NUSONICS Technical Note

Sulfuric Acid Analyzer - A Comparison to Conductivity Meters

There are several technologies available to measure concentrated acid (80 Wt % or greater), among the most common are conductivity meters which measure liquid electrical conductance, and NuSonics analyzers which measure the speed of sound through the acid. Associated with each type are different range, accuracy, out of range performance, installation and maintenance considerations. The most significant influence on accuracy is the response curve. As you can see on the graph, a concentration change from 93 to 94 Wt.% will not significantly change the conductivity of the acid, and therefore even the precise conductivity meter cannot measure this % change. All the response curves shown are non-linear, and therefore the accuracy of the acid strength measurement will be different at different strengths. Changes in temperature also change the response curves. Given all the complexities, the best method for selecting an appropriate analyzer for a desired range is to obtain an accuracy statement from the analyzer manufacturer. Accuracy should be specified as a range, in acid strength units, and over a temperature range, as NuSonics does: +/- 0.1 Wt. % for 90-100 Wt. % over a range of 0-100 C, for clean and bubble free Sulfuric Acid. The response curve also determines the possible range of measurement, which must be continuously rising or continuously descending. Based on this requirement, a conductivity meter may be ranged from about 94 to 100 Wt. %. This limit is imposed because 95% acid has the same conductivity as 88% acid, and there is no way for the analyzer to distinguish which of the possibilities is the correct answer. The response curve also determines the out of range performance. Some may assume that at 94 to 100 % acid conductivity meter will simply "bottom out" at 94 should the acid strength be lower. This is not the case. At 88% acid, a conductivity meter will observe the conductivity associated with 95 % and report this erroneous value; in fact, as the acid strength decreases further, the meter would indicate higher values. Failure to foresee this performance can lead to potentially tragic consequences; with costs far in excess of the value of any analyzer. Since the sound velocities for lower acid strengths are all higher than 80 %, there are no conditions where the NuSonics analyzer cannot be trusted. Extended range performance is also valuable during process start up or upset. While a conductivity meter be setup for a limited range, should the acid fall out of this range, the conductivity meter cannot assist the unit operators in recovery to normal conditions. The NuSonics analyzer will provide accurate information both during the normal conditions and during those times when accurate information is most valuable.

Mesa Laboratories Inc. 12100 West 6th Avenue Lakewood, Colorado 80228 (303) 987-8000 FAX (303) 987-8989 www.mesalabs.com

Maintenance and calibration needs vary greatly among the different analyzer types. Sensor coating or electronic aging will weaken the signal of some other analyzers, necessitating calibration sometimes as often as every 3 months. NuSonics sulfuric acid analyzers have no recommended maintenance schedules and thus have the lowest possible operating cost. The calibration stability is achieved by the method of measuring the speed of sound though acid. This is determined by observing the time it takes for a sound pulse to traverse a known distance. Should the sensor foul a little, the received signal will be weaker, which doesn't matter since the important variable is how long the signal took to arrive. Maintenance requirements directly affect operating costs. A NuSonics analyzer has a typical lifetime of 5-10 years and when selected in lieu of a conductivity meter, will save a facility many times its price in operating costs alone. The extraordinary stability also allows NuSonics to offer NIST traceable accuracy certification. When accuracy, range and maintenance matter, NuSonics analyzers provide the solution.

Mesa Laboratories Inc. 12100 West 6th Avenue Lakewood, Colorado 80228 (303) 987-8000 FAX (303) 987-8989 www.mesalabs.com