Online Process Analysis ______

with an unparalleled range of instruments

for refractometry and ultrasonic measurementConcentration Measurement

______

Density Measurement ______

Reaction Monitoring______

Phase Detection______

Product Identification______

Process Control______

Neutralization______

Polymerization______

Reliable

process analysis

even under

the most difficult

application conditions

www.fl exim.com

2

Measurement in “Real Time”– not “from Time to Time”______

Modern industrial production would be

unthinkable without modern measure-

ment technology. Continual processing

demands continual process control. Effec-

tive industrial managing requires con-

tinual monitoring of the classical process

parameters temperature, pressure, flow

and level. Measuring and control instru-

ments insure that optimal reaction con-

ditions are precisely maintained. Without

a doubt, the trend is leading towards a

comprehensive process analysis. What

before was determined by regular spot

checks in the laboratory can be measured

and fed into the process control system

on a continual basis by a real-time

process analysis system.

A comparison between the average labo-

ratory analysis costs and the total costs of

an online process analysis system shows

that an investment in online process

analysis pays off, even at only one meas-

urement per day. Moreover, the direct

benefits of a process analysis system

are not derived from the reduction in

laboratory costs, but rather by gathering

and transmitting measurement data –

in real time. This allows an immediate

adjustment when changes or irregular-

ities arise, without the slightest delay.

The production process can be optimized

effectively and abnormal lots are pre-

vented from the very beginning.

Optimal Solutions for yourProcess______

There is no “one size fits all” device suita-

ble for all online process analysis needs.

The various process conditions (corrosive-

ness, viscosity, composition, pressure,

density, and temperature) require special

procedures.

According to your individual needs and

application conditions, FLEXIM solves

these measurement problems using

either refractometry or ultrasonic tech-

nology. Depending on the measured

medium and the measuring task, the

following techniques can be used: trans-

mission refractometry, critical angle

refractometry, non-invasive clamp-on

techniques or wetted sensors. Sensors

can be installed either in the mainstream,

in the bypass or directly in the vessel

containing the measured medium. In

many cases, a combination of several

different techniques will be chosen in

order to reach optimal results.

Expertise Gained ThroughExperience______

Often, the point where others have al-

ready given up is where FLEXIM rises to

meet the challenge. Due to FLEXIM’s vast

experience, especially in problematic

applications, its precise and reliable

technology has already become an indis-

pensable part of many industrial pro-

cesses.

Each tailor-made solution offered by

FLEXIM includes not only the field service

by experienced applications engineers but

also the installation of the highly reliable

FLEXIM equipment. In this way, FLEXIM

guarantees that the measuring task is

being successfully completed using

state-of-the-art technology solutions.

FLEXIM Online Process Analysis

_____

Sound velocity as a function of time during a

CIP process

3

FLEXIM Process Analysis

PIOX® Measuring Systems

➔

TransmissionRefractometer

PIOX® R

Transmitter

PIOX® TRfor Refractometers

Transmitter

PIOX® TSfor Ultrasonic Sensors

Critical Angle Refractometer

PIOX® G

Clamp-On Transducersfor non-invasive Measurement

Wetted Sensor

CP1N

➔➔ ➔➔

➔

Sender Receiver

S

t

Image sensor

Medium

Prism

Light sourceImage sensorLight source

Critical Angle

MediumPrism

t

v

Sender Receiver

4

Refractive index

co

nce

ntr

ati

on

(M

%)

■ 10°C

■ 20°C

■ 30°C

Sulfuric Acid

1.33000 1.33500 1.34000 1.34500 1.35000 1.35500 1.36000 1.36500 1.37000

0

5

10

15

20

25

30

35

Bringing Light into the Darkness______

Refractometry is a proven analytical

method. In laboratories, refractometers

are quite common measuring instru-

ments used to determine the purity,

concentration and density of liquids.

Ever increasingly, refractometry is being

moved out of the laboratory and onto the

production floor in order to take there

advantage of its benefits. The measure-

ment is rapid, precise, reliable and envi-

ronmentally friendly. It is independent

of the color and turbidity of the medium,

and it is not affected by the presence of

gas bubbles.

In general, all measurement which can

be accomplished in a laboratory setting

can be effectively done in situ using a

process refractometer. This method is

especially adapted for the analysis of

binary liquids (i.e. liquids consisting of

two components). Including an additional

measuring quantity even allows the

determination of ternary solutions.

Principle of Measurement______

Every substance is characterized by a

specific dependence between its re-

fractive index, the temperature and the

concentration of its components. Once

the refractive index and temperature

of the medium is measured, the trans-

mitter is capable of determining the

concentration of the medium based on

this relationship.

Through the use of materials which are

optimized for the specific process needs,

the PIOX® refractometers offer the opti-

mal solution to meet all your process

requirements. The probes comply with

all hygiene requirements for the food

industry and are CIP-capable. Further-

more, special models are available for

especially corrosive chemical media.

Representative Applications______

In the chemical industry, the process

refractometer is utilized not only for

quality control by measuring the con-

centration of a final product, but also for

process optimization. An example of this

is found in acrylic fiber manufacturing,

where a specific concentration of the

solvent DMAC must be maintained

during the entire processing cycle.

PIOX® R monitors the concentration of

the recycled solvent in order to keep

the chemical properties of the fiber’s

raw material stable for the entire pro-

duction process.

Refractometry is a precise and recog-

nized method for determining the con-

centration of sugar solutions. During

the production of mixed juices and soft

drinks, refractometers can be installed

directly into the production stream to

monitor the contents of the mixing vessel

and maintain the desired sugar concen-

tration. The sensing element (prism) is

resistant to the corrosive cleaning agents

used during the CIP process (hot water,

alkaline solutions, acids).

Precise, Reliable & Flexible______

FLEXIM’s PIOX® refractometers provide

highly reliable and flexible measurement

instruments for controlling and opti-

mizing various processes. In order

to cover the wide scope of industrial

applications, FLEXIM offers two basic

types of refractometers:

– Transmission refractometer for a

“true” drift free measurement with-

out the need of a cleaning device

– Critical angle refractometer for

media with high light absorption

Refractometry_____

Dependency of the refractive index of sulfuric

acid on the concentration

Transmitter_____

PIOX® TR

Chemical Industry

➔ Concentration determination in distillation or rectification processes

➔ Concentrationmeasurement ofsodium hydroxide

➔ Concentrationmeasurementduring the distilla-tion of ethanol

➔ Monitoring of thedegree of polymer-ization during theplastic and synthet-ic resin productionprocesses

➔ Concentrationmeasurement of ablend of colloidalsilicic acid andwater

➔ Continual meas-urement of thesugar concentra-tion (Brix) duringsugar boiling

➔ Continual moni-toring of the sugarconcentrationduring the finalmixing of juicesand soft drinks(Brix)

➔ Wine Must meas-urement

➔ Monitoring therelative content oforiginal wort in thecold wort duringthe beer brewingprocess

➔ Beer analysis(alcohol measure-ment, wort, andoriginal wort) incombination with a density meter

➔ Continuous measurement ofpastes and thicksubstances (liquidsugars, molasses,honey, milk,yogurt, tomatopaste, apple sauce,marmalades, winemust, mash)

Fiber Chemistry & Textiles

➔ Control of the concentration ofspinning solutions(DMAC, DMF)

➔ Concentrationmeasurement of Caprolactamsolutions

Oil & Gas Industry

➔ Control of the concentration ofmonoethylene glycol/water-blendduring transport of natural gas

PharmaceuticalIndustry

➔ Monitoring of theconcentrations ofascorbic acid andcetogulon acidduring the manu-facturing of vita-min C

Basing on the measured refractive index

and medium temperature, the trans-

mitter PIOX® TR calculates the para-

meters needed for process control:

density, solid content, turnover degree,

concentration, etc...

Having the capability of connecting up

to two sensors, PIOX® TR is able to

monitor complex processes. The trans-

mitter can take into account additional

measured values (conductivity, density,

sound velocity), thus enabling the

analysis of ternary mixtures. The

self-diagnostic feature helps avoid

system failures.

The concentration in mass percentage

or volume percentage, the refractive

index, the temperature compensated

refractive index, as well as the °Brix

value can be selected as a quantity of

measurement. In addition, up to 6 user-

defined scales can be defined for the

quantity to be measured. These scales

are configured and sent to the electron-

ic unit with the help of the software

RMKoeff. Various algorithms are avail-

able in order to adequately model the

characteristic curves of the medium.

Typical Applications for Refractometry

5

Food and Beverage Industry

TransmitterPIOX® TR

Up to 2 sensors per

transmitter______

Versatile algorithms to model

the media’s characteristics______

Short reaction time______

Flexible configuration of

inputs and outputs______

Determination of ternary

solutions

6

Get a Good Look with Transmitted Light______

In contrast to conventional critical angle

refractometers, the PIOX® R refracto-

meter utilizes transmitted light. The

actual refraction angle of the transmitted

light is directly measured. A large part

of the probe volume is traversed and

contributes to the measured value. The

results are about 10 times more accurate

than the results of conventional critical

angle methods. These precise meas-

urements made by the transmission

technique are truly drift free.

Immediate Precision______

Transmission refractometry with PIOX® R

realizes laboratory precision directly in

the process. Furthermore, the entire

measuring range needed for the majority

of industrial applications is covered by

a single prism.

The measuring principle of the PIOX® R

refractometer allows for a very short

reaction time (< 1s). The refractometer

can therefore be used under extreme

process conditions and track rapid

process changes.

Transmission

Refractometer_____

PIOX® R

After crossing the medium, the light of a point light

source is refracted at the interface between the

medium and an optical prism. The refracted light

then falls onto an image sensor where it appears as

a bright spot. Basing itself on the position of this

spot, the transmitter calculates the refractive index

of the medium.

Image sensor

Medium

Prism

Light source

TransmissionRefractometer PIOX® R

Very high resolution

and accuracy______

Complete accuracy across

the whole measuring range ______

“True” drift free performance

without the need for a

cleaning device______

Short reaction time______

Practically maintenance-free______

No minimum flow required

7

Through Thick and Thin______

This well established and dependable

measuring technique is the method

of choice for media with high light

absorption that does not facilitate the

transmission method. Here the refraction

is measured indirectly by determining

the critical angle of total reflection. This

angle is correlated to the refractive index

through the law of optical refraction.

A Matter to Reflect Upon______

Here, unlike in the case of the trans-

mission refractometer, the light does not

cross the probe before hitting the light

detection array. Consequently, the degree

of light absorption in the probe is of limit-

ed practical relevance for this measure-

ment. This makes critical angle refrac-

tometry well suited for media displaying

high light absorption characteristics such

as pastes, liquid-to-liquid emulsions,

liquid-to-solid suspensions or black lye.

Critical Angle

Refractometer _____

PIOX® G

The light of a monochromatic point source meets

the boundary surface between the process solution

and an optical prism at different angles. Light mee-

ting the surface with a small incident angle is

refracted into the medium, as opposed to light mee-

ting the surface at greater angles, which is totally

reflected and remains inside the prism. In this way,

the reflected light rays fall onto an image sensor

which maps the resulting sharp transition between

darkness and illumination. The exact position of this

transition is subsequently detected by the transmit-

ter, which then calculates the refractive index of the

medium.

Image sensorLight source

Critical Angle

MediumPrism

Critical AngleRefractometerPIOX® G

Well established and reliable

measuring technique______

Appropriate for media with a

high light absorption______

Compact design______

CIP capable______

Chemically and mechanically

stable

8

Proven Innovation______

Process analysis using ultrasound is

an innovative method for the charac-

terization of binary liquids. The required

process parameters can be determined

independently of the medium’s pressure,

color or turbidity. FLEXIM’s PIOX® S can

monitor a large variety of processes:

crystallization, neutralization, poly-

merization or phase separation, etc.

It can also be used for quality control

and product recognition. In order to cover

a wide range of industrial applications,

FLEXIM offers wetted sensors as well

as non-invasive clamp-on transducers.

Listen to Your Process! ______

The velocity of sound, as well as the

density, boiling point or refractive index,

is a substance specific parameter and

can therefore be used for process analy-

sis. The determination of the sound velo-

city is realized by measuring the transit

time of an ultrasonic signal for a defined

distance. Using the measured sound

velocity and temperature, the transmitter

calculates the required process para-

meter (density, solid content, turnover

degree, etc.). The calculation is based on

the characteristic curve of the medium.

This curve describes the relationship

between the measured value and the

sought parameter. All needed curves

are logged in the internal data base of

the electronic unit.

Concentrate on the Sound______

The powerful dual-μP electronics built

into the FLEXIM transmitters feature

digital signal processing and allows for a

very precise determination of the sound

velocity. The actual accuracy that can

be achieved for the concentration

depends on the respective run of the

characteristic curve of the substance.

This non-invasive measuring method is

classically used in the beverage industry

in order to determine the sugar content

(°Brix). It can also be used in combina-

tion with a vibrating element density

transducer in order to measure the cold

wort and original wort in beer (°Plato)

and the density of wine must (°Oechsle).

Application Example: Sulfuric Acid

PIOX® S is used in the production of high

purity sulfuric acid, a substance needed

by the pharmaceutical and semiconduc-

tor industries. The non-invasive measu-

ring method with clamp-on transducers

assures that absolutely no contamina-

ting substances are introduced into the

closed production cycle. This method

is also ideal for the food and beverage

industry due to its strict hygienic stand-

ards where it is used to monitor the

alcohol or sugar content of liquids.

Application Example: Coffee Extract

PIOX® S is perfectly suited to control the

production process of soluble coffee.

Coffee extracts display a well defined

linear correlation between concentration

and sound velocity over a vast range of

temperatures and concentration values

(see graph). The decisive advantage non-

invasive ultrasonic measurement has

over other possible methods is that it is

not influenced at all by the rapid buildup

of coating on the inner surface of the

pipe.

Concentration

Measurement

with Ultrasound_____

Sender Receiver

S

t

concentration in M%

c i

n m

/s

■ 52.9°C

■ 47.3°C

■ 41.9°C

■ 35.9°C

■ 30.6°C

coffee extract

0 2 4 6 8 10 12 14 16 18 20

concentration in M%

c i

n m

/s

■ 70°C

■ 60°C

■ 50°C

■ 40°C

■ 35°C

■ 30°C

■ 25°C

■ 20°C

H2SO4

0 20 40 60 80 100 120

Sound velocity of sulfuric acid as a function of

temperature and concentration

The transit time of an ultrasonic signal for a

defined distance is measured and allows the

calculation of the sound velocity

9

Transmitter _____

PIOX® TS

Food Industry

➔ CIP optimizationthrough product identification

➔ Control of the con-centration of sugarsolutions

➔ Measurement ofsugar content (°Brix)

➔ Monitoring of the concentration of coffee extract

➔ Determination of thealcohol content

Chemical Industry

➔ Determination of the concentration ofhighly concentratedsulfuric acid

➔ Monitoring polymerization, crystallization, neutralization, phase separation,etc...

➔ Determination of the concentration ofsodium hydroxide

➔ Determination of the concentration ofethanol

➔ Detection of hydro-fluoric acid

Fiber Chemistry

➔ Measurement ofwater concentration in Caprolactam

AutomobileIndustry

➔ Controlling the concentration of awater/glycol solutionon an engine testbench

Construction Industry

➔ Measurement of thesolid content of sandsludge

The PIOX® TS transmitter precisely

determines the sound velocity of the

medium based upon the ultrasonic

transit time measured by the sensor.

The concentration or the needed process

parameters (density, solid content, turn-

over degree, etc.) are calculated with the

help of characteristic curves pre-pro-

grammed into the instrument.

PIOX® TS stands out with its powerful

dual-μP-technology that uses Digital

Signal Processing (DSP) and delivers

highly dependable results even under

the most difficult measurement condi-

tions. The PIOX® TS can work with wetted

sensors as well as non-invasive clamp-

on transducers. The measuring principle

allows for an extremely short reaction

time and is therefore adequate for mo-

nitoring rapid process changes.

Typical Applications for Ultrasound Technology

PIOX® TS is perfectly suited for controlling

complex processes. Up to two ultrasonic

sensors can be connected to a single

electronic unit. Additional measured

values such as conductivity, density or

sound velocity can be processed, allowing

for the measurement of ternary solutions.

Operating the PIOX® TS is especially easy

because of its straight forward and self-

explanatory menu structure.

TransmitterPIOX® TS

Wetted sensors and

clamp-on transducers______

Up to 2 sensors per

electronic unit______

Short reaction time______

Flexible configuration of

inputs and outputs

The Ideal Outsider______

Clamp-on transducers are mounted on

the outer surface of a pipe. As they are

not in contact with the medium, they are

ideal for measurement of chemically

aggressive, corrosive, abrasive or ultra-

pure media. Additionally, they are not

subject to wear and tear.

PIOX® S allows for trouble-free con-

centration measurement of hydrofluoric

acid, ammonia gas used in manufactur-

ing fertilizers as well as of silica sand in

water solutions. Wear-free and main-

tenance-free. Worries about the sensor’s

chemical resistivity, contamination and

sealing are a thing of the past.

With the clamp-on technology, retro-

fitting on existing installation is very

easy and can be made without cutting

into the pipe and without process

interruption.

Absolutely Contact Free ______

This non-invasive acoustical technique is

the method of choice when the materials

and process place high demands on

safety and hygiene. For example, PIOX® S

can be used to measure the concentra-

tion of high purity sulfuric acid. The

clamp-on transducers guarantee a con-

tamination-free environment. Ultrasonic

measurement is also well suited for the

food and beverage industry with its high

hygienic standards. There, it is used

for the measurement of alcohol or

sugar content in liquids, and is a proven

method for CIP process optimization

for example.

10

Clamp-On Transducers for Process Analysis

Using Ultrasound_____

Clamp-On Transducers

Non-invasive measurement______

Watertight stainless steel

housing______

No contact with the medium,

no risk of corrosion, hygienic

measurement______

No pressure loss, no risk of

leakage______

No ion contamination ______

Resistive, maintenance free,

watertight, no pressurized

parts______

Installation without process

interruption

11

Take a Quick Look Inside______

The wetted sensor is particularly well sui-

ted for concentration measurements in

batch reactors and stirring machines. It

produces a very precise measurement.

The factory calibration makes zeroing

procedures unnecessary and the opera-

ting point does not need to be set. Mea-

surement can begin immediately after

installation.

Tough Stuff ______

The wetted sensor is available as an

immersion probe or as a flow-through

unit. Its construction materials make it

possible to adapt the measuring system

to the chemical stability demands of the

process. Thanks to the seal free con-

struction, resistivity is not a problem.

Special versions are available for use in

especially chemically aggressive media.

Wetted Sensor

for Process Analysis

Using Ultrasound_____

Wetted Sensor

Operating temperature:

from –30 °C to +150 °C______

Operating pressure: 40 bar

(depending on process

connection)______

Process connection:

Immersion probe with

DIN flange (DN40, 50, 80,

100; PN10 to 40) or flow-

through version______

Seal free construction,

maximum resistivity______

Short reaction time______

High accuracy______

Factory calibrated

12

For over 15 years FLEXIM has been an

active leader in many areas of process

instrumentation in both national and

international markets. In addition to

non-invasive flow measurement systems,

FLEXIM specializes in innovative online

process analysis using ultrasonic

technology and refractometry.

Year after year, the Berlin based company

continues its substantial investment in

research and development in order to

maintain and further improve its position

as an industry leader. As a result, our

customers benefit greatly from our

cutting edge patented technology.

Competent and professional associates

in our sales offices and regional head-

quarters in Europe and overseas ensure

the worldwide distribution of FLEXIM’s

proven technology and guarantee you

qualified service.

FLEXIM_____

A short portrait

FLEXIM GmbH

Berlin, Germany

Tel. +49 30 93 66 76-60

Fax +49 30 93 66 76-80

info@flexim.de

www.flexim.com

FLEXIM AMERICAS

Corporation

Headquarters

250-V Executive Drive

Edgewood, NY 11717

Phone: (631) 492-23 00

Fax: (631) 492-21 17

Toll free: 1-888-852-7473

(North America only)

usinfo@flexim.com

www.flexim.com

FLEXIM

Instruments Asia Pte Ltd

Singapore

Phone: +65 67 94 53 25

Fax: +65 68 62 28 36

asia@flexim.com

Shanghai, China

Phone: +86 (21) 649 575 20

shanghai@flexim.com

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