Introduction
Control of sodium chloride (NaCl) concentration at a salt dissolver where solid salt is dissolved in water, is highly important because of the electrolysis efficiency. A conventional way of measuring the concentration of supersaturated NaCl solution had been performed by using non-contact type sensors (e.g., γ-ray density meter) since NaCl, impurities, and precipitates are in the solution. In this way, there were disadvantages such as troublesome maintenance and therefore, the radiation control is required for γ-ray density meter. Responding to these backgrounds, the ISC202 inductive conductivity analyzer provides concentration reading and realizes to improve substantial maintainability, cost performance and measurement accuracy.
Caustic Soda Production Process
Expected Benefits
- Measures NaCl concentration in salt dissolvers
- Reduces operating costs
Process Overview
In an electrolysis plant, the solid salt is dissolved in water in a salt dissolver to make brine. This brine contains impurities, such as calcium, magnesium or sulfates, that decrease electrolysis efficiency. The brine is purified by removing these impurities before being fed to an electrolyzer, where the purified brine is electrolyzed to produce caustic soda and chlorine. The caustic soda solution produced at the cathode in the electrolyzer is concentrated in a multiple effect evaporator, as a result the concentration is increased from approximately 32% to 48%.
Solution Details
Measurement system
2-wire inductive conductivity system
| Sensor | ISC40G(J)-GG-T1-☐☐ |
|---|---|
| Flow-through holder | ISC40FF(J)-PJ |
| Transmitter | FLXA202-D-BｰD-☐-C5-NN-A-N-LA-☐-NN |
Inductive Conductivity Sensor & Transmitter Installation Diagram
Utilities
| ISC202G inductive conductivity transmitter | |
|---|---|
| Power supply voltage: | 17 - 40 V DC (from distributor) |
| Power consumption: | 0.9 VA maximum |
| PH201G distributor | |
| Power supply: | |
| 100 V: | 20 to130 V DC/80 to 138 V AC, 47 to 63 Hz |
| 220 V: | 120 to 340 V DC/138 to 264 V AC, 47 to 63 Hz |
| Power consumption: | 24 V DC: approx. 200 mA |
| 100 V AC: approx. 7 VA | |
| 220 V AC: approx. 11 VA | |
Notes
Sampling should be done in the supernatant liquid in a salt dissolver. The supernatant liquid is collected in a settling tank and then the supernatant liquid of the tank is transported to a measurement tank where the sensor is installed.
Field Data
1. Process conditions (salt dissolver)
| Temperature: | Approx. 65°C |
|---|---|
| Pressure: | Atmospheric pressure |
| Sample: | Supersaturated brine |
| NaCl concentration control range: | 200 to 360 g/L |
| --> 18.1 to 30 wt%* | |
* Depends on user's actual data of specific gravity.
2. ISC202G setting parameters
Relationship between conductivity and concentration is based
on the linear approximation of S = 16.3x that is obtained by actual measurement using SC72 Personal Conductivity Meter.
- NaCl temperature compensation table is used
- Reference temperature setting: 25°C
- Output setting: Code 04
| Output (%) | Concentration (%) | Conductivity (mS/cm) |
|---|---|---|
| 0 | 18 | 293 |
| 50 | 24 | 391 |
| 100 | 30 | 489 |
Industries
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Chemical
Chemical plants rely on continuous and batch production processes, each posing different requirements for a control system. A continuous process calls for a robust and stable control system that will not fail and cause the shutdown of a production line, whereas the emphasis with a batch process is on having a control system that allows great flexibility in making adjustments to formulas, procedures, and the like. Both kinds of systems need to be managed in available quality history of product, and to be able to execute non-routine operations. With its extensive product portfolio, experienced systems engineers, and global sales and service network, Yokogawa has a solution for every plant process.
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Specialty & Fine Chemical
Yokogawa has long served customers in the specialty and fine chemicals market. With a market leading batch solution that offers the best in class reliability and flexibility as well as industry experts who understand the complex requirements in designing a batch solution, you can be assured that in your partnership with Yokogawa you will have a system that will enable you to produce products that meet your customers’ needs in the future while maintaining safety and regulatory compliance.
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