CERTAIN applications often have trouble with consistent performance, which requires extra monitoring by operators and maintenance personnel.
A well-known French titanium dioxide manufacturer had been looking for a reliable level measurement solution for a specific process. Previous devices had given unreliable readings despite significant investments in service and maintenance.
The breakthrough came when the company started using a VEGAPULS level sensor with an 80GHz transmission frequency.
Titanium dioxide is a crucial white pigment ingredient that enhances the protective properties of varnishes and paints used in various industries such as automotive, food, textile, and paper.
End users demand the highest standards of purity and quality, making the production of titanium dioxide complex and hazardous. As a result, the manufacturing process requires high levels of automation.
The maintenance staff often face challenges due to sensor buildup and corrosion. The titanium dioxide plant in Thann, France, experiences extreme stresses on sensor materials, particularly during the initial production phase following the sulphating procedure.
This phase involves adding weak sulphuric acid to a premix of ores and sulphuric acid, resulting in a violent, exothermic reaction that produces aggressive and adhesive vapours.
Once the mixture is dissolved and stabilized, the containers are emptied to remove natural impurities like iron compounds, which could discolour the pure white titanium dioxide.
Two different level measurement technologies were used in this stage, but neither delivered satisfactory results. Initially, an older radar measuring device with a cone-shaped Teflon-coated antenna and an operating voltage of 230 V AC was utilised.
Later, a bubbler back-pressure level system was attempted. Both methods failed to provide reliable measurements during certain decomposition phases, even with regular, time-consuming, and hazardous preventive maintenance.
The manufacturer aimed to achieve reliable level measurement while reducing high maintenance costs. As a VEGA customer for over 30 years, the manufacturer valued the trusted relationship and VEGA’s prompt service response.
At first, the client was uncertain whether the VEGAPULS sensors could endure the harsh conditions of the decomposition process. However, the first trial, conducted under real production conditions, was promising. The sensor’s narrow measuring beam allowed for easy installation in an existing socket, reducing engineering and preparation time. Setup and commissioning were straightforward, as the false signal suppression procedure was largely unnecessary.
The VEGAPULS level sensor provided precise and dependable measurements, resulting in its permanent installation in the reaction vessel. Its performance was so impressive that the company replaced the previous level sensors in other production vessels with VEGAPULS instruments as well.
