Seeking help with a reactor level gauge
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The total volume of the reaction tank is 8 cubic meters, and a double-flange differential pressure level gauge is used; the distance between the upper and lower flanges of this level gauge is 3.5 meters. The problem is that the medium used for measurement consists of several materials with different densities, which are added in stages in proportion; their relative densities are 0.9, 1.22, and 1.09 respectively, and a reaction occurs after mixing. I would like to ask those who have experience using similar level gauges: how is the measurement range of such level gauges set? And how to calculate the volume of the medium based on the liquid level? Thank you, Haiyou!
Partial pressure in the gas phase: 10 KPa； The initial temperature is 40 degrees, and it reaches 60 degrees during the reaction ； The viscosity is high after the reaction; an extended flange type is used for the level gauge. The reaction procedure specifies the proportions of the materials, and the liquid level is used to calculate the volume in order to verify the amount of material added; in other words, it serves to determine whether too much or too little of a certain material has been added, or it acts as a reference for the material feeding flow meter.
I think you should modify the manufacturing process; how can you operate in this way! You have a specific ratio for this; otherwise, you should produce in intermittent periods! Otherwise, there’s a feeding scale to compare the feeding amount!
If the density changes, then differential pressure can’t be used.
Amateur advice: First, use differential pressure transmitter 1 at the bottom of the reactor to measure the density of the mixture； The measured density is used, along with the differential pressure transmitter 2, to determine the liquid level in the reactor.
Using double flanges in your case is a mistake; double flanges basically cannot meet your process requirements. In mixed media, double flanges make it impossible to accurately determine the density of the media, which results in inaccurate measurement values
Using a radar level gauge – simple and practical； There is no need to consider the medium density; it is installed on top of the reactor
If the amounts of liquid you add are all fixed, there is no need for a level gauge at all; instead, use a weight measurement module attached to the container’s support, which provides much greater accuracy and eliminates the need for complicated conversions.
Since double flanges are being used, there’s no need to worry too much. Our reactor situation is quite similar to yours: the reaction pressure is 0.3 MPa, and the medium is also somewhat viscous. With a range of 3.5 meters, the operating range is quite wide. Set the parameters for the double flanges based on the average density of those media; then explain to the process engineers that there will be some deviations. Calculate the range of these deviations and inform them, so they can be careful during operation. Forget using it to measure this idea; haha, just rely on your flow meter instead. Our reaction kettle has been in use for several years, and we haven’t had any problems with the liquid level. Moreover, high and low level switches can be added for interlock purposes, enhancing safety even further.