Sulfuric acid storage tanks are mainly used to store sulfuric acid produced in acid production. The accuracy of the liquid level of the sulfuric acid storage tank is directly related to the continuity of production. Because the sulfuric acid storage tank stores 98% concentrated sulfuric acid. There will be Part of the acid mist will have a certain impact on the liquid level detection.

Because of the anti-corrosion and anti-disturbance problems, the traditional detection instruments are not suitable for detection. Only the radar liquid level sensor can achieve a relatively high measurement accuracy. It has the characteristics of high continuous measurement accuracy, non-contact type, large measurement range, and good anti-corrosion performance.

Sulfuric acid storage tank level measurement-Radar level sensor

Radar Level Measurement and guide wave radar level measurement
Radar Level Measurement and guide wave radar level measurement Image source:

Very short microwave pulses with very low energy are transmitted and received through the antenna system. The radar wave runs at the speed of light. The operating time can be converted into level signals by electronic components. A special time extension method can ensure stable and accurate measurement in a very short time.

Electromagnetic waves propagate in the air at the speed of light. The distance between the radar level sensor and the surface of the material can be expressed by the following formula:   

D = (1/2)*CT

In the formula:

D ———the distance between the radar level sensor and the surface of the material;   

C ———Speed of light   

T ———Pulse time.

Then the liquid level is:   L = E-D

In the formula:

L — liquid level;   

E ———The total height of the tank;   

D ———Air height.

Even in the presence of false reflections, the new micro-processing technology, and the unique ECHOFOX- software can accurately analyze the level echo. By inputting the size of the container, the distance value can be converted into a signal proportional to the level. The instrument can be debugged with empty positions.

Extended reading: FMCW Radar Level Transmitter 120GHz

  • The radar level sensor adopts an integrated design and has no moving parts. There is no mechanical wear and long service life;
  • The electromagnetic wave emitted by the radar liquid level sensor does not need a transmission medium. Not affected by the atmosphere, steam, and volatilized fog in the tank;
  • Not affected by the density and concentration of the liquid in the tank;
  • Can be used for high temperature and high-pressure liquid level measurement;
  • Strong corrosion resistance and can adapt to highly corrosive environments;
  • It has the function of false echo suppression. Suppress the false echo signal from the liquid surface to the antenna through false echo. Eliminate the interference of false echoes;
  • The radar liquid level sensor has no measurement blind zone, and the accuracy can be very high.

Extended reading: Radar Level Sensor Advantages and Disadvantages

Extended reading: Non contact level measurement

Sulfuric acid storage tank level measurement

We have provided customers with radar level transmitters for level measurement in sulfuric acid tanks.

The diesel-sulfuric acid storage tank is a vertical storage tank. Because there is a large amount of volatile gas in the tank. Therefore, the equipment is required to be explosion-proof without being affected by the gas. Based on the internal structural characteristics of the pyrosulfuric acid storage tank and the characteristics of the storage medium. Our company chose a non-contact intelligent radar level transmitter to measure the level of the medium.

There are 6 sulfuric acid storage tanks, and the tanks can be connected. To ensure the accuracy and safety of the measurement. Radar level transmitters are installed on the 6 tanks respectively, which are on standby for each other. And under normal circumstances, the accuracy of the two liquid level measurement values ​​can be compared by reference.

When installing the radar wave level transmitter, the inclined installation method was first adopted. Its inclination angle does not exceed 15°.

Extended reading: Diesel Tank Level Monitoring System

When debugging the level gauge, it is found that there is no level data display. Analyze the cause of the failure because the emitted radar wave is reflected back on the steel plate of the tank. The main reason is that the false echo interference is too large. After re-adjusting the installation angle of the radar level transmitter, it was found that level data appeared. However, the data fluctuates greatly, and due to analysis reasons may be due to liquid level fluctuations.
Radar wave reflections cause effects.

For this reason, it was decided to install a reflector in the measuring tube in the tank. Readjust the installation of the radar level transmitter. Make the plane of the transmitting antenna of the radar wave parallel to the reflector. The level data measured in this way is more accurate.

Calculation of the area of ​​the reflector:
Adopt an intelligent radar liquid level transmitter. Its antenna size parameter DN80/3″
Beam angle a=10°,
According to the formula Tan5°=W/2D,
It can be calculated that W=900mm,
Furthermore, the area of ​​the reflector is obtained.

Therefore, we can make a disc with a diameter of not less than 900mm.

Extended Reading: Silo/Bin material level measurement system

Connect the signal wire on the wiring terminal of the radar level transmitter to the safety barrier. That is, first pass the safety barrier and then connect to the I/0 card of the DCS and the SIS system. And complete the software configuration and the parameter setting of the radar level transmitter.

The change of the medium level of the storage tank can be monitored in real-time through the DCS system. And to realize the remote control of the storage tank level and the monitoring of real-time/historical data.

Extended reading: Radar Liquid Level Sensor|Corrosive, steam, volatile liquids

Extended reading: Diesel fuel tank level gauges & indicators

Level measurement of corrosive hazardous chemicals tank

We generally encounter liquid level measurement in chemical plants such as petroleum storage tanks, chemical storage tanks, chemical storage tanks, sewage treatment plants, dosing tanks, seasides, and docks. Used to measure corrosive media such as sulfuric acid, nitric acid, hydrochloric acid, hydrofluoric acid, sodium hydroxide, and concentrated alkali.

When encountering these corrosive media, we generally choose corrosive ultrasonic level sensors and use non-contact radar level sensors to measure corrosive liquids such as sulfuric acid, hydrochloric acid, and nitric acid. Below we introduce, we have to consider two major principles in the selection of level sensor measurement.

The first principle: the principle of non-contact measurement needs to be considered. Choose a non-contact level sensor.

Because the probe of the level sensor does not need to touch the medium. The principle of the sensing band is used to obtain the current liquid level information. For example, when the radar level sensor measures the level, it does not touch the measured medium. The selected material is tetrafluoroethylene. At the same time, it is a fully enclosed anti-corrosion structure. Therefore, the effect is very good for the liquid level measurement of viscous, corrosive, turbid, and other liquids.

Extended Reading: GWR Level Sensor for High Temperature & High Pressure

The second principle: to consider the convenience of on-site installation.

Due to the uniqueness of the measurement of corrosive liquids such as sulfuric acid, hydrochloric acid, and nitric acid. It needs to be easily installed on-site. It needs to be simple to open a hole in the jar.

Therefore, in the selection process of the level sensor, it is necessary to consider the characteristics of reliable work, easy installation, long service life, and maintenance-free.

The third principle: sensor selection.

When the radar level sensor measures corrosive media, the general manufacturers will choose the anti-corrosion type tetrafluoro material contact surface. Considering environmental factors, a physically sealed anti-corrosion probe should be selected for this occasion.

Extended reading: Applicaitons Of Magnetostrictive Level Transmitters

The fourth principle: the choice of the host part.

For the most part, good sealing is required. As long as there is a little leakage of the medium. It is possible to enter the inside of the level sensor from the housing or the wire inlet. As a result, the internal circuit board is corroded. For corrosive gases in the environment, anti-corrosion high-frequency radar level sensors can be used to protect the service life of the host.

The above is how we analyzed how to choose a level sensor for concentrated sulfuric acid and hydrochloric acid. If concentrated sulfuric acid and hydrochloric acid exceed a certain temperature range, and steam or vaporization occurs, it is necessary to consider the actual situation on-site and re-select the appropriate level sensor.

Extended reading: Ultrasonic level transmitter for Hazardous Liquids

From the working principle of ultrasonic level transmitter and radar level transmitter, we can see that the two have many similar parts. There is little difference in sulfuric acid corrosion resistance. This is also an important reason why many meter users do not know how to choose.

Both dilute sulfuric acid and concentrated sulfuric acid have acid mist and are volatile. Moreover, when the sulfuric acid pump is running, foams of different degrees will be generated on the surface of the sulfuric acid. These factors will affect the accuracy of the sound velocity measurement of the ultrasonic liquid level transmitter. In this regard, feedback results from a large number of user applications show that in measuring the level of sulfuric acid, both domestic and foreign ultrasonic level transmitters are not ideal.

Because the electromagnetic wave of the radar level transmitter is less affected by factors such as gas, foam, and dust. Therefore, radar level transmitters, especially high-frequency radar level transmitters, can be better used for sulfuric acid level measurement.

Extended Reading: Low Cost Float Level Sensor for Tank Liquid Volume Monitoring

In comparison, the measurement of the radar level transmitter is more accurate. Therefore, the radar level transmitter is more suitable for the level measurement of sulfuric acid than the ultrasonic level transmitter.

In specific practice, although the radar level transmitter is effective in measuring the level of sulfuric acid. But in the measurement of the sulfuric acid level in the first suction tank, the sulfuric acid level in the second suction tank, and the sulfuric acid level in the underground tank. Anti-corrosion float level transmitters are widely used. This is because the price of radar-level transmitters is relatively expensive. The anti-corrosion float level transmitter is more cost-effective.

But in terms of measuring the level of sulfuric acid storage tanks. Few sulfuric acid plants use anticorrosive float level transmitters. This is because the anti-corrosion float level transmitter is under the impact of liquid from a higher tank. The guide rod is prone to bend. It is not suitable for use in sulfuric acid storage tanks. Most sulfuric acid plants use radar level transmitters for sulfuric acid level measurement.

Read More about: Ultrasonic level transmitter VS Radar level transmitter

Extended reading: Radar Oil Tank Level Sensor

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Sino-Inst is a manufacturer of Radar level sensor for Sulfuric acid storage tank level measurement.
Sino-Inst offers over 30 Radar level sensors for level measurement.
About 50% of these are used as oil level meters, 30% is the Sulfuric acid storage tank level meter. A wide variety of Radar level sensor options are available to you, such as free samples, paid samples.

Sino-Instrument is a globally recognized supplier and manufacturer of Sulfuric acid storage tank level measurement instrumentation, located in China.

Sulfuric acid storage tank level measurement instruments are most popular in North America, Domestic Market, and South America. You can ensure product safety by selecting from certified suppliers, with ISO9001, and ISO14001 certification.

Sino-Inst’s entire team is well trained, so we can ensure that each customer’s needs are met. If you need any help with your product requirements, whether it is a radar level sensor, pressure sensor, or other equipment, please give us a call.

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