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