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, system 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-effective solution with a short payback period

Challenge

Nitrier- und Mischsäureprozesse zählen zu den anspruchsvollsten Verfahren in der chemischen Industrie, da sie hochreaktive Medien, enge Prozessfenster und stark exotherme Reaktionen vereinen. Bereits geringe Abweichungen in der Säurekonzentration, Temperatur oder Phasenverteilung können die Prozessstabilität beeinträchtigen und erhebliche Sicherheitsrisiken verursachen. Bei der verwendeten Messtechnik ist der Einsatz von korrosionsbeständigen Materialien, wie zum Beispiel Tantal, zwingend notwendig. Gleichzeitig steigen die Anforderungen an Anlagenbetreiber durch strenge EHS-Vorgaben, erhöhte Verfügbarkeitsziele und den wachsenden Fokus auf Nachhaltigkeit und Ressourceneffizienz. In diesem Umfeld sind zeitverzögerte Laboranalysen und manuelle Probenahmen nicht mehr ausreichend. Gefragt sind kontinuierliche, verlässliche Inline-Lösungen und präzise Prozessdaten, um kritische Zustände frühzeitig zu erkennen und sicher zu beherrschen.

Risks

Uncontrolled temperature and concentration peaks
Runaway reactions due to deviations in the mixed acid ratio
Delayed response to process disruptions

Approach

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

To use

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

Our solution: LiquiSonic^®

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

Sound speed measurement:

Precise determination of the absolute speed of sound and other physical quantities, for example conductivity or density.

Fully Encapsulated Sensors:

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

Digital signal transmission:

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

Measuring principle

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

The underlying measuring principle uses the interaction of 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. This means that even dynamic processes with rapid changes in load or concentration can be reliably monitored.

A key advantage of this measuring principle is its insensitivity to turbidity, gas bubbles or impurities, which often occur in nitrating 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.

The direct inline measurement eliminates the time delay of classic laboratory analysis. Process deviations become immediately visible so that regular measures can be initiated at an early stage. The measuring principle not only supports process reliability, but also stable process operation, precise dosing and reliable detection of phase transitions.

Economic benefit

Continuous inline monitoring of the acid concentration creates the basis for stable and reproducible process operation. Fluctuations in the mixed acid ratio have a direct impact on reaction kinetics, selectivity and product yield and often lead to increased waste or rework. Real-time data allows deviations to be immediately identified and corrected before they cause economic damage. At the same time, the permanent transparency reduces the need for safety margins when dosing and enables more efficient use of raw materials.

Economic effects at a glance:

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

Application examples

Fine chemicals & specialty chemicals

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

Explosives & Energetics

Nitration is not an optimization issue here, it's about safety. Acid concentration variations have a direct impact on reaction speed, temperature rise and runaway risks. Continuous monitoring reduces the dependence on empirical values and significantly increases operational safety.

Polymers & Dyes

In these applications, the 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 efforts. Inline measurement data helps to run processes more robustly and minimize material losses.

Over 35 years of experience in concentration measurement

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

Our systems are used 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 profitability?

Inline measurement technology from SensoTech improves cost-effectiveness by enabling precise acid dosing and reducing possible safety surcharges. More stable processes lead to less scrap, lower rework costs and higher system utilization. At the same time, raw material consumption and disposal costs 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 if 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 allows safety-critical situations to be controlled at an early stage.

How can the acid concentration be reliably monitored inline?

The acid concentration can be measured directly in the process stream using the inline measuring system LiquiSonic^® 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 control.

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 dyes industries. In these areas, safety, product quality and cost-effectiveness are directly dependent on a stable acid concentration. Maintenance-free sensors from SensoTech enable continuous process monitoring without sampling.

What advantages does continuous measurement have over classic 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 just reacting retroactively.

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

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

Is LiquiSonic also suitable for existing systems?

Yes, the measurement technology can be integrated into new systems as well as existing processes. It is suitable for continuous and batch processes. The integration typically takes place inline, without fundamental changes to the system. SensoTech specializes in finding individual solutions for specific customer requirements.

How does LiquiSonic support acid recycling and spent acid recovery?

Continuous monitoring of the acid composition enables targeted control of recycling and regeneration processes. Fluctuations in the spent acid flow are detected early and can be compensated for. This increases the recovery rate and reduces the need for fresh acid. This is how LiquiSonic wears^® also contributes to the economic efficiency of the process.

What role does inline measurement technology play in 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 cycles and lower product losses reduce the ecological footprint. At the same time, the increased process reliability improves the social and regulatory compliance of the system.

Concentration measurement in acids

The continuous measurement of acid concentrations is a central component 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 affect 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 reliability, material resistance and measurement stability as nitrating and mixed acid processes. Our measuring systems enable constant monitoring of the sulfuric acid concentration and help to avoid critical operating conditions and achieve higher system availability.

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Design nitration and mixed acid processes safely and economically