Introduction To Industry Scenarios
Nonferrous metal smelting by pyrometallurgy (smelting/blowing/refining, high temperature 1200-1500 ℃), hydrometallurgy (leaching/electrolysis/extraction, strong corrosion, atmospheric pressure/low pressure), electrolytic aluminum (high temperature melting, strong corrosion, high current), core features: strong corrosion (acid alkali/salt solution), high temperature, high dust, strong electromagnetic interference, flammable and explosive (gas/organic solvent), medium prone to crystallization/scarring.
Typical measuring points:
Pyrometallurgical melting: cooling water tank level, flue gas pressure, gas/combustion air pressure, waste heat boiler level in the melting furnace
Wet leaching: acid leaching/alkali leaching reaction kettle liquid level, pressure, crystallizer liquid level, slurry tank liquid level
Electrolysis workshop: electrolyte level in the electrolytic cell, circulating electrolyte pressure, and acid-base regeneration tank level
Extraction/Refining: Extraction tank liquid level, organic/aqueous phase interface, refining furnace cooling liquid level, pressure
Public auxiliary: Gas cabinet pressure, circulating water/sewage treatment tank liquid level, acid and alkali storage tank liquid level
Adapt to Core Products
QDY30A anti-corrosion input type liquid level transmitter (PVDF/Hastelloy, acid alkali/organic solvent resistant) IP68、 Anti crystallization)
QDY60 series slurry type static pressure liquid level transmitter (resistant to slurry/suspended solids, anti clogging, long-term immersion)
QDW90A-3051 anti-corrosion flange liquid level transmitter (Hastelloy/Tantalum diaphragm, strong corrosion resistance, easy crystallization medium, flat diaphragm anti scarring)
QDKG anti-corrosion/explosion-proof pressure switch/transmitter (316L/Hastelloy, acid and alkali resistant, vacuum/low pressure, explosion-proof Ex d II CT6, anti vibration)
GLG anti-corrosion signal isolator/RS485 isolator (moisture-proof/anti-corrosion, anti electrolytic high current interference, long-distance transmission)
S803/SS803 anti-corrosion digital display instrument (316 stainless steel shell, acid and alkali corrosion resistance, local alarm, Modbus communication)
Product Function
QDY30A anti-corrosion type+QDW90A-3051 anti-corrosion flange liquid level class
Wet leaching reaction kettle/slurry tank liquid level: PVDF/Hastelloy anti-corrosion, anti crystallization/scarring, precise control of leaching liquid level, ensuring stable slurry concentration, leaching efficiency ≥ 95%, and improving metal recovery rate.
Electrolyte level of electrolytic cell: 316L sanitary anti-corrosion, no dead corners, stable electrolyte level, ensuring uniform electrolysis current, preventing short circuit/plate burning, and improving electrolysis purity (≥ 99.99%).
Liquid level of acid/alkali storage tank/regeneration tank: PTFE anti-corrosion and strong corrosion resistance, monitoring of chemical inventory, automatic replenishment of linked dosing pump, low liquid level alarm, ensuring stable leaching/electrolysis of chemicals and avoiding drug breakage/waste.
Liquid level of cooling water tank/waste heat boiler for pyrometallurgical smelting: resistant to high temperature of 150 ℃, anti scaling, real-time monitoring of cooling water volume, prevention of water cut-off and furnace burning, ensuring continuous operation of smelting, and recovering waste heat for power generation.
QDKG anti-corrosion/explosion-proof pressure switch/transmitter
Leaching reactor pressure/vacuum degree: 0.075 level, Hastelloy anti-corrosion, temperature resistance of 150 ℃, precise control of leaching pressure, improved leaching rate, shortened reaction time, and reduced energy consumption.
Electrolytic circulating fluid pressure: anti-corrosion diaphragm, low pressure type, stable electrolyte circulating pressure, ensuring uniform flow rate of electrolytic cell, improving product quality, and preventing pipeline blockage.
Pyrometallurgical melting of gas/flue pressure: explosion-proof certification, high temperature resistance, monitoring of gas pressure, prevention of leakage and explosion, ensuring stable melting temperature, and improving metal recovery rate.
Extraction tank/refining furnace pressure: anti-corrosion, micro pressure type, monitoring tank pressure, preventing organic solvent leakage, ensuring safe and efficient extraction/refining.
GLG anti-corrosion signal isolator/RS485 isolator
High current interference in electrolysis workshop: 2500V isolation, strong electromagnetic interference resistance, cutting off ground loop, suppressing interference, stable DCS signal, no drift, no false interlocking, ensuring continuous operation of electrolysis.
Wet process strong corrosive environment: moisture-proof/anti-corrosion design, long-term stable operation, no corrosion damage, and reduced maintenance.
Long distance signal (workshop → central control): RS485+Modbus, signal attenuation free, real-time data upload, stable traceability.
S803/SS803 anti-corrosion digital display instrument
Wet/electrolytic workshop on-site display: 316 stainless steel, acid and alkali corrosion resistance, high brightness LED, visual inspection reading, no need to enter strong corrosion areas, safe and efficient.
Over limit alarm/interlock: relay output, linked dosing valve/pump, emergency stop, 1-second response, anti leakage/overflow accidents.
Data upload/accumulation: Modbus communication, access to central control SCADA, chemical consumption/energy consumption statistics, fault tracing, meeting environmental/compliance requirements of the non-ferrous metal industry.
Addressing Industry Issues
Strong corrosive environment, extremely short instrument life
Acid alkali/organic solvent corrosion, ordinary instruments are damaged within 1-3 months, frequently replaced, high maintenance costs, and contaminated media.
The medium is prone to crystallization/scarring, measurement failure
Slurry/salt solution crystallization scarring, ordinary probe blockage/adhesion, large drift, inaccurate liquid level/pressure, process loss of control, low metal recovery rate.
High safety risk (corrosion leakage/gas explosion)
Strong corrosive medium leakage burns/contamination; Gas leakage, explosion/poisoning; Electrolytic short circuit burns the electrode plate, resulting in significant losses.
Unstable electrolysis/leaching parameters, low recovery rate
Fluctuations in liquid level/pressure, low leaching efficiency, substandard electrolysis purity, low metal recovery rate, and waste of raw materials.
Dangerous and inefficient manual patrol inspection
Strong corrosion/high temperature/toxic environment, high risk and low efficiency of manual liquid level measurement/meter reading, data lag and untimely adjustment.
Direct Customer Benefits
Quality and Recovery Yield (Core)
Accurate liquid level/pressure control: leaching efficiency increased by ≥ 5%, metal recovery rate increased by 2% -4%, and annual metal recovery value increased by ≥ 5 million yuan.
Stable electrolysis parameters: The purity of electrolytic metal remains stable at ≥ 99.99%, batch consistency improves by ≥ 98%, and product premium increases by ≥ 3%.
Anti crystallization/scarring: instrument failure rate reduced by ≥ 85%, long-term stable measurement, reduced process fluctuations, and product qualification rate increased by ≥ 99.8%.
Safety and environmental benefits
Corrosion prevention+explosion prevention: The risk of corrosion leakage/gas explosion is reduced by ≥ 95%, the safety accident rate is reduced by 100%, and significant personal/equipment losses are avoided.
Closed measurement+interlocking: Reduce medium leakage by ≥ 90%, reduce environmental pollution risks, meet the environmental emission requirements of the non-ferrous metal industry, and avoid fines.
Energy conservation, consumption reduction, and cost-benefit analysis
Accurate dosing/adjustment: Reduce medication consumption by 12% -18%, saving medication costs of ≥ 2 million yuan annually.
Stable electrolysis/melting: energy consumption reduced by 10% -15%, with an annual energy-saving/seasonal value of ≥ 1.5 million yuan.
High reliability design: The instrument has a lifespan of 2-3 years, with annual maintenance costs reduced by ≥ 75% and spare parts/labor expenses reduced by ≥ 400000 yuan.
Maintenance and labor benefits
Long maintenance free cycle: reducing manual cleaning/calibration by ≥ 80%, saving labor costs of ≥ 120000 yuan per year.
Unmanned operation: Reduce manual inspections by ≥ 85%, eliminate the risk of strong corrosion/high temperature operations, and enhance employee safety.
Management and compliance benefits
Accurate and traceable data: meets the environmental/safety compliance requirements of the non-ferrous metal industry, the data is authentic and cannot be tampered with, and has successfully passed environmental/safety inspections.
Intelligent upgrade: Connected to the smart smelting platform, remote monitoring/scheduling, management efficiency improved by ≥ 55%, in line with the national policies of intelligent manufacturing and green smelting of non-ferrous metals.
