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- Insulation Assembly
The waste heat recovery system plays a crucial role in the sulfuric acid production process, which is not only responsible for energy recovery, but also ensures the absorption efficiency of the system. In this system, the accuracy of the acid concentration analyzer directly determines the recovery efficiency and the operational safety of the entire system. Therefore, it is essential to quickly identify and resolve any failures in the acid concentration analyzer.
Measurement of sulfuric acid concentration is a critical task in waste heat recovery systems. The temperature range of measurement is 120~220°. C high temperature concentrated sulfuric acid. In order to meet this requirement, non-contact conductivity sensors (hereinafter referred to as sensors) are mainly used to measure sulfuric acid concentration. The working principle of the sensor is based on two coils: one acts as a transmitter and the other as a receiver. When an electric current passes through the transmitter coil, it creates an induced current in the sulfuric acid, and this induced current is proportional to the conductivity of the sulfuric acid. The receiver coil then detects the strength of the current and calculates the conductivity of the sulphuric acid, which in turn gives its concentration.
- Sensor Structure Diagram
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- Solution
Because high temperature sulfuric acid is strongly corrosive, and traditional insulation materials cannot withstand this high temperature environment, the two coils are not in direct contact with sulfuric acid. In order to form a conductive circuit, the electrode flanges at both ends of the sensor need to be connected.
When using the sensor, ensure that the sensor flange is insulated from the mounting flanges at both ends. When installing sensors in the field, commonly used insulation bolts include PTFE or paper-plastic insulation materials. However, at high temperatures, the PTFE material may soften, resulting in a weakening of the original preload force, which may cause the flange to leak sulfuric acid, thus affecting the normal operation and safety of the sensor. On the other hand, when using paper-plastic materials as insulators, due to the influence of factors such as bolt torque, moisture and acid fog, the paper insulation pad may be damaged, which also leads to flange leakage of sulfuric acid, which affects the performance and safety of the sensor.
The main reason for the release of sulfuric acid at the flange position of the sensor is that the insulation components of the original configuration are susceptible to high temperature deformation, sulfuric acid corrosion and rain softening and bolt torsion deformation. Only by solving the problem of these insulation components can the sensor sulfuric acid leakage be effectively prevented. To this end, according to the sensing performance requirements and the characteristics of sulfuric acid, we independently developed an insulation component designed for the sensor, aiming to completely solve the problem of sulfuric acid leakage in the sensor flange. The LJ80 non-high temperature insulation assembly is suitable for the temperature range of -40 to 260 ° C, and it uses engineering plastics with excellent insulation properties and corrosion and torque resistance as insulation pads. The fastening bolts are made of 304 stainless steel, and the surface is coated with Teron material to ensure that they do not soften at high temperatures, and the fastening force remains stable, so as to ensure that the flange joint does not leak acid waves. The component can resist the corrosion of dilute sulfuric acid, and reduce the impact of rain on the conductivity of the sensor, to ensure that the sulfuric acid concentration analyzer in the long-term use of the process will not be due to sulfuric acid drainage hole analysis failure, thus ensuring the safe and stable operation of the device.
- Selection Parameter
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