Condensate polishers are a common variable of many industrial processes, including power and steam generation in the fertilizer industry. Condensate polishers are utilized in this process to maintain water quality by removing impurities from the return condensate to make it suitable for reuse in steam generation systems, which is critical in producing nitrogen-based fertilizers.
To ensure efficient operation, operators implement conductivity measurements in this process to monitor the polishers’ outlet. Monitoring conductivity allows operators to assess the effectiveness of the condensate polishing process. Lower conductivity values suggest lower levels of dissolved ions and impurities. A sudden increase in conductivity could signal a breakthrough of impurities, indicating a potential issue with the polisher that requires attention. With accurate conductivity measurements, operators can make informed decisions on utilizing caustic (NaOH) and acids (H2SO4) to regenerate the cation and anion resins within the polisher at the appropriate concentrations.
Challenges in Condensate Polishers
Measuring conductivity in fertilizer condensate polishers can pose several challenges due to the nature of the industrial environment and the specific characteristics of the condensate. Some challenges include:
Corrosive Environments: Condensate return in fertilizer production may contain corrosive elements that impact the life span of the polishers and the equipment that the reused effluent eventually flows through. Regular maintenance and appropriate material selection for both sensors and equipment are essential to mitigate corrosion-related issues.
Temperature Fluctuations: Industrial processes in fertilizer production often involve temperature variations. Conductivity is temperature-dependent, and fluctuations in temperature can affect the accuracy of conductivity measurements. It’s essential to compensate for temperature changes to obtain reliable conductivity readings.
The Solution
The SE 605 & 625 are Memosens coaxial conductivity sensors for high-purity water or steam condensate applications. These sensors boast a large measuring range for ultrapure water of 0.001…1,000 µS/cm. An integrated temperature element also ensures accurate compensation for the process media temperature in all conductivity measurements. The robust sensor design, along with the integration of Memosens technology, significantly reduces the overall cost of ownership.
The Stratos Multi is the most versatile and flexible analytical transmitter on the market. The transmitter connects to Memosens digital sensors and analog or other digital sensors. Sensors can be connected simultaneously and in any combination. Furthermore, the intuitive user interface features full-text menu navigation, graphical icons, and charts to communicate the device’s condition and guided automatic sensor calibration.
Customer ROI
Reduced Water Consumption: By effectively removing impurities from the condensate, condensate polishers enable the reuse of water throughout the process. This minimizes the need for freshwater intake and supports eco-friendly practices.
Extended Polisher Life: The extended life of condensate polishers directly results from their role in reducing water consumption. A decreased load of contaminants entering the system reduces wear and tear on polishing components.
More efficient use of Resin Columns: The high-purity water produced by these systems means that the ion exchange resins or other filtration media are exposed to fewer impurities. This vastly reduces the frequency of regeneration cycles and optimizes resin utilization.
Higher purity water: Accurate conductivity measurements allow for higher purity water that meets stringent quality standards. This purified water is necessary for maintaining the integrity of steam and power generation equipment in fertilizer production.
