This project is a practical case study of Anhui Beichen Electric Technology in our company. Please carefully check the manufacturer information on the product nameplate for the selection and exchange of viscosity meters!
In March 2024, a fine chemical plant in the Yangtze River Delta encountered viscosity control difficulties during the commissioning of a newly built polymer production line. This production line requires real-time monitoring of the viscosity of reaction materials in an environment with a high temperature of 80 ℃ and a pressure of 5MPa. Traditional offline sampling detection has three major pain points: manual sampling takes 30 minutes per time, resulting in delayed process adjustments; Sampling in high temperature and high pressure environments poses a risk of burns; The deviation between laboratory data and real-time operating conditions is ± 15%, causing batch quality fluctuations.
After multiple technical discussions, the factory introduced our customized online viscosity monitoring solution in May 2024. The device is equipped with a non-contact sensing module, which is directly integrated into the DN150 process pipeline, achieving the following breakthrough functions:
10 high-frequency samples per second, real-time data transmission to DCS system
Resistant to high temperature of 120 ℃ and PN16 pressure rating
Built in self-cleaning mechanism to avoid material deposition interference, the system has achieved significant results after operation: the process response speed has been improved by 87%, and the single batch production cycle has been shortened by 22 minutes; The quality pass rate has jumped from 83% to 98.5%; More than 800 manual sampling operations were reduced annually, resulting in a decrease of 360000 yuan in comprehensive operation and maintenance costs. More importantly, the equipment has been running without any malfunctions for 18 consecutive months and has withstood the rigorous test of a 95% humidity environment during the rainy season in 2025. The technical director of the factory specifically pointed out at the project summary meeting that "this monitoring system has completely changed the traditional viscosity control mode, and the stability of equipment operation and data reliability far exceed expectations. Now we can accurately grasp the material characteristics of each reaction stage, providing data support for the development of high value-added new products." Based on successful experience, the company has planned to expand the online monitoring application of three production lines in the 2026 technical renovation project.