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Process optimization in the
Polycondensation

Polycondensation is the most important step in the polymer resin production. LiquiSonic® provides precise monitoring and analysis of your processes - completely maintenance and drift-free.

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Reaction monitoring

Real-time measurement

Wartungs- & driftfrei

Cost-saving

Challenges in polycondensation

Polycondensation represents the central step in polymer resin production and is particularly susceptible to fluctuations in the process. Even slight deviations in the progress of the reaction can lead either to too high a degree of cross-linking or to too low a molecular mass. The consequence is brittle and unusable resin with insufficient mechanical properties. To prevent waste, precise control of viscosity and degree of cross-linking is therefore crucial. Additionally, the precise determination of the reaction progressis technically very demanding.

Challenges

  • Exact control of the reaction progress required
  • Too much crosslinking leads to brittle, unusable resins
  • Too low molecular weight causes insufficient mechanical properties
  • Laboratory measurements are delayed and do not provide continuous data
  • Narrow process window: Even small deviations lead to rejects

Solution: LiquiSonic®

  • Continuous ultrasonic measurement of the reaction progress in real time
  • High accuracy through temperature-compensated sound velocity measurement
  • Robust sensor design, individually adaptable to process conditions
  • Automated data collection and evaluation for seamless process documentation
  • Integration into process control systems via digital and analog interfaces

Your advantages

  • Consistent product quality through real-time monitoring
  • Reduction of rejects through precise process control
  • Reduction of time-consuming analyses, higher process efficiency
  • Stable, maintenance-free, drift-free, and cleaning-free sensors
  • Sustainable and economical polymer resin synthesis

Our solution: The LiquiSonic® Measuring system

Monitor concentration in real time

LiquiSonic® solves the central challenges of polycondensation in polymer resin production through continuous and highly precise ultrasonic measurement of the reaction progress. Since the speed of sound directly correlates with the concentration and properties of the resin, critical deviations can be detected early and corrected immediately. The robust sensor design allows for direct installation in reactors or pipelines and provides temperature-compensated real-time data that can be automatically documented and transferred to theprocess control system. In this way, reaction parameters can be better regulated, laboratory analyses reduced to a minimum, and consistent quality ensured. This often involves using an above-average sensor length, which (as one of many customization options of the measurement system) allows optimal integration into your specific process.

  • Continuous, precise real-time monitoring
  • Robust, temperature-compensating sensor design
  • Flexible customization options

Technical and economic details

Ultrasonic measurement principle

The ultrasonic measurement method of LiquiSonic® is based on a high-precision time measurement. From the measured sound transit time and the known distance between transmitter and receiver, the sound velocity is calculated, which is directly related to the concentration and the properties correlates with the polymer resin. This allows the progress of the reaction during polycondensation to be determined continuously and in real-time – a decisive advantage over laboratory-based methods. Although viscosity measurement is traditionally considered the standard procedure in polycondensation, it is slower, less sensitive to concentration fluctuations (especially at high concentrations), and leads to clogged sensors during inline measurement. Ultimately, the ultrasonic method provides a more stable measurement andis also completely drift-free, maintenance-free, and requires no cleaning.

The ultrasonic method offers additional advantages: robust inline measurement without interruption, high accuracy, temperature compensation, reliable gas bubble detection, and flexible adjustment of sensor length and installation variant to the respective plant geometry. Continuous data collection also allows the creation of a 'Golden Batch' profile that documents the optimal reaction process. Future batches can be compared with this reference process so that deviations are immediately detected and corrected. In this waya consistently high quality of the resin is ensured and the process management is sustainably optimized.


Economic Benefit

In addition to the technical advantages, the use of LiquiSonic® also offers significant economic potential:

  • Reduction of waste  through immediate detection of mismixes
  • Optimized raw material consumption thanks to precise dosing and optimized final concentrations

  • Faster reaction times in case of process deviations, minimizing downtime

  • Savings on energy and operating costs through more efficient process management
  • Reliable documentation  through automatic data storage
  • Higher plant availability through robust, drift-free, maintenance-free, and cleaning-free sensors
  • Faster ROI through reduced operating costs and higher process stability


Application example

Polycondensation is the most important step in the
polymer resin production. Nur bei korrekter Viskosität kann das Polymerharz für die gewünschte Anwendung genutzt werden. Das LiquiSonic® Measuring system überwacht die Konzentration kontinuierlich per Ultraschallmessung und erkennt selbst kleinste Abweichungen in Echtzeit. Dadurch lassen sich Fehlmischungen vermeiden und der Materialeinsatz exakt steuern. Die robuste Plug-&-Play-Sensorkonstruktion ermöglicht eine direkte Integration in den Prozess. Sensorlänge und Anschlussvariante können individuell an den Prozess angepasst werden, sodass der Polycondensationprogress can be continuously monitored. All measurements are automatically documented and available for subsequent analysis or audits. In this way, ecological responsibility is combined with economic efficiency.

Success stories and references:

Detailed case studies and customer references are available from our sales team. Feel free to contact us for specific application examples!

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The main advantages at a glance

Consistent quality

Real-time monitoring prevents too much or too little cross-linking and ensures consistent product quality.

Cost savings

Less waste, reduced raw material and energy consumption - with consistent product quality and process stability.

Highest efficiency

Real-time data enables faster decisions and optimized processes.

Robust sensors

Completely maintenance-free, drift-free, and cleaning-free sensors that require no consumables.

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Frequently asked questions

What is SensoTech?

SensoTech GmbH is a leading company in the field of process measurement technology based in Barleben, near Magdeburg, Germany. We develop and produce innovative solutions for monitoring and optimizing industrial processes. Our specialization lies in the precise measurement of concentrations, densities, and other parameters in liquids – in real-time and directly during the process.

How does LiquiSonic® react to temperature fluctuations?

Since the speed of sound is influenced by temperature, all our LiquiSonic® sensors are equipped with high-precision temperature sensors. This allows the influence of temperature on the measurement to be directly compensated Therefore, it is not necessary to include additional temperature sensors during the polymer resin production  process.

Which process conditions can be covered?

Our sensors operate reliably within a temperature range of -40 °C to 200 °C and pressures up to 500 bar. Through various material options such as stainless steel, Hastelloy, or PFA coatings, aggressive media can also be measured. Explosion protection for Zone 1 and 2 is also available.

Can extreme operating ranges also be covered?

Yes, our sensors are designed for extreme conditions. In addition to the extended temperature and pressure range, we offer custom adjustments such as sensor lengths up to 3000 mm, special alloys for corrosive media, and various protection types, for example, optional explosion protection. Each sensor is individually configured according to your requirements configured.

Can multiple components be monitored simultaneously?

Yes, by combining the speed of sound measurement with additional physical quantities (e.g., conductivity), multiple components gleichzeitig bestimmt werden. So lassen sich auch Zusatzstoffe bei der polymer resin production  überwachen.

What distinguishes LiquiSonic® from conventional measurement technology?

Unlike optical methods, which are influenced by color or turbidity, conductivity-based methods, which are sensitive to electrical conductivity, or density-based methods, which can be disturbed by temperature or gas bubbles, our ultrasonic method is independent of these influences. Unlike viscosity measurement, the method is also less sluggish, requires no sample extraction, and responds more sensitively to concentration fluctuations.  The LiquiSonic® measurement technology also contains neither moving parts nor components that can wear out or be consumed. Therefore, after installation, the measurement system is completely maintenance-free and drift-free. The sensors offer digital signal transmission up to 1000 m and enable continuous inline measurement without sampling.

How is the integration into existing automation systems carried out?

The system offers various digital interfaces (e.g., Profibus, Ethernet/IP, Foundation Fieldbus) as well as analog 4-20 mA outputs. The integration is seamless via standardized protocols.

What maintenance is required for reliable polycondensation?

There are no mechanical wear parts, seals, or optical windows that could be attacked or stick during inline measurement. Regular calibration is not required - the sensors remain stable over the years. Unlike viscosity measurement, our ultrasonic method ultimately provides a more stable measurement and is also completely drift-free, cleaning-free, and maintenance-free.

How quickly do you get measurement results in polymer resin production?

The system delivers results in real-time.  Based on these measurements, you receive a current measurement value every second. This fast response time enables effective process control and early detection of undesirable deviations during polycondensation.

Further applications


Blending of resins

When blending, different resins, additives, or solvents are mixed to achieve specific properties and a homogeneous composition.

Formaldehyde production

Formaldehyde production places high demands on process management, as even small deviations in methanol oxidation can have noticeable effects on efficiency and product quality.

Polymerization

Polymerization is a chemical process in which smaller molecules (monomers) combine to form larger molecules (polymers). This process is fundamental to the production of many plastics and other materials.