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The efficient and cost-effective supply of energy is crucial for the chemical industry.

At the chemical park of a leading industrial service provider in Knapsack, Germany, being able to ensure a reliable supply of steam, alongside other resources like electricity, natural gas, and compressed air, is paramount. The steam required for various chemical processes at the site is sourced from local generation plants, including a refuse-derived fuel (RDF) power plant, which converts up to 300,000 tons of alternative fuels into steam and electricity annually. Additionally, a nearby RWE power plant supplements this steam supply.

Importance of accurate volume measurements:

Accurate volume measurements are essential for managing the steam network efficiently. These measurements help balance the quantities of steam generated and fed into the grid with the quantities consumed. However, natural measurement uncertainties and unrecorded purchases can lead to discrepancies. To address this, creating smaller balancing sub-networks is an effective strategy.

Forming two balancing sub-networks:

The chemical park is divided into two sections, with these sections being connected by an internal road and a pipe bridge that also carries steam from Knapsack to a second plant. Measuring the steam quantity on this connecting line forms two balancing sub-networks – crucial for identifying discrepancies, but halting production at the second plant to install measurement devices would be highly disruptive.

Adoption of advanced measurement technology:

Innovative clamp-on ultrasonic flow measurement technology offered a solution. The experts at the chemical park already had significant experience of the benefits of this non-intrusive technology, which was further enhanced by recent advancements made by Flexim’s developers. These developments expanded the use of non-intrusive flow measurement to superheated steam, generating considerable interest.

Cross-correlation method for high-temperature steam:

Traditional ultrasonic flow measurement relies on the transit time difference principle, but for high temperature steam, Flexim’s meters use the cross-correlation method. This involves mounting two pairs of ultrasonic transducers on the pipe at a defined distance, creating two acoustic measurement barriers. The ultrasonic signals interact with the vortices of the flowing steam, and as these vortices travel through the barriers, they modulate the signals, which are then cross-correlated over time to determine the flow velocity. The mass flow is calculated based on the pipe geometry and the physical parameters of the steam.

Validation and implementation:

To validate this new measurement technology’s reliability and accuracy, a long-term test was conducted. The measurement point was installed at the RDF plant exit, and its readings were compared with those of an inline ultrasonic measurement system, showing good agreement. This success led to the decision to purchase and install the system on the pipe bridge between the two plants. For precise mass flow calculation, temperature and pressure are also recorded directly at the measuring point.

This innovative approach ensures a reliable and efficient steam supply for the chemical park, highlighting the importance of adopting advanced technology to help maintain operational excellence in the chemical industry.

Want to revolutionise your flow measurement process?

Discover the real-world benefits of clamp-on ultrasonic flow measurement in the chemical industry. Whether you need a permanent mains-powered installation, or flexible battery-powered rental meters for one week or longer, contact Simon Millington to find out more: www.emerson.com | flexim-uk@emerson.com | +44 (0)1606 781 420

External URL: www.emerson.com