lot of gas present, choosing the installation point also helps, for example at a well-flooded location with upward flow.

Does the measurement also work with glacial acetic acid?

Nearly water-free acetic acid solidifies at around 16.7 °C, so lines and vessels are heat-traced accordingly. The sensor can be installed in such heated sections. Whether the desired resolution can be achieved in the high-concentration range is something we verify based on your data. In that exact range, the curve profile determines the result.

Which materials can withstand acetic acid?

For diluted, cold acid, stainless steel is usually sufficient. Hot and highly concentrated acetic acid is more demanding; here, Hastelloy or coated versions with PFA, ETFE, or Halar are used. Tell us the concentration, temperature, and accompanying substances, and we will suggest the right combination.

Do I need an explosion-proof version?

Concentrated acetic acid is flammable, with a flash point of about 39 °C. For this reason, tank farms and heated plant sections often have hazardous area classifications. Suitable sensor versions are available for explosion-protection requirements, along with a wide selection of materials. Tell us the classification of your measuring point, and we will suggest the appropriate version.

How accurate is the measurement?

That depends on the concentration range, temperature spread, and composition. In a tightly controlled target band, the achievable resolution is high; over a very wide range, it is lower. We provide a reliable specification for your case instead of promising a general number.

What about mixtures in which acetic acid is only one component?

Often solvable. As long as the accompanying substances remain within known limits, a product data set can be stored for the specific mixture, for example acetic acid with acetate, anhydride, or residual solvent. If the composition varies greatly, we clarify feasibility in advance using a sample in the lab.

How does the measured value get into my control system?

Via 4–20 mA as well as Modbus, Profibus, Profinet, or EtherNet/IP. Limit values for concentration and disturbance variables can also be assigned to digital outputs and used directly for dosing valves or switching functions.

How do I know if my acid concentration is drifting between two lab samples?

Usually not at all, until a batch stands out. A slightly too weak dilution may initially go unnoticed in the process, but it costs effectiveness, yield, or specification compliance. Only a continuous trend shows whether the concentration was truly stable or drifted between two samples.

What maintenance is required?

None during operation. There are no moving parts, no seals in the measuring path, and no optical window that would need cleaning. The factory calibration remains stable for years, and regular recalibration is not strictly necessary.

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