Wie trägt LiquiSonic zur Wirtschaftlichkeit bei?

Inline-Messtechnik von SensoTech verbessert die Wirtschaftlichkeit, indem sie eine präzise Säuredosierung ermöglicht und eventuelle Sicherheitsaufschläge reduziert. Stabilere Prozesse führen zu weniger Ausschuss, geringeren Nacharbeitskosten und einer höheren Anlagenauslastung. Gleichzeitig sinken Rohstoffverbrauch und Entsorgungsaufwand. Das LiquiSonic® Messsystem hat eine durchschnittliche Amortisationszeit von 12 Monaten.

Wie kann LiquiSonic die Sicherheit von Nitrationsprozessen erhöhen?

Ein Nitrationsprozess ist sicher, wenn kritische Prozessparameter wie die Säurekonzentration und das Phasenverhalten kontinuierlich überwacht werden. Die Inline-Messtechnik von SensoTech liefert Echtzeitdaten und erkennt Abweichungen sofort, bevor diese zu gefährlichen Reaktionen oder Runaway-Szenarien führen. Dadurch lassen sich sicherheitskritische Situationen frühzeitig beherrschen.

Wie kann die Säurekonzentration zuverlässig inline überwacht werden?

Die Säurekonzentration kann direkt im Prozessstrom mit dem inlinefähigen Messsystem LiquiSonic® überwacht werden. Im Vergleich zur manuellen Probenahme stehen die Messwerte kontinuierlich und in Echtzeit zur Verfügung. Das ermöglicht eine stabile Regelung des Mischsäureverhältnisses und eine reproduzierbare Prozessführung.

Für welche Industrien ist eine kontinuierliche Inline-Überwachung besonders relevant?

Die Inline-Überwachung der Säurekonzentration ist besonders relevant für die Feinchemie und Spezialchemikalien, für Explosivstoffe und Energetics sowie für die Polymer-, Kunststoff- und Farbstoffindustrie. In diesen Bereichen sind Sicherheit, Produktqualität und Wirtschaftlichkeit direkt von einer stabilen Säurekonzentration abhängig. Wartungsfreie Sensoren von SensoTech ermöglichen eine kontinuierliche Prozessüberwachung ohne Probenentnahme.

Wie können Phasengrenzen in Mischsäureprozessen zuverlässig erkannt werden?

Phasengrenzen lassen sich durch Inline-Messung direkt im Prozessstrom erkennen, auch bei trüben oder aggressiven Medien. Im Gegensatz zu zeit- oder erfahrungsbasierten Methoden liefert das LiquiSonic® Messsystem ein eindeutiges Signal für Phasenübergänge. Dadurch werden Fehltrennungen und Produktverluste vermieden.

Ist LiquiSonic auch für bestehende Anlagen geeignet?

Ja, die Messtechnik kann sowohl in Neuanlagen als auch in bestehende Prozesse integriert werden. Sie eignet sich für kontinuierliche und chargenweise Prozesse. Die Integration erfolgt typischerweise inline, ohne grundlegende Änderungen an der Anlage. SensoTech ist darauf spezialisiert, individuelle Lösungen für spezielle Kundenanforderungen zu finden.

Wie unterstützt LiquiSonic das Säurerecycling und Spent-Acid-Recovery?

Eine kontinuierliche Überwachung der Säurezusammensetzung ermöglicht eine gezielte Steuerung von Recycling- und Regenerationsprozessen. Schwankungen im Spent-Acid-Strom werden frühzeitig erkannt und können ausgeglichen werden. Das erhöht die Rückgewinnungsquote und reduziert den Bedarf an Frischsäure. So trägt LiquiSonic® auch zur Wirtschaftlichkeit des Prozesses bei.

Welche Rolle spielt Inline-Messtechnik für ESG- und Nachhaltigkeitsziele?

Das LiquiSonic® Messsystem unterstützt ESG-Ziele, indem es Rohstoffverbrauch, Abfallmengen und Energieeinsatz messbar reduziert. Effizientere Säurekreisläufe und geringere Produktverluste senken den ökologischen Fußabdruck. Gleichzeitig verbessert die erhöhte Prozesssicherheit die soziale und regulatorische Compliance der Anlage.

Design nitration and mixed acid processes safely and economically

Real-time process information for maximum safety, plant availability, and sustainable acid processes.

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Real-time measurement

Continuous monitoring without delay

Maintenance-free

No moving parts or wear components

Highest accuracy

Precise measurement even under difficult conditions

Reduced operating costs

Cost-efficient solution with short payback time

Challenge

Nitration and mixed acid processes are among the most demanding procedures in the chemical industry, as they combine highly reactive media, narrow process windows, and strongly exothermic reactions. Even small deviations in acid concentration, temperature, or phase distribution can impair process stability and cause significant safety risks. For the measurement technology used, the application of corrosion-resistant materials, such as tantalum, is absolutely essential. At the same time, requirements for plant operators are increasing due to strict EHS regulations, higher availability targets, and the growing focus on sustainability and resource efficiency. In this environment, delayed laboratory analyses and manual sampling are no longer sufficient. What is needed are continuous, reliable inline solutions and precise process data to detect critical conditions at an early stage and control them safely.

Risks

Uncontrolled temperature and concentration spikes
Runaway reactions in the event of deviations in the mixed acid ratio
Delayed response to process disturbances

Approach

Continuous inline measurement of critical process parameters
Early detection of deviations using real-time data
Reduction of manual interventions

Benefits

Transparent processes
Robust, maintenance-free technology for demanding process conditions
Sustainable cost reduction through optimized process control

Our solution: LiquiSonic^®

LiquiSonic^® measurement systems optimize your nitration and mixed acid processes. Our maintenance-free sensors enable continuous process monitoring without sampling.

Sound velocity measurement:

Precise determination of the absolute sound velocity and another physical variable, for example conductivity or density.

Fully encapsulated sensors:

No seals, moving parts, or wear. Our sensors are maintenance-free and drift-free.

Digital signal transmission:

Interference-free data transmission, even over long distances. Easy integration into existing systems.

Measurement principle

The measuring system LiquiSonic^® is based on the continuous measurement of physical material properties directly in the process stream. The sensor operates without moving parts and requires no consumables, which makes it particularly robust for use in aggressive acid environments. The measurement is carried out directly in the medium, inline or in the bypass, and provides permanent real-time data on the composition in the process.

The underlying measurement principle uses the interaction between sound and the medium. Changes in acid concentration, mixing ratio, or phase behavior lead to measurable changes in the physical properties of the liquid. These changes are continuously recorded and converted into stable, reproducible measurement signals. As a result, even dynamic processes with rapid load or concentration changes can be monitored reliably.

A key advantage of this measurement principle is its insensitivity to turbidity, gas bubbles, or impurities, as frequently occur in nitration and mixed acid processes. The sensor technology is designed for high temperatures, high acid concentrations, and highly corrosive media and is suitable for both continuous and batch processes. The measurement data is immediately available for process visualization, control, or automation.

Direct inline measurement eliminates the time delay of conventional laboratory analysis. Process deviations become visible immediately, allowing control measures to be initiated at an early stage. The measurement principle therefore supports not only process safety, but also stable process operation, precise dosing, and reliable detection of phase transitions.

Economic benefits

Continuous inline monitoring of acid concentration creates the basis for stable and reproducible process operation. Fluctuations in the mixed acid ratio directly affect reaction kinetics, selectivity, and product yield and often lead to increased waste or rework. Real-time data makes it possible to detect and correct deviations immediately before they cause economic damage. At the same time, permanent transparency reduces the need for safety margins in dosing and enables more efficient use of raw materials.

Economic effects at a glance:

Fewer off-spec products, lower rework or disposal costs
Higher plant utilization through stable and reproducible operation
Faster response to disturbances without production interruption
Reduced resource consumption through precise dosing instead of safety reserves

Application examples

Fine chemicals & specialty chemicals

In fine chemicals, nitration processes are often highly selective and operate within very narrow process windows. Even small concentration deviations in the mixed acid have a major impact on yield, by-product formation, and product quality. Inline measurement technology enables reproducible operation and reduces the risk of costly off-spec batches.

Explosives & energetics

Here, nitration is not an optimization issue, it is about safety. Concentration deviations in the acid have a direct effect on reaction rate, temperature rise, and runaway risks. Continuous monitoring reduces dependence on empirical values and significantly increases operational safety.

Polymers & dyes

In these applications, acid concentration is crucial for the degree of reaction, product structure, and subsequent processing properties. Fluctuations often lead to product losses, unstable phase separations, or increased recycling effort. Inline measurement data helps make processes more robust and minimize material losses.

Over 35 years of experience in concentration measurement

Since 1990, SensoTech has been a leading provider of inline measurement technology and has established itself as a specialist in precise concentration and density measurements.

Our systems are in use worldwide, including in critical applications.

35+

Years of experience

1000+

Installed systems

50+

Countries worldwide

ISO 9001

Certified quality

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Frequently asked questions

How does LiquiSonic contribute to cost-effectiveness?

SensoTech's inline measurement technology improves cost-effectiveness by enabling precise acid dosing and reducing potential safety margins. More stable processes lead to less waste, lower rework costs, and higher plant utilization. At the same time, raw material consumption and disposal effort are reduced. The LiquiSonic^® measuring system has an average payback period of 12 months.

How can LiquiSonic increase the safety of nitration processes?

A nitration process is safe when critical process parameters such as acid concentration and phase behavior are continuously monitored. SensoTech's inline measurement technology provides real-time data and detects deviations immediately before they lead to dangerous reactions or runaway scenarios. This makes it possible to control safety-critical situations at an early stage.

How can acid concentration be reliably monitored inline?

The acid concentration can be monitored directly in the process stream with the inline-capable LiquiSonic measuring system^® be monitored. Compared to manual sampling, the measured values are available continuously and in real time. This enables stable control of the mixed acid ratio and reproducible process operation.

For which industries is continuous inline monitoring particularly relevant?

Inline monitoring of acid concentration is particularly relevant for fine chemicals and specialty chemicals, for explosives and energetics, as well as for the polymer, plastics, and dye industries. In these sectors, safety, product quality, and cost-effectiveness depend directly on a stable acid concentration. Maintenance-free sensors from SensoTech enable continuous process monitoring without sampling.

What are the advantages of continuous measurement compared to conventional laboratory analysis?

Laboranalysen liefern häufig nur Momentaufnahmen, sind bei hochkonzentrierten Säuren schwierig handzuhaben und die Ergebnisse sind zeitverzögert. Prozessabweichungen werden häufig erst erkannt, wenn sie bereits wirtschaftliche oder sicherheitsrelevante Auswirkungen haben. Eine kontinuierliche Inline-Messung mit dem LiquiSonic^® measuring system shows changes immediately and allows the process to be actively stabilized instead of merely reacting retrospectively.

How can phase boundaries in mixed acid processes be reliably detected?

Phase boundaries can be detected through inline measurement directly in the process stream, even in turbid or aggressive media. In contrast to time-based or experience-based methods, the LiquiSonic^® measuring system provides a clear signal for phase transitions. This avoids incorrect separations and product losses.

Is LiquiSonic also suitable for existing plants?

Yes, the measurement technology can be integrated into both new plants and existing processes. It is suitable for continuous and batch processes. Integration is typically done inline, without fundamental changes to the plant. SensoTech specializes in finding individual solutions for specific customer requirements.

How does LiquiSonic support acid recycling and spent-acid recovery?

Continuous monitoring of acid composition enables targeted control of recycling and regeneration processes. Fluctuations in the spent-acid stream are detected early and can be compensated for. This increases the recovery rate and reduces the need for fresh acid. In this way, LiquiSonic^® also contributes to the cost-effectiveness of the process.

What role does inline measurement technology play for ESG and sustainability goals?

The LiquiSonic^® measuring system supports ESG goals by measurably reducing raw material consumption, waste volumes, and energy use. More efficient acid circuits and lower product losses reduce the ecological footprint. At the same time, increased process safety improves the plant's social and regulatory compliance.

Concentration measurement in acids

Continuous measurement of acid concentrations is a key building block for safe and stable acid processes. Our inline measurement technology provides real-time data directly from the process. This allows concentration fluctuations to be detected and controlled at an early stage before they impair process safety or product quality.

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Sulfuric acid production

The production and processing of sulfuric acid places similarly high demands on process safety, material resistance, and measurement stability as nitration and mixed acid processes. Our measuring systems enable constant monitoring of sulfuric acid concentration and help avoid critical operating conditions and achieve higher plant availability.

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Design nitration and mixed acid processes safely and economically