In the chemical industry, processes such as synthesis, polymerization, and catalysis often require the use of reactors as core equipment. These reactors must withstand harsh process conditions, including high temperatures, high pressures, and high vacuum, with the pressure measurement system serving as a critical safeguard for process safety. However, these extreme environments pose significant challenges to pressure monitoring during production, such as ensuring the long-term stability, corrosion resistance, and measurement accuracy of pressure sensors. By analyzing the measurement difficulties encountered at customer sites, we aim to provide tailored solutions that address these needs, helping customers achieve safer, more efficient, and cost-effective pressure and level measurement solutions.
Customer Profile
Customer XX is a well-known trademark enterprise in its province, specializing in the production of organic pigments and chemical intermediates. Since 2023, we have established close cooperation with three subsidiaries of this group, supplying a total of over 700 smart pressure transmitters. Our high-precision, high-stability products have ensured the customer's safe production needs.
Customer Pain Points
The customer faces demanding operating conditions in a specific carbonylation reactor process: a vacuum of -97 kPa, temperatures reaching 280°C, and a corrosive acidic medium. Pressure transmitters are required for long-term monitoring of process parameters to ensure stable production line operation. In recent years, pressure transmitters from several domestic brands introduced by the customer have failed under these extreme conditions, experiencing issues such as inaccurate output and diaphragm bulging, necessitating instrument replacement every 1-2 months. This not only increases maintenance costs but also impacts overall efficiency due to production downtime, and could even lead to safety hazards from inaccurate monitoring. The customer urgently needs a pressure monitoring solution that is resistant to high temperatures and high vacuum, and offers long-term stability to enhance production safety and economic benefits.
Customized Solution for High-Temperature, High-Vacuum Applications with Smart Pressure Transmitters
- Technical Advantages: The product features a proprietary digital filtering algorithm and an integrated, thickened dual-chamber housing design, significantly enhancing anti-interference capability and overall structural strength. The core sensing element utilizes ultra-high purity (9N grade) Si-Si bonded MEMS silicon wafers, combined with a diamond-shaped floating sensor structure and symmetrical mechanical design, effectively suppressing the impact of installation stress and vibration on measurement accuracy. The entire unit has passed 10g random vibration testing and successfully obtained multiple stringent certifications and type tests, including NEPSI (China), CSA (North America), and ATEX (European Union). It comprehensively achieves anti-interference, anti-vibration, 0.05%FS high accuracy, and 10-year long-term stability, ensuring reliable adaptation to various harsh industrial environments.
- Customized Solution for High-Temperature, High-Vacuum Conditions: This solution employs a fully welded structure, thickened 316L stainless steel material, high-temperature silicone oil, and a structural design and processing technique specifically for high-temperature and high-vacuum applications (for sections with extremely high temperatures, a capillary tube + remote diaphragm seal structure is used). This effectively resolves measurement stability issues under high-temperature and high-vacuum working conditions.
Customer Value
- Safety and Compliance: The smart pressure transmitter, with its SIL2 certification and explosion-proof design, thoroughly resolves the challenges of real-time process monitoring under high-temperature and high-vacuum conditions, ensuring the safety of personnel and equipment.
- Efficiency Improvement: Stable and reliable pressure data facilitates process optimization in reactors, reducing scrap rates and increasing capacity utilization.
- TCO Optimization: With an extremely low failure rate and maintenance-free design, it saves over 30% in annual maintenance costs and extends the equipment replacement cycle to three times the industry average.
We have a professional pre-sales and after-sales technical team that can conduct detailed analyses of pressure transmitter selection and installation based on the specific conditions at the customer's site. This ensures that pressure monitoring and measurement needs under special working conditions are met, effectively improving the accuracy and service life of the pressure transmitter, and guaranteeing safe and smooth production at the customer's facility.
Recommended Products
MDM7000 Smart Pressure Transmitter Series
- High Accuracy: ±0.075%, ±0.05%
- High Stability: ±0.1% of Span for 10 years
- High Reliability: MTBF > 438,000 hours
- Output Signals: 4mA~20mADC + HART 7.0 with Bluetooth, Modbus-RS485, 1~5V Low Power, PA
- Multiple Explosion-Proof Certifications: Ex ia IIC T4 Ga; Ex db IIC T6 Gb; Ex tb IIIC T85°C Db
- Diaphragm Material Options: 316L, HC-276, Tantalum, Titanium, Monel400, 321, Inconel718, Duplex 2507 SST, etc.
