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Process optimization in the
Polycondensation

Polycondensation is the most important step in the Polymer resin production LiquiSonic® delivers precise results using ultrasound measurements Monitoring and analysis of your processes - completely maintenance and drift-free.

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Response monitoring

Real-time measurement

Maintenance & drift free

Cost saving

Challenges in polycondensation

Polycondensation is the central step in polymer resin production and is particularly susceptible to fluctuations in the process. Even small deviations in the progress of the reaction can lead to either too high a degree of crosslinking or too low a molecular mass. The result is brittle and unusable resin with inadequate mechanical properties. In order to prevent rejects, precise control of viscosity and degree of crosslinking is crucial. In addition, the precise determination of the reaction progress is technically very demanding.

challenges

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

Solution: LiquiSonic®

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

Your advantages

  • Constant product quality through real-time monitoring
  • Reducing scrap through precise process control
  • Reduction of time-consuming analysis, 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 high-precision ultrasound measurement of the reaction progress. Since the speed of sound correlates directly with the concentration and properties of the resin, critical deviations can be detected early and corrected immediately. The robust sensor design allows direct installation in reactors or lines and provides temperature-compensated real-time data that can be automatically documented and transferred to the process control system. In this way, reaction parameters can be better regulated, laboratory analyzes can be reduced to a minimum and constant quality can be ensured. An above-average sensor length is often used, which (as one of many adjustment options for the measuring system) allows optimal integration into your specific process.

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

Technical and economic details

Ultrasonic measuring principle

The ultrasonic measurement method from LiquiSonic® is based on high-precision time measurement. The speed of sound is calculated from the measured sound transit time and the known distance between the transmitter and receiver, which is directly linked to the concentration and properties of the polymer resin correlates. This allows the reaction progress 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 method in polycondensation, it is slower, reacts less sensitively to concentration fluctuations (especially at high concentrations) and leads to sticky sensors during inline measurement. The ultrasonic method ultimately delivers a more stable measurement and is also completely drift-free, cleaning-free and maintenance-free.

The ultrasonic process offers further advantages: Robust inline measurement without interruption, high accuracy, temperature compensation, reliable gas bubble detection and flexible adaptation of sensor length and installation variant to the respective system geometry. The continuous data collection also allows the creation of a “Golden Batch” profile that documents the optimal reaction process. Future batches can be compared to this reference process so that deviations are immediately identified and corrected. In this way, a 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 significant economic potential:

  • Reduction of rejects through immediate detection of incorrect mixes
  • Optimized raw material consumption thanks to precise dosage and optimized final concentrations

  • Faster response times in case of process deviations, which minimizes downtimes

  • Saving energy and operating costs through more efficient process management
  • Reliable documentation through automatic data storage
  • Higher system availability thanks to robust, drift-free, cleaning-free and maintenance-free sensors
  • Fast ROI through reduced operating costs and greater process stability


Application example

Polycondensation is the most important step in polymer resin production. The polymer resin can only be used for the desired application if the viscosity is correct. The LiquiSonic® Measuring system continuously monitors the concentration using ultrasound measurements and detects even the smallest deviations in real time. This allows incorrect mixing to be avoided and the use of materials to be precisely controlled. The robust plug-and-play sensor design enables direct integration into the process. Sensor length and connection variant can be individually adapted to the process so that the polycondensation progress can be continuously monitored. All measured values ​​are automatically documented and are available for subsequent analyzes 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. Please contact us for specific application examples!

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The most important advantages at a glance

Constant quality

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

Cost savings

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

Maximum 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 of our LiquiSonic® sensors are equipped with high-precision temperature sensors. This allows the influence of temperature on the measurement directly compensated become. Therefore it is not necessary to use additional temperature sensors during the Polymer resin production  to incorporate.

Which process conditions can be covered?

Our sensors work reliably in one Temperature range from -40°C to 200°C and Pressures up to 500 bar. Aggressive media can also be measured using various material options such as stainless steel, Hastelloy, or PFA coatings. Explosion protection for zones 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 customer-specific adjustments such as sensor lengths up to 3000 mm, special alloys for corrosive media and various types of protection, for example optional explosion protection. Every sensor will individually according to your requirements configured.

Can multiple components be monitored at the same time?

Yes, by combining sound speed 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?

In contrast to optical methods, which are affected by color or haze, conductivity-based methods, which are sensitive to electrical conductivity, or density-based methods, which can be disturbed by temperature or gas bubbles, ours Ultrasound procedure independent of these influences. In contrast to viscosity measurement, the method is also less sluggish, does not require sampling and reacts more sensitively to concentration fluctuations.  The LiquiSonic® measuring technology also contains neither moving parts nor components that can wear out or be used up. After installation, the measuring system is therefore 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 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 easy 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 necessary - the sensors remain stable for years. In contrast to 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 receive measurement results when producing polymer resin?

The system delivers Real-time results. Based on these measurements, you receive an up-to-date reading every second. This fast response time enables effective process control and early detection of undesirable deviations during polycondensation.

Other applications


Blending resins

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

Formaldehyde production

Formaldehyde production places high demands on process control, as even small deviations in methanol oxidation have a noticeable impact 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.

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