In a groundbreaking collaboration, Rhosonics, a leader in non-nuclear density measurement technology, and Flottweg, a pioneer in industrial separation processes, have successfully overcome a common challenge in the industry: scaling in water/solids slurry pipelines. This innovative solution promises to revolutionize density measurement reliability, paving the way for improved operational efficiency in similar industrial applications.
The Challenge: Scaling and Inconsistent Density Measurements
Scaling and fouling in pipelines have long posed significant challenges in industrial processes, where accurate density measurement is crucial for optimizing operations. In Flottweg’s water/solids slurry pipeline, scaling on the sensor tip caused inaccurate density readings. Instead of detecting the actual slurry medium, the sensor occasionally picked up the scaling layer, leading to inconsistent measurements and reduced reliability.
This issue not only hampered process accuracy but also increased maintenance demands, complicating the operational workflow.
The Solution: A Flush System for the SDM Sensor
Rhosonics’ R&D team took on the challenge and developed an innovative flush system integrated into the SDM sensor’s spool piece. By incorporating an additional port, operators could clean the sensor and pipeline daily without dismantling equipment. This daily maintenance approach prevents scaling buildup and ensures uninterrupted, precise density measurements.
Moreover, the solution included the installation of a Pt100 sensor to monitor and compensate for temperature fluctuations in the slurry, further boosting the sensor’s accuracy and reliability.
The Impact: Restored Accuracy and Operational Reliability
The flush system proved highly effective, restoring measurement accuracy and providing consistent, reliable data. With this innovation, density measurements now vary by only 0.01 S.G., aligning closely with manual readings.
This advancement has been successfully implemented at a plant in Austria, with preparations underway for deployment at another facility in Germany. The collaboration has set a new benchmark for reliability in density measurement technology.
Christine Bauer-Salomon from Flottweg praised the solution, stating:
“The flush spool in our last project is doing well. It is much better for the sensor with flushing, and the data is more stable.”
Advancing Technology: The Launch of the SDM ECO
Building on the success of the SDM-4 sensor, Rhosonics introduced the SDM ECO in 2023. This next-generation device offers several advancements, including:
- Enhanced measurement accuracy.
- Faster response times.
- A wider operating temperature range.
- An upgraded sensor design tailored for modern industrial demands.
The SDM ECO has set a new industry standard in non-nuclear density measurement, further solidifying Rhosonics’ position as a global leader in the field.
A Step Forward for Industrial Efficiency
The collaboration between Rhosonics and Flottweg highlights the power of innovative engineering to solve real-world industrial challenges. With the integration of the flush system and the introduction of the SDM ECO, industries reliant on accurate density measurements can now operate with greater confidence and efficiency.
As this solution gains traction, it is expected to redefine best practices in pipeline density measurement, reinforcing the importance of innovation in addressing industry-wide challenges.
