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FLEXIM GmbH
PIOX / Analytical
Measuring & Sales Methods
FLEXIM GmbH
PIOX - Process Analyzers
PIOX R - Process Refract meter Measurement
PIOX S – Non-intrusive Ultrasonic Measurement
with Laboratory Accuracy
Concentration
Nitric Acid
Density
Mass Flow
HCL
Ammonium Nitrate
Concentration
Density
Refractive Index
Urea
Sulfuric Acid
Glycol / Water
FLEXIM GmbH
PIOX S - Speed of Sound of Liquids
Speed of Sound is a physical property
of a liquid at a given temperature:
Water 1480 m/s
Crude Oil 1300 m/s
Hexane 1080 m/s
Butan 943 m/s
Caustic Soda 10% 1800 m/s
Caustic Soda 50% 2450 m/s
Within mixtures or solutions, the Speed of Sound changes with the concentration
Thus, the liquid soundspeed can be used for
concentration measuring
FLEXIM GmbH
PIOX S –
Measurement of Sound Velocity
02
ttt
lc
updown
FluidFluid
Sound Speed
is calculated by path length of
the signal traveling in a medium
and the average transit time
within the medium.
To achieve highest
accuracy
the transit time and path
length of the signal traveling
within the sensor and the pipe
wall has to be taken into
account and a field calibration
is necessary.
FLEXIM GmbH
Sound Velocity vs. Concentration
Specifically at concentration levels above 55%wt, the sonic velocity has a clear
measuring effect due to the steep slope of the nitric acid
Accuracy above 60%wt concentration, accuracies better than 0.1%wt absolute are
dependant upon temperature.
FLEXIM GmbH
PIOX S - Flow Measurement Principal – Transit Time Difference
Calculation of
Volume Flow [Q]
Q - Volume Flow
KRE - Fluid Mechanical
Correlation Factor
A - Cross-Sectional
Area of Pipe
ka - Transmitter-Constant
D t - Transit Time Difference
tt - Transit Time in Medium
FLEXIM GmbH
PIOX S - How to calculateconcentration, density or mass flow
Outputs : Volume flow
or Mass flow
Concentration
or Density
Temperature
Volume = Mass/Density Density = Mass/Volume Mass = Density x Volume
FLEXIM GmbH
PIOX S - Capabilities Ultrasonic
Clamp-on
Flow velocities: from 0.015 up to 45 m/sec
Accuracy flow measurement:+/- 1.6% of reading with standard calibration+/- 1.2% of reading with extended calibration+/- 0.5% of reading with field calibration
Repeatability: 0.15% of reading
Accuracy concentration measurement depends on fluid properties
E.G. - In Nitric Acid from 60 to 98%wt typically < 0.1%wt absolute
Fluid properties:no influence of conductivityalso for high viscous liquidsup to ~10% gas/solid/2-phase content
FLEXIM GmbH
PIOX S Advantages
Maintenance and drift free
(highly durable and robust)
Corrosion free
Long life cycle of ownership
Low energy consumption compared to intrusive
metering
Low Cost
of
Ownership
Maintenance free
No process shutdown during installation
and commissioning
Almost not effected by deposits and blisters
Zero
Downtime
No Contamination risk of process fluid
Fast measuring response
quick detection of process measurement changes
Product
Quality
No leakage riskPlant
Security
Triple Purpose Volume Flow, Concentration
and Mass Flow
No Bypass piping required
Non-intrusive – No custom piping or materials
Instrument costs are independant to pipe size or
pressure ratings
Measurement up to 750F pipe temperature
Low
Investment
Cost
FLEXIM GmbH
Concentration curve comparison
Sound Speed Refractive Index
When PIOXS is not the best fit, we can go with PIOXR
FLEXIM GmbH
PIOX R - Process Refractometer
Unique Transmitted Light principle
Patented bi-prism
Zero point calibration not required
Drift free Refractive Index measurement
Calculation of m%, density, g/l, mol/l, Brix
Integrated high accuracy Pt1000 RTD
Allows for measuring of Turbidity
Independent of fouling and accumulation
Various materials for corrosive liquids
High precision (0.00002 nD – typ. 0.01M%)
Capable of high temperatures (150°C / 302°F)
Intrinsic safety (ATEX Zone 0/1)
FLEXIM GmbH
Competition - Critical Angle Refractometer
Light from a point source meets the surface between
the optical prism and the liquid at different angles
Light with a small incident angle is refracted into the
medium
Light meeting the surface at larger angles is totally
reflected and is detected by a CCD Sensor
The position of the slope is calculation basis for the
refractive index
Total reflection:
α = arcsin (n1 / n2)
FLEXIM GmbH
Real World Examples of light refraction
Long angles reflect
Short angles refract
FLEXIM GmbH
Competition - Critical Angle Refractometer
Critical angle principle at laboratory refractometer
only small sample volumes necessary
easy sample change
easy cleaning
FLEXIM GmbH
Competition - Critical Anlge Refractometer
Critical angle refractometer in process
surface measurement: only the medium in direct
contact with the prism is measured
therefore already tiny particles at prism surface
contribute to reflection
the calculated refractive index is influenced
Drift and faulty measured values
FLEXIM GmbH
Competition - Critical Angle Refractometers
• All use critical angle design
• All subject to drifting with
coating buildup
FLEXIM GmbH
Flexim - Transmitted Light Refractometer
A beam of parallel light crosses the medium and is
refracted at an optical prism
The light beam is focussed to an image sensor (CCD)
The refractive index is calculated from the light spot
position on the sensor
Additionally the amplitude of the signal is measured
n1 sin α = n2 sin β
FLEXIM GmbH
Transmitted Light Principle in Process
Only the light passing through contributes to the
measurement
The light beam passing the fluid is parallel, therefore
the direction does not change, even if the whole
beam does not pass through
The signal position on the CCD sensor remains the
same
Only the signal amplitude is reduced
correct measurement of process
medium
no drift !
FLEXIM GmbH
Refractometer Principles
Critical Angle
measures surface of medium
all particles on the prism influence value
=> faulty measurement
therefore high cleaning frequency
no possibility to check validity of
measurement
Transmitted Light
measures through the medium
parallel light beam, therefore:
despite build-up correct measured value
signal amplitude indicates validity of
measurement and build-up on prism
FLEXIM GmbH
Differential Measurement
Transmitted light principle with bi-prism
two symmetrical signals are detected on the CCD
sensor
zero point is mean value between both signals
calculation of R.I. according distance of both signals
differential principle establishes drift free refractive
index measurement
temperature normalization of refractive index
through integrated Pt1000 temperature probe
From refractive index and temperature other physical
properties will be calculated:
e.g. m%, density, g/l, mol/l, Brix
FLEXIM GmbH
Use of Signal Amplitude
shows that measured value is valid
Fouling / build-up indicator
Turbidity indicator
Monitoring of solving
processes
wide range 1 : 10000
FLEXIM GmbH
Advantages PIOX® R400
Unique Transmitted light refractometer for
process
Patented differential measurement with bi-prism:
no drift
correct measurement even with build-up
possibility to detect build-up
additional highlights:
high precision (0,00002 nD – typ.0,01 m%)
wide measuring range
ATEX Zone 0/1
Max. Temp. 150°C
FLEXIM GmbH
PIOX R – Improved Sensor design
Internal Gaskets
Improvements of
sapphire Optics
Increased reliability
Maximized Durability in
aggressive and corrosive
liquids
Chemical & Hygienic
designs
FLEXIM GmbH
PIOXR – Stainless Steel Design
3” Tri-Clamp
Design
1”-2”-3”
ANSI150
Direct Flange
Mount Design
Flow Chamber
Design
Threaded or Flanged
FLEXIM GmbH
PIOXR – TEFLON Design
2”-3”-4”
ANSI150
Direct Flange
Mount Design
PFA Lined
Flow Chamber
FLEXIM GmbH
PIOX R - Refractive Index of Nitric Acid
Also the Refractive Index of Nitric Acid is in distinct relation to its concentration
over a wide range
PIOX R and PIOX S can be complimentary tools for concentration
measurement over the whole concentration range of Nitric Acid
1.3300
1.3400
1.3500
1.3600
1.3700
1.3800
1.3900
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00
Nitric Acid Concentration vs. refractive index (20°C) nD
Nitric Acid Concentration vs. refractive index (20°C) nD
FLEXIM GmbH
PIOX R Advantages
Predictive Maintenance Diagnosis implemented
Drift free, 5% transmittance capable for operation
Free of Corrosion with a variety of
wetted materials
Long life cycle in comparison to similar measuring
No moving mechanical parts
Cost
of
Ownership
Almost no effect by deposits
Easy to maintain, including diagnostic output
No drift from surface fouling
Factory Calibrated and certified
Plant
Availability
Laboratory accuracy directly in proccess
Proccess temperatures up to 150°C
Product
Quality
Durable design for chemical applicationsPlant
Security
FLEXIM GmbH
PIOX - Process Analyzers
PIOX R - Process Refract meter Measurement
PIOX S – Non-intrusive Ultrasonic Measurement
with Laboratory Accuracy
Concentration
Nitric AcidDensity
Mass Flow
ConcentrationDensity
Refractive Index
FLEXIM GmbH
Nitric Acid Application Example
Truck filling station
Simultaneaous measurement of:
concentration
mass flow
stainless steel 304 pipe DN100 (4“)
inline temperature probe for fast reaction
FLEXIM GmbH
PIOX S for Nitric Acid
Installed Measurements:
YARA Sluiskil, Netherlands
YARA Ambes, France
YARA Rostock, Germany
AgroLinz / Borealis, Austria
El Dorado Nitrogen, Texas
FLEXIM GmbH
PIOX - Process Analyzers
PIOX R - Process Refract meter Measurement
PIOX S – Non-intrusive Ultrasonic Measurement
with Laboratory Accuracy
Concentration
DensityMass Flow
Ammonium Nitrate
ConcentrationDensity
Refractive Index
FLEXIM GmbH
Ammonium Nitrate Concentration and Flow
How do you measure the Flow around your AN pumps?
Flow measurement of Ammonium Nitrate Solution
80%...97%
temperature 140°C…190°C
pipes DN80…DN150
Advantages:
Accurate, non-intrusive measurement with PIOX-S ultrasonics
No plant shutdown during installation & commissioning
No life cycle replacement due to liquid corrosion
No equipment damage from product solidification at ambient temperature
Concentration measurement via dilution 96..92%
FLEXIM GmbH
Ammonium Nitrate Concentration
1600
1650
1700
1750
1800
1850
1900
1950
2000
30.00M% 40.00M% 50.00M% 60.00M% 70.00M% 80.00M% 90.00M% 100.00M%
30°C USS
25°C USS
20°C USS
15°C USS
10°C USS
70°C USS
65°C USS
60°C USS
55°C USS
50°C USS
Ultrasonic sound speed vs. concentration
FLEXIM GmbH
PIOX - Process Analyzers
PIOX R - Process Refract meter Measurement
PIOX S – Non-intrusive Ultrasonic Measurement
with Laboratory Accuracy
Concentration
DensityMass Flow
Urea
ConcentrationDensity
Refractive Index
FLEXIM GmbH
Urea - Concentration
FLEXIM GmbH
Urea - Concentration
Refractive Index of Urea
Urea
1,33
1,34
1,35
1,36
1,37
1,38
1,39
1,4
1,41
0 5 10 15 20 25 30 35 40 45 50
content weight%
nD
(20)
nD
FLEXIM GmbH
PIOX - Process Analyzers
PIOX R - Process Refract meter Measurement
PIOX S – Non-intrusive Ultrasonic Measurement
with Laboratory Accuracy
Concentration
DensityMass Flow
Urea Ammonium Nitrate
ConcentrationDensity
Refractive Index
FLEXIM GmbH
Urea Ammonium Nitrate – Total N-content
Combinational method
FLEXIM GmbH
Urea / Ammonium Nitrate PIOX Solution
FLEXIM GmbH
Urea and UAN
CF Industries, Donaldsonville Nitrogen Complex, Louisiana
UAN is produced at 32% - refractometry used for qualitiy control
combined with a density meter
PIOX R300 and PIOX R400
Prior solution: critical angle refractometer:
drifting measured values due to deposit building
FLEXIM GmbH
CF Industries, Donaldsonville
Concentration of
Urea Ammonium Nitrate
Used Critical Angle Refractometer
PIOXR Advantages:•Continuous Process Control
•Precise Measurement
•Drift Free
Selling Points•Increase of Product Quality
•Avoidance of waste batches
•Cost savings by elimination of
maintenance
FLEXIM GmbH
Measuring Point – Cherokee Nitrogen (US)
Parameter
Pipe Mat.: Stainless Steel
Outer Diameter: 88,9 mm,
Wall Thickness: 2,8 mm
Offset: 13m/s
Diagnostics
GAIN: 53 dB
SCNR: 51 dB
SNR: 33 dB
Ampl.: 95,0
Qual.: 48,5
PIOX-S
PIOX-RR400 – Flexim flange
Flow Chamber ANSI 3“
CDM – Transducer
2 soundpath
38,1mm distance
PIOXR Application Examples
PIOXR Application Examples
PIOXR Application Examples
PIOXR Application Examples
PIOXR Application Examples
PIOXR Application Examples
PIOX FAST Form
• Combination form for both
PIOXR & S
• Contains required information
to prepare a quotation
• Customer supplied data
needed to generate
concentration files
• Outlines installation, Area
Classification and electrical
requirements
• Orders cannot be processed
without FAST form. Part of
production process
‘Hello Oliver,
I would like to congratulate Flexim Instruments on being named among this year’s
Flow Control Innovation Awards winners for the key innovations represented by its
PIOX Mass Flow Measuring System. 2014 Innovation Awards winners will be
announced in the September issue of Flow Control magazine with short overviews
of each winning technology and with voter comments.’’
Amy Richardson / Flow Control
FLEXIM PIOXS2014 Flow Control Innovation Award winner
Coming Soon September 2014
Thank You
PIOX R
Transmitted Light
PIOX S
Speed of Sound