Pickling fluid multicomponent (online analyzer) analysis system

ENCE GmbH Engineering Company offers a modern automated system of pickling fluid concentration multicomponent analysis for steel strip etching stage.

Continuous information on concentration of each main component is extremely necessary for optimal process control as it ensures high quality of etching process; improves process line performance as well as secures reliable operation of all units in the etching area. These data are necessary for both continuous and batch processes in the metallurgical industry.

Generally the industrial analyzers are used for online components analysis in metallurgy. Their operation principle is based on various classical laboratory methods of analysis. These analyzers are characterized by complex structures. These devices allow determining a concentration of individual components in the multicomponent mixture of pickling fluid. But such devices have a number of disadvantages:

• High maintenance expenses;
• Reagent expenses;
• Irregular operation.

As an alternative for such devices, an automated online analyzer with a combined method by which the system processes the signals can be the proposed; the signals characterize physical properties of multicomponent mixture. This method does not require any expensive equipment and is different from others by low maintenance expenses and long lifetime.

The signals that are transferred from the sensors of the offered analyzer are processed within the multidimensional model that allows calculating the current concentrations of each component.

Depending on the task set, the operating principle of the analyzer can be based on measuring the parameters in the following combination:

• Sound velocity and density;
• Sound velocity and conductivity;
• Sound velocity and refraction index.

Online ultrasonic analyzer is designed to measure the liquids concentration and density. The analyzer operation principle is based on measuring sound velocity and comparing its value with the calibration curve data of sound velocity dependence on the concentration in the liquid medium.

Img.1 Concentration and mixing process monitoring

Img.2 Limit value monitoring

Online analyzer is adjusted by the operator via controller. The controller has a large graphical display and is served intuitively through four functional keys. Easy integration into any control system is provided due to the interface with multiple digital options. Depending on the application purposes, conditions and factory equipment, there are controller models with various options.

User-friendly menu allows optimal configuration of the multi-component analysis system which provides higher accuracy, resolution and data reporting.

• 32-bit microprocessor technology, TFT color display with high resolution for a better visibility in any lighting conditions;
• IP65 Front panel protection, possible installation of controller casing into the switchboard or distribution cabinet;
• Input and output signals from 4 to 20 mA, relay contacts, fault-tolerant contacts with protocols like TCP / IP and Fieldbus;
• Memory for data storage, events tracking and display of current parameter values through several channels;
• Long-term RAM card for system data configuration and processing;
• Multilingual user interface;
• Access codes to the different system levels depending on user rights;
• Special system that can be used for direct observation of the transmitted signal.

Convenient sensors with the necessary equipment for installation are offered for almost every range of application. There is an option of connection the sensor to the pipe with size up to 1 mm (1/8"), as well as an integrated temperature sensor option, that easily meets the basic use guidelines.

• Sensor in a hard and completely enclosed case;
• Patented high-performance technologies producing reliable results even in the conditions of gas bubbles high content;
• Wide range of operating temperatures and pressure (temperatures up to 200 ° C, pressure up to 500 bars);
• Additional options, such as determining of flow presence or the medium around the sensor.
• A digital sensor ensures high accuracy of results, low response time and reliable data transfer.
• Graphical display of the received high frequency sound, which allows configuring the measuring system in the optimal way.

As an example, company ENCE GmbH proposes to consider an online option of the multicomponent concentration analyzer of pickling fluid for steel strip etching stage.

Quantity: 1 pce.

Description and configuration

Registrations

• Graphic TFT-display (LCD-display with an active matrix), 320×240 pixels;
• Display of concentration and temperature;
• Display of product name;
• Display of status and limit values information.

Functions

• Choice of the product from available 16 products;
• Plain error notification;
• Parameters set as tree-type structure;
• Multilingual operator instructions (operator manual).

Inputs and outputs

• 2 analog outputs 4…20 mA;
• 1 analog input 4…20 mA;
• 2 digital outputs;
• 4 digital outputs;
• Interface RS232.

Sensors

One connected sound velocity sensor.

Quantity: 4 pieces.

Description and configuration

Registrations

• Graphic TFT- display 320×240 pixels;
• Display of concentration and temperature;
• Display of product name;
• Display of status and limit values information.
• Trend presentation.

Functions

• 2 concentration count;
• Choice of the product of available 32 products;
• Data registration protocol, 15000 data sets, with 32 measured magnitudes per each set;
• Change of product name;
• Plain error notification.

Event logging protocol inputs and outputs

• 4 analog outputs 4…20 mA;
• 4 analog inputs 4…20 mA;
• 6 digital outputs;
• 8 digital inputs;
• Interface RS232.

Sensors

• Sound velocity sensor;
• Sensor with two physical measured magnitudes (density, conductivity and refraction index). Connection is carried out by means of analog input.

Supply voltage regulator

For voltage 24 V DC supply adjustment.

1. Regulator industrial modem

Quantity: 1 piece.

Programmable, with TBR21, TBR15, TIA/EIA/IS-968 cables used mainly in EC, USA and Canada.

2. Profibus DP bus bar connection.

Quantity: 1 piece.

3. PC software

Quantity: 1 piece.

Convenient PC software that ensured fast and easy fulfillment of various configuration tasks on the controllers, and namely:

• Production data registration loading;
• Controller registration log reading;
• Process control directly on the line and display of an average curve;
• Measurement data storage;
• Apparatus parameter entering;
• Apparatus parameters table formatting;
• Remote control through modem connection;
• Access to the apparatus through network connection;
• Calculation of Production data set.

4. Tubular sensor

Quantity: 5 pcs.

Flange sensor is designed for use in corrosion active medium in nonhazardous areas.

5. High-performance ceramic item processed by ultrasound

Quantity: 5 pieces.

High-performance ceramic item processed by ultrasound allows application under tough measuring conditions.

6. Bus-cable

Quantity: 4 pcs.

Bus-cable for wiring inside and outside @ temperature from -30 to +70 ° C. Standard coil of 10 meters. The outer casing is according to VDE0816. This design is suitable for hard and conditionally flexible cabling in the inner and outer room space, and also for laying in the ground. When ground cabling, the outer casing is insensitive to the ambient UV radiation.

7. Outside cable for 4–20 mA connection

Quantity: 40 meters (4 coils, 10 meters each).

Cable for wiring inside and outside at the temperature from -30 to +70 ° C. Outside diameter is 7.4 mm. Resistance in circuit is 18,6 Ohm/100 m. The outer casing according to VDE0816. This design is suitable for hard and conditionally flexible cabling in the inner and outer room space, and for cabling in the ground as well. When ground cabling, the outer casing is insensitive to the ambient UV radiation.

9. Sensor for nonelectrode conductivity measurement

Quantity: 4 pieces.

Each ultrasonic probe (tubular sensor) operates with its own microprocessor, which assumes the overall control and communicates with the controller via a BUS cable. One ultrasonic probe can be operated by a single controller with the controller No. 1. Up to 4 ultrasonic probes can be operated by single controller with the controller No. 2. Probes are connected to the controller via a bus cable with a maximum wire length of 1000 meters. Each probe has extensive features of self-calibration and diagnostics.

ENCE GmbH Company is able to supply separate units, assemblies and component parts for coiled steel automation pickling lines, coiled steel hot galvanizing lines and steel strip lacquer and polymeric coating spreading lines in addition to the offered online multicomponent concentration analyzer for pickling fluid.

• Decoilers
• Recoiler
• Ready coils tilting cradles
• Noncontact thickness gauges (X-ray and Isotopic)
• Vertical and looping storage batteries
• Electrochemical cleaning sections
• Nonoxidation heating furnaces
• Galvanizing baths with ceramic lining or made of special alloys
• Zink heating inductors
• Submersible ceramic heaters
• Electromagnetic stabilizer on coiled steel galvanizing line (EM – stabilizer)
• Pinch-pass mills
• Surface defects measure automatic systems
• Emulsion air blowing system in pinch-pass mills
• Intershop rail transport