Electrolyzer Solution: Instruments and Solution for Ion-Membrane Electrolyzer Plant ApplicationPDF

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Fundamental Materials for Industries

Caustic soda and hydrochloric acid, produced in electrolyzer plants, are fundamental materials used in varieties of industries; chemicals, pharmaceuticals, petrol-chemicals, pulp and papers, etc.

Profitability from Efficient Production

Profit is the result of the effective production with minimized running / maintenance cost.

Effective Production

Proper control of the process brings you stabilized quality of products with the vast operational profit. The process condition may vary often. When conditions are changed, the process controller and sensors have to follow well.

Energy Cost

Ion-Membrane electrolysis bath is the most effective among all types of electrolyzer in caustic soda production. But it still consumes huge energy. Energy consumption has to be reduced to minimize the environmental stress like CO2 emissions, for increasing your profitability.

Maintenance Cost of Membrane

A Membrane has life time. It should be maintained periodically. To prolong operating life, the electrolyzer plant should be monitored for optimized control.

Tough Environments

There is an intensive electromagnetic field around electrolysis bath. In addition chlorine and other by-products are corrosive. Sensing devices have to be tough against such environment with providing accurate measurement all the time.

Total Cost of Ownership (TCO)

Maintenance costs for these sensing devices should be considered as TCO, next to the initial cost of your investment. Those should be in good balance.

Why Buy Yokogawa?

Our devices can afford to perform accurate measurements under tough condition in electrolyzer plant application. You can minimize these maintenance costs, achieving the maximum profit from the control of the process with accurate measurement.

Salt Dissolver: Monitoring NaCl

ISC202 Inductive Conductivity Transmitter
ISC202 Inductive Conductivity
Transmitter & PEEK Sensor

Overview and Problems

  • NaCl concentration monitoring
  • Raw salt easily clog the sensor
  • Correlation characteristic changes depending on components of salt

Solution

  • Wide hole sensor, no clogging of suspended solids, etc...
  • Concentration (Weight %) free programmable
  • Recommend bypass sampling

Benefits

  • Reduce maintenance cost
  • Supply stable brine to electrolysis bath

Electrolysis Bath: Monitoring pH

PH202 pH Transmitter & Sensor
PH202 pH Transmitter & Sensor

Overview and Problems

  • pH monitoring to detect membrane leakage
  • Sensor is easily deteriorated by high temperature and saturated Chlorine gas

Solution

  • Special anti-corrosive glass membrane
  • Special anti-corrosive structure of Ag ion trap

Benefits

  • Rapid detection of pin hole of electrolysis membrane
  • Maintenance cost reduction

Electrolyzer Plant: Flow Measurements

 ADMAG
ADMAG AXF Series
Magnetic Flowmeter

Overview and Problems

  • Flow measurement in electrolyzer plants
  • The stray current from electrolysis bath harms the measurement by magnetic flowmeter
  • High corrosive liquids such as caustic soda, sulfuric acid etc

Solution

  • Dedicated DC Noise Cut Filter to minimize the stray current
  • 0.35 % of reading, highly accurate and stable measurement by Dual Frequency Coil Excitation Method

Benefits

  • High accurate and stable flow measurement is realized in electrolyzer plant
  • Simple maintenance
Electrolyzer Plant
 
Liners and Electrodes
Yokogawa can prepare a wide variety of wetted Parts Materials

Lining:
• PFA
• Ceramic, and more

Electrode and Earth Ring:
• SUS316L
• Platinum
• Tantalum, and more

Electrolysis Bath: Cell Voltage Monitoring

Overview and Problems

  • Need multi-channel data logging with fast sampling measuring each cell voltage
MX100 Data Acquisition Unit
MX100 Data Acquisition Unit

Benefits

  • Rapid detection of pin hole of membrane
  • Longer maintenance period of each cell
  • Less maintenance of relays
  • Can accept other process inputs: pressure, temperature, pH, ...

Solution

  • 10 msec sampling fastest
  • Isolated inputs, High Withstand Voltage: 600 VRMS/VDC (cont.)
  • Up to 60 ch per system, Ethernet interface for expandability
  • Individual cell-voltage measurement with ± 0.004 V accuracy
  • Long-life semiconductor relay

HCl Plant: Monitoring HCl Concentration

ISC202 Inductive Conductivity Transmitter
ISC202 Inductive Conductivity
Transmitter & PEEK Sensor

Overview and Problems

  • HCl concentration monitoring
  • High concentration HCl easily deteriorate the sensor

Solution

  • Special electrode material resistant to concentrated HCl
  • Concentration (Weight %) free programmable

Benefits

  • High stability and accuracy for quality control

Final Production: Monitoring NaOH Concentration

Analyzer- DM8C Liquid Density Converter
DM8 Liquid Density Analyzers

Overview and Problems

  • NaOH concentration monitoring after electrolysis tank and concentrate drum • Need accurate measurement not affected by temperature variation

Solution

  • Special tuning fork sensor
  • Stable density measurement against temperature change

Benefits

  • High stability and accuracy, for quality control of Caustic Soda

Chlorine Gas Drying Process: Monitoring H2SO4

ISC202 Inductive Conductivity Transmitter
ISC202 Inductive Conductivity
Transmitter & PFA Sensor

Overview and Problems

  • H2SO4 concentration monitoring
  • High concentration H2SO4 easily deteriorate sensor
  • Various measurement range

Solution

  • Special material resistant to H2SO4
  • Concentration (Weight %) free programmable
  • Wide range ability in terms of conductivity
    (100 µS/cm – 2 µS/cm)

Benefits

  • High stability and accuracy to improve efficiency of drying process
  • Only 1 spare sensor for 3 steps drying tower tank
Sensor for Conductivity
Yokogawa can prepare a wide variety of sensors and fittings

Sensor Materials:
• PEEK
• PFA

Fittings:
• Direct Insertion
• Flow Holder, and more

Technologies Commit Users' Benefits

Inductive Conductivity Sensors

Dual Frequency Coil Excitation

Our Goal:
Our shared goal is customer satisfaction through operational excellence. Yokogawa has brought true innovations to industry. We are committed to ensuring accuracy, reliability, and safety of your production system throughout your business life cycle. Our comprehensive solutions and expertise help you achieve more results with less total costs of ownership. Below key technologies shall aim for your operational excellence.

ASIC for Accurate Measurement

Inductive Conductivity Sensors

ISC sensors use a high performance engineering plastic of PEEK (polyetheretherketone) that provides abrasion and corrosion resistance. The sensor has a large bore (17 mm) for optimal resistance to fouling processes and when properly installed, the flow will keep the sensor clean, to help avoid measuring errors. This large bore also allows quick response even on low flow measurement. Also available upon request is a PFA lined sensor that provides excellent heat and chemical resistance.

High Withstand Voltage

Dual Frequency Coil Excitation

Magnetic Flowmeters measure flow volume with Faraday's law. The frequency of excitation current given to coils affects in the measurement accuracy and response time. Dual Frequency Coil Excitation is Yokogawa's original technology to ensure ± 0.35 % accurate measurement as well as 0.1 second fast response simultaneously. Our signal processing technique enables us to bring the benefits of an AC & DC magnetic flowmeter into a single magnetic flowmeter.

ASIC for Accurate Measurement

The measurement engine for DAQMaster series is requested to ensure accurate measurement even under the sampling speed as fast as 10 msec measurement interval. This performance is achieved with by Yokogawa developed special A/D converter.

High Withstand Voltage

For performing accurate monitoring for each of cell voltage as well as other parameters like temperature, isolation between channels is the key. A/D circuits of DAQMaster input modules use special transformers. Semiconductor relay, designed by Yokogawa, is another key component for tough isolation. This enables high-speed scanning, while eliminating the periodic replacement of relay board. In addition, DAQMaster's input modules employ integrating A/D converters with superior noise rejection performance.

For Your Operational Excellence

ISC202 Inductive Conductivity TransmitterInductive Conductivity Transmitter: ISC202

  • Single stain-resistant sensor covers a wide measuring range
  • Process-independent customized temperature compensation
  • Fieldbus communication capability
  • Intrinsically safe version

PH202 pH Transmitter & SensorpH Transmitter: PH202

  • Designed for two-wire system configuration
  • Fieldbus communication capability
  • Event logbook
  • Intrinsically safe version

Analyzer- DM8C Liquid Density ConverterLiquid Density Analyzers: DM8

  • Measures liquid density with high sensitivity and excellent stability
  • Measuring range of 0.5 to 2.0 g/cm³, unaffected by flow rate and viscosity
  • Sanitary and flameproof detector also available

MX100 Data Acquisition UnitData Acquisition: DAQMaster Series

  • Modular layout up to 60 channels
  • High speed sampling: 10 msec fastest
  • High Withstand Voltage (Reinforced Insulation): 600 VRMS/VDC (cont.)
  • CF Card for data backup
  • Expandability over Ethernet

ADMAGMagnetic Flowmeter: ADMAG AXF Series

  • Best-in-class performance with dual frequency excitation method
  • Predictive electrodes adhesion diagnostics
  • Variety of liners & electrode materials
  • Fieldbus communication capability

iab-app-dpharp-001-en.jpgPressure Transmitter: DPharp EJA/EJX Series

  • Best installed performance
  • Compact and rugged design
  • Multi-sensing digital sensor
  • SIL2 as standard (EJX)
  • Fieldbus communication capability

YTA110Temperature Transmitter: YTA Series

  • High resolution, high stability and high versatility
  • Dual compartment housing for harsh environments
  • SIL2 safety as standard feature
  • Fieldbus communication capability

ADMAG AXF and DAQMASTER are registered trademark of Yokogawa Electric Corporation.
DPharp is a trademark of Yokogawa Electric Corporation. Ethernet is a registered trademark of Xerox Corporation.
Other company names and product names appearing in this document are registered trademarks or trademarks of their respective holders.

Related Products & Solutions

2-Wire Transmitter/Analyzer FLEXA

The model FLEXA® two-wire analyzer is used for continuous on-line measurements in industrial installations. It offers an option for single or dual sensor measurement, making it the most flexible 2-wire analyzer available. The model FLEXA® modular designed series analyzer offers 4 parameter choices – pH/ORP (oxidation-reduction potential), contacting conductivity (SC), inductive conductivity (ISC) or dissolved oxygen (DO) – with the respective sensor module.

ADMAG AXF

The AXF magnetic flow meter is a sophisticated product with outstanding reliability and ease of operation, developed on the basis of decades of field experience. Based on FOUNDATION™ fieldbus specifications, AXF Fieldbus Magnetic Flow meter models offer more flexible instrumentation.

DAQWORX

DAQWORX is the previous generation data logging software compatible with most Yokogawa recorders, data loggers, temperature controllers, and measuring instruments. 

Inductive (Torodial, Electrodeless) Conductivity Sensor ISC40

The model ISC40 sensors are designed for use with the EXA ISC analyzers. This combination exceeds all expectations for conductivity measurement in terms of reliability, accuracy, rangeability and price performance. 

Liquid Density Analyzer DM8C, VD6

The DM8 liquid density analyzer measures liquid density of general process liquids with high sensitivity and excellent stability. It has a measuring density range of 0 to 2.0 g/cm3, and unaffected by flow rate and viscosity. Besides general-purpose sensor, sanitary and explosionproof sensor are also available.

PC-Based MX100

For test applications with data logging requirements, the MX100 scales from four to 1200 channels. It streams, records, displays, and reports with no programming required.

YTA110/310/320 Temperature Transmitter

The YTA110/310/320 series is Yokogawa's base traditional temperature transmitter in the field-mount transmitter line.
YTA110 HART protocol model has been discontinued.

YTA50

The YTA50 is a 2-wire analog temperature transmitter that outputs a simple 4 to 20 mA output that correspondes to the temperature measured.

YTA510 Wireless Temperature Transmitter

The high performance temperature transmitter YTA510 accepts Thermocouple, RTD, ohms or DC mill volt inputs. The transmitters transmit not only process variables but also the setting parameters using wireless signal. The transmitters run on internal batteries, and the installation cost can be decreased since hard-wiring is not required. The communication is based on ISA100.11a protocol specifications. 

YTA70

Like the YTA50, the YTA70 is a 2-wire analog temperature transmitter that outputs a simple 4 to 20 mA output that correspondes to the temperature measured. However, it adds HART® 5 (Code -E) or selectable HART® 5 or HART® 7 (Code -J) digital communication.

Field Wireless

The flexibility of wireless solutions enables less investment in infrastructure while providing greater insights into plant operations.

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