Commercial chlorine generator systems are an economical alternative to traditional chlorine systems. Traditionally chlorine needs to be added to water at precise dosing, which means it needs to be stored in large quantities, and water chemistry routinely measured. Chlorine generators use salt (NaCl), and water to generate Hypochlorous acid (HOCl). Muriatic acid is also used to prevent off gassing of the Hydrogen and Chlorine. Commercial chlorine generators are economical because they reduce water usage, chlorine usage, and salt, saving end users on their operating costs.
Muriatic acid is also used to prevent off gassing of the Hydrogen and Chlorine. Commercial chlorine generators are economical because they reduce water usage, chlorine usage, and salt, saving end users on their operating costs.
For these systems to operate correctly they require accurate level sensing of the Hypochlorous and Muriatic acid. Both solutions are very corrosive so typical contact-based level sensing is not practical. In addition, not only is level important for proper dosing, but is important to verify that these solutions are not leaking from the tanks causing a hazard to operators. The level is continuously monitored and any unplanned drop in level can alert personnel to investigate for any potential tank failures.
Challenge: Finding a cost-effective, easily configurable non-contact level sensor that can handle highly corrosive vapors and still provide an accurate level measurement.
Solution: Gems’ Non-Contact Radar Level Sensor
The Gems’ radar level sensor is a non-contact continuous level transmitter. Radar technology works by sending out short microwave signals toward the liquid via the sensor. The microwave signal then hits the liquid surface and bounces back toward the sensor. The sensor utilizes the time-of-flight principle which uses the known speed of the microwave, and the time it took for the signal to return, divided by two (since it had to travel down to the liquid and then back up to the sensor) to determine the distance between the liquid level and the sensor. Since most level is based on the height of the liquid, not the height of the non-liquid (air), the air height is subtracted from the total tank depth to determine the liquid level!
Gems’ non-contact radar sensor is a great fit in Chlorine Generators for several reasons.
- Non-contact design means no media ever touches the Radar sensor.This eliminates the need to worry about material compatibility between the media and sensor components
- Constructed from PVDF which is a highly inert plastic that is chemically compatible with most corrosive medias and vapors that are found in chlorine generators
- Externally mounted capacitance sensors designed to sense through tank walls can be unreliable and be temperature sensitive
- Comes standard with Bluetooth® configuration/setup.This saves sourcing and inventory costs as it reduces inventory management from multiple specific transmitters for each different tank depth down to one!
- Gems’ radar sensor is a compact design which helps reduce expensive shipping costs and transit times.This also helps make installation easier.
- The non-contact design is by default a no moving parts solution, which eliminates the potential for any mechanical failures from a float or probe-based sensor.
- Radar through the air technology is a very accurate sensing technology and can detect liquid level within 5mm, with no effect on its accuracy based on changes in temperature or pressure.
- Radar technology is not affected by condensation or dust in the air like ultra-sonic based sensors.
With an Ingress Protection rating of 68, it can be installed on the exterior of these tanks that are exposed to the elements with no risk of moisture intrusion. With a 2” NPT mounting it can easily be mounted in one of the ports found on top of these acid tanks. Gems’ non-contact radar level sensor does not need adjustment when used with different medias and has standard outputs including 4-20mA, and Modbus. With a maximum process temperature rating of 80 degrees Celsius and full vacuum to 43 PSI rating, it can withstand extreme applications.