SEPARATION PROCESS MONITORS

INTRODUCTION

Physical treatment processes cover a variety of separation methods that have been used in the chemical industry for a long time. Some form of physical treatment is usually the first consideration for separation of a process containing liquids and solids.

Typically, physical treatment systems are simple and cost effective and may include the following: filtration, centrifugation, distillation, evaporation, sedimentation, clarification, evaporation, stripping, etc. While each one effects separation from a liquid phase, the quality and characteristics of the solids in relation to the carrier liquid will ultimately determine the method used. Physical separation methods may be preceded by chemical treatment to improve efficiency or convert unwanted insoluble material to suspended solids for physical removal.

APPLICATION

Suspended solids removal often includes such operations as centrifugation and filtration. The end of the filter run, or filtration phase, is reached when the suspended solids in the process start to increase or breakthrough beyond an acceptable level. (For additional information see Application Note 1.001.AO.) During the centrifugation cycle, the centrate will have carry-over of solids if an upset occurs or the run has exceeded its limit. In addition, the feed rate of the slurry and/or polymer is important to maximize the separation rate.

It is critical that whenever any separation process becomes inefficient or fails, there be some type of warning/upset monitor to reduce rework, downtime, and possible adverse affects downstream. It is also cost effective if each process condition is optimized to maximize throughput.

SOLUTION

The Monitek suspended solids monitor will continuously check the process liquid and will immediately detect the presence of solids that have failed to be removed during separation. (These “solids” may be in the form of particles, crystals or emulsions.) The Monitek unit warns the operator of the smallest quantities of contaminants and enables him to take immediate action to protect the process. By continuously monitoring the process, you are ensuring several factors such as: quality control, process control, automated process monitoring, etc.

Monitek offers a strategically integrated array of products to monitor suspended solids in liquids. These include products designed for harsh environments and hazardous areas commonly found in any chemical plant.

ADDITIONAL COMMENTS

There are so many separation processes within the chemical industry it is impossible to list all the potential locations where a suspended solids monitor would solve an application nightmare.

Here are a select few that have proven to be very beneficial for each manufacturing facility.

1. In production of melamine crystal powder, the solution is pumped through a bank of filters to remove impurities and undissolved matter. If undetected, tons of off-spec product would require reprocessing.
   
   

2. During production of nylon, all solids must be filtered prior to injection into spinning machines. If solids are not thoroughly removed, spinners are clogged with resulting downtime.
   
   

3. In the manufacturing of Kevlar, the process goes through a bank of filters, a centrifuge, and polishing filters to remove any trace of solids which could undermine the integrity of the product.