Acid Slurry Tanks: Jiwei Radar for Accurate Acid Level Control
1. Introduction: Why Acid Level Control Matters
In modern petrochemical processes, acid slurry tanks play a critical role in alkylation units. These tanks contain highly aggressive acids and vapors, creating one of the harshest environments for instrumentation.
Accurate acid level control is essential for process efficiency and safety. Poor level measurement can lead to process disruptions, equipment failure, and hazardous chemical leaks, causing costly downtime and safety hazards.
The solution is Jiwei radar technology, specifically designed for corrosive and high-temperature applications.
2. Process Conditions and Technical Challenges
Actual process data highlights the measurement challenges:
- Measuring Task: Level measurement
- Measuring Point: Tank
- Measuring Range: Up to 4 m
- Medium: Acid liquid
- Process Temperature: +25 °C to +220 °C
- Special Challenges: Highly corrosive acids, vapors, and hazardous areas
Traditional sensors like floats, ultrasonic, or differential pressure transmitters often fail under these conditions due to corrosion, mechanical wear, or interference from acid vapors.
3. Why Choose Jiwei Radar for Acid Slurry Tanks?
3.1 Corrosion Resistance and Long-Term Reliability
Jiwei radar level transmitters demonstrate exceptional corrosion resistance in acid tank applications. Key components feature PFA lining and 316L stainless steel combined with PTFE or PFA protective layers, providing robust protection against highly corrosive media such as sulfuric acid and hydrofluoric acid. This advanced material combination ensures long-term operational stability, significantly extends service life, reduces maintenance frequency, and minimizes downtime costs compared to conventional level instruments.
3.2 Extreme Temperature Performance
Unlike conventional instruments that fail above 150°C, Jiwei radar operates reliably in temperatures up to +220 °C, making it ideal for high-temperature alkylation units and other challenging environments.
3.3 Maintenance-Free and Cost-Effective
The non-contact radar principle eliminates moving parts, meaning no mechanical wear, no frequent calibration, and no sensor fouling from acid deposits. This significantly reduces maintenance costs and downtime, while improving operational safety.
4. Advanced Measurement Technology
Jiwei radar uses FMCW 80 GHz radar, delivering exceptional accuracy and stability even in acid slurry tanks with vapors and turbulence.
The narrow beam angle allows precise targeting, avoiding interference from internal tank structures, while strong signal focusing penetrates acid mist and foam. This ensures consistent, real-time level readings under the most demanding conditions.
For integration, Jiwei radar supports 4…20 mA/HART, Modbus RTU, and Profibus PA, enabling compatibility with virtually any control system.
5. Safety and Compliance
Working with aggressive acids in hazardous areas requires equipment that meets the highest safety standards. Jiwei radar transmitters are fully Ex-certified, guaranteeing reliable and safe operation in hazardous and explosive environments.
The device is equipped with an integrated Bluetooth® feature supporting Bluetooth® v5.4 protocol, enabling local wireless parameter configuration and commissioning via mobile devices. This reduces on-site operational risks, enhances convenience, and meets the safety and intelligent control requirements of critical level measurement applications.
In addition, Jiwei radar is designed in accordance with IEC 61508 principles, supporting enhanced safety performance for critical applications. For tank overfill protection, Jiwei radar complies with API 2350, significantly reducing the risk of catastrophic chemical spills.
6. Real-World Application Performance
Jiwei radar has been successfully installed in alkylation units handling acid slurry. One example involved a tank operating at 180 °C (with design up to 220 °C), containing highly aggressive acids.
Over three years of continuous service, the system delivered stable, accurate measurements with zero maintenance issues. Plant operators reported a significant reduction in downtime and total cost of ownership (TCO) compared to mechanical or ultrasonic alternatives.
7. Key Benefits for Operators
Operators gain multiple advantages by using Jiwei radar:
- High reliability in corrosive and high-temperature environments
- Zero maintenance thanks to non-contact design
- Improved safety compliance with international standards
- Cost savings from reduced maintenance and longer equipment life
- Easy installation and setup with intuitive configuration tools
These benefits make Jiwei radar the smartest investment for acid level control in demanding chemical processes.
8. Frequently Asked Questions (FAQ)
Q1: Can Jiwei radar handle HF acid and sulfuric acid?
✔ Yes, thanks to PTFE and Hastelloy construction.
Q2: What is the maximum process temperature?
✔ Up to +220 °C, suitable for alkylation units.
Q3: Does it support remote monitoring?
✔ Yes, via HART, Modbus, or Profibus.
Conclusion and Call to Action
For acid level control in acid slurry tanks, Jiwei radar delivers unmatched accuracy, safety, and cost efficiency. Its corrosion resistance, extreme temperature capability, and global certifications make it the ultimate solution for challenging chemical processes.
👉 Contact Jiwei today to request a customized solution for your acid measurement needs.