The difficulty of liquid level measurement in chemical electrolytic cells

In the field of chemical engineering, electrolytic cells are common and crucial equipment, widely used in various chemical reaction processes. However, in the actual production process, the liquid level measurement of chemical electrolytic cells is confronted with numerous complex and intractable problems. First, the electrolyte is prone to crystallization, adhering to the cell wall, electrodes and measuring devices, directly hindering the capture of measurement signals and resulting in inaccurate data. Secondly, corrosive gases such as hydrogen fluoride generated by electrolytic reactions can erode the metal parts of the instrument, reduce accuracy and even damage the equipment. Thirdly, the electrical signals and electromagnetic fields generated during the electrolysis process can interfere with the signal transmission of measuring instruments, causing data fluctuations and distortions, and making it difficult to achieve precise monitoring.

GRAEFF radar level gauge

The GRAEFF radar level gauge relies on 76-81GHz frequency-modulated continuous wave technology. Based on the time travel principle, it emits high-frequency microwave pulses to the surface of the medium. After the pulses are reflected, they are received by the probe. The system accurately converts the liquid level height by calculating the round-trip time of the signal. Its unique millimeter-wave characteristics can specifically solve the measurement problems under the complex working conditions of electrolytic cells, making it the preferred solution for industrial liquid level measurement.

The advantages of GRAEFF radar level gauges

Non-contact measurement, fearless of complex media

It adopts a non-contact measurement mode, and the probe does not need to come into contact with the electrolyte, thus avoiding the influence of crystal adhesion and hydrogen fluoride corrosion from the root. Equipped with dedicated accessories such as anti-corrosion antennas and quartz isolation flanges, it can maintain stable operation even in highly corrosive and high-viscosity medium environments, significantly extending the service life of the equipment.

It has strong anti-interference ability and accurately captures liquid level signals

Equipped with a 5GHz ultra-wide frequency modulation scanning width, combined with false echo learning, multiple filtering algorithms and professional anti-interference technology, it can effectively filter out interference factors such as electromagnetic fields, medium turbulence and steam dust in the electrolytic cell. It is equipped with rich echo processing algorithms and working condition experience data to ensure stable transmission and reception of microwave signals, with measurement errors controlled within a high-precision range of ±0.5mm.

Wide measurement range and high precision, suitable for various working conditions

The measurement range covers 0.08m to 120m, with a blind zone as low as 2cm. It can not only meet the short-distance measurement requirements of small electrolytic cells but also be adapted to the long-distance monitoring of large storage tanks. With a measurement resolution of 1mm and a narrow beam design of less than 2°, it can accurately capture liquid level changes even in confined Spaces or guided wave pipes, meeting the production requirements of electrolytic cells of different specifications.

It has strong environmental adaptability and can withstand harsh working conditions

The casing is made of aluminum alloy and stainless steel, with a protection grade of IP68 and an explosion-proof grade of ExdiaIICT4. It can operate stably in an environment with a temperature range of -40 to 85℃ and a pressure range of -0.1 to 2MPa. In response to the strong corrosive and high humidity characteristics of the chemical industry, its sealing structure and anti-aging design can handle harsh working conditions with ease, ensuring long-term reliable operation.

Easy to operate and suitable for industrial scenarios

It supports standard HART, RS485/MODBUS bus protocols and can be operated on-site through the upper computer software, tank side meter or 128×64 dot matrix display screen + 4 keys. The parameter Settings are intuitive and easy to understand. It offers multiple installation methods such as threaded and flange, and can be adapted to electrolytic cells of different structures without complex modifications. The commissioning process is simple and efficient, lowering the threshold for on-site application.

Wide range of applicable fields

Radar level gauges, with their core advantages such as non-contact measurement, strong anti-interference, and wide environmental adaptability, have broken through the limitations of a single chemical industry scenario and achieved stable application in complex working conditions across multiple industries, becoming a "universal solution" for industrial level measurement.

Petrochemical industry

As the main application scenario of radar level gauges, it can comprehensively cover the measurement requirements of the entire process from raw material storage to production reaction. In storage tanks of flammable and explosive media such as crude oil, gasoline and diesel, with the ExdiaIICT4 explosion-proof grade and the ability to resist volatile gas interference, it can not only avoid equipment failure caused by medium corrosion, but also meet the safety requirements of lightning strike prevention and overflow prevention. In high-temperature and high-pressure reaction vessels and distillation columns, the liquid levels of acid and alkali solutions, polymers and other media can be precisely monitored. For instance, in the atmospheric pressure tower of an oil refinery, it can achieve ±1mm accuracy measurement at the oil-gas interface, ensuring the stability of the reaction process and avoiding the risk of product scrapping caused by abnormal liquid levels. For various corrosive raw material tanks and solvent tanks in chemical industrial parks, the combination design of anti-corrosion antennas and stainless steel materials can easily cope with the erosion of strong corrosive media such as hydrochloric acid and sodium hydroxide.

Water treatment and environmental protection industry

It is perfectly adapted to the complex medium environment of municipal and industrial water treatment. In the clear water tanks of waterworks, aeration tanks and sedimentation tanks of sewage treatment plants, it is not disturbed by water vapor, foam and suspended solids. Compared with ultrasonic level meters, its measurement stability is significantly improved, providing reliable data for the regulation of water quality purification processes. In corrosive waste water tanks such as chlorine-containing wastewater and chemical tail water, the IP68 protection grade and anti-corrosion structure can resist medium erosion and avoid the frequent maintenance of traditional instruments caused by blockage and corrosion. For scenarios such as sludge thickening tanks and slurry storage tanks, the non-contact measurement mode fundamentally solves the problem of probe blockage, ensuring precise control of the sludge discharge and dosing processes.

The food and pharmaceutical industry

It meets the standards of hygienic applications and performs outstandingly in the demanding food and pharmaceutical scenarios. The model made of 316L stainless steel and equipped with FDA-certified sealing parts can be adapted to liquid food storage tanks such as juice, milk, and edible oil. The non-contact measurement method avoids medium contamination and meets hygiene standards such as 3A and EHEDG. In fermentation tanks for beer, yogurt, etc., it can withstand the interference of carbon dioxide gas produced during the fermentation process, and monitor the liquid level changes in real time to ensure the stability of the fermentation process. In the liquid medicine tanks and raw material powder silos of the pharmaceutical industry, high-precision measurement and intelligent data storage functions can achieve traceability of the production process and comply with GMP management standards.

The power and energy industry

It is suitable for extreme working conditions such as high temperature, high dust and high pressure in energy production. In the steam drum of a thermal power plant boiler, water levels can be precisely measured under conditions of 300℃ high temperature and 15MPa high pressure, preventing safety accidents such as "full water causing steam to carry water" or "lack of water leading to dry burning of the boiler". In material storage equipment such as raw coal silos and fly ash silos, narrow beam design and anti-dust interference technology can penetrate high-concentration dust layers, accurately measure the material level height, and prevent boiler material interruption caused by empty silos or blockage of the conveying system caused by full silos. In addition, in the coolant storage tanks and lubricating oil tanks of the new energy field, its wide range characteristics can meet the liquid level monitoring requirements of energy storage devices of different specifications.

Metallurgy and building materials industry

It can withstand high-temperature radiation and strong wear conditions, providing stable support for heavy industrial production. In the blast furnace of steel smelting, it can withstand high-temperature radiation above 1500℃, precisely monitor the slag liquid level, and provide data basis for the control of slag discharge time. In pulp storage tanks, the non-contact measurement mode avoids the wear of the probe by pulp containing metal particles and resizes the strong corrosiveness of sulfur-containing pulp at the same time. In the building materials field, radar level gauges can achieve reliable monitoring in high-dust environments such as cement silos and lime silos, as well as in high-temperature liquid level measurement of molten glass in glass kilns, thanks to their technical advantages. 

If your enterprise is currently facing similar liquid level measurement challenges, choosing GRAEFF radar level gauges can help you break through complex working conditions with its technological advantages, provide reliable data support for production regulation, and empower efficient and safe production!