Process Instrumentation

for the Chemical Industry

Anton Paars
Process Instrumentation Guide
for Chemicals

Anton Paar has been developing, producing

and distributing high-precision measuring and
analytical instrumentation for laboratory and process
applications since 1922.
Anton Paar solutions are realized with a passion for
precision, a love of science and shared enthusiasm
throughout the entire chain of production, every step
of the way.
Rising raw material costs, environmental sustainability
and a global economy are some of the future
challenges for the chemical industry. In order for
production processes to run at peak performance,
highly accurate, rugged and easily integrated field
instrumentation are needed. Anton Paars process
instruments are used to guarantee efficient, reliable
and economic production throughout the chemical
industry and to safeguard your competitiveness.

Introduction and
Content

Technologies for the

Chemical Industry

6
Sulfuric
Acid

Phosphoric
Acid

11

Acid
Acid
Applications Applications

12
Ammonia

14

Sc

Acid
Acid
Applications Applications

10

21

13
Ammonia
Applications

39
Y

22
Ti

40
Zr

57
La

89
Ac

23

72

24
Cr

41
Nb

73

42
Mo

74

25
Mn

43
Tc

75

26
Fe

27
Co

44
Ru

45
Rh

76

77

Hf

Ta

Re

Os

Ir

104

105

106

107

108

109

Unq

Unp

Unh

Uns

Uno

28
Ni

46
Pd

78
Pt

Une

15

Ammonia Diammonium
Applications Phosphate

16
Chlorine

18

17
Chlorine
Applications

19

90 Years of Anton Paar

Innovation Instruments

20
3

Technologies for the Chemical Industry

Anton Paars instruments embody decades of

technical know-how. This continuously growing
knowledge at the cutting edge of technological
developments forms the basis for robust and reliable
process instrumentation.
Anton Paars deep understanding of measurement
principles results in precise process instrumentation
with excellent performance and reproducibility.
Openness to customer requirements, attention to
new market trends and embracing innovation, ensure
sustainability.

Trust, but

raw materials, intermediates, products,

concentrations, processes and quality.

Production Control
Control the process
Save raw material and energy
Save time
Increase production
Increase revenue
Real time, continuous inline measurement
Maintenance free
Typical life cycle 170,000+ hours

Quality Control
Improve product quality
Control quality
Assure quality
Conform to specifications
Detect and prevent errors

H2SO4

Sulfuric Acid

Sulfuric acid is one of the most important industrial chemicals used in the world and found in many
completely unrelated industries. Anton Paar offers several inline process solutions tailored to all kinds
of applications.

Important facts
Sulfuric acid is produced from sulfur, oxygen and water in the common contact process (DCDA) and the wet
sulfuric acid process (WSA).
The chemical formula of sulfuric acid is H2SO4. 100 % sulfuric acid is a clear, odorless liquid that shows highly
hygroscopic behavior.
Sulfuric acid can be diluted with water in any ratio; however, a large amount of heat is generated during
the dilution process, which therefore calls for great caution. Sulfuric acid (particularly oleum) has a highly
destructive effect on tissue and fabric.
To date, the most relevant industrial process for producing sulfuric acid is the so called double contact
process. H2SO4 is produced by dissolving sulfur trioxide (SO3) in concentrated sulfuric acid and diluting
the solution with water to achieve the desired concentration. An online determination of sulfuric acid
concentration is essential for controlling the H2SO4 production and dilution process.

Production process
Contact process (DCDA)

H2SO4
Air

SO2

Sulfur
In the first step, sulfur is burned to
produce sulfur dioxide (SO2). This is then
oxidized to sulfur trioxide (SO3) using
oxygen in the presence of a vanadium (V)
Burner
oxide catalyst. This reaction is reversible and
the formation of the sulfur trioxide is exothermic.

The sulfur trioxide is absorbed into 9798 % H2SO4 to form

oleum (H2S2O7), also known as fuming sulfuric acid. The
oleum is then diluted with water to form concentrated sulfuric
acid (H2SO4).

Absorption
tower

SO3
SO3
Converter

Note that directly dissolving SO3 in water is not practical due to the highly
exothermic nature of the reaction between sulfur trioxide and water. Instead of a
liquid, the reaction forms a corrosive aerosol that is very difficult to separate.

Dilution tank

H2SO4

1 2
Sulfuric acid has many applications and is a central substance in the chemical
industry. Principal uses include lead-acid batteries for cars and other vehicles, mineral processing, fertilizer
manufacturing, oil refining, wastewater processing and chemical synthesis.

Sulfuric acid and oleum: All with one instrument

Anton Paar produces the only single sensor capable of measuring the entire range of H2SO4 and oleum!
6

H3PO4

Phosporic Acid

Phosphoric acid is a non-toxic, inorganic, rather weak triprotic acid, which, when pure, is a solid at
room temperature and pressure. Phosphoric acid, also known as orthophosphoric acid or phosphoric
(V) acid, is a highly polar molecule and therefore highly soluble in water.

Important facts
Phosphoric acid is commonly used as an aqueous solution of 85 % phosphoric acid or H3PO4. Phosphoric
acid may be used as a "rust converter", by direct application to rusted iron, steel tools, or surfaces. The
phosphoric acid converts reddish-brown iron (III) oxide, Fe2O3 (rust) to black ferric phosphate, FePO4. Foodgrade phosphoric acid (additive E338) is used to acidify foods and beverages such as various colas, but not
without controversy regarding its health effects. It provides a tangy or sour taste and, being a mass-produced
chemical, is available cheaply and in large quantities. Its low cost and bulk availability sets phosphoric acid
apart from more expensive seasonings that give comparable flavors, such as citric acid which is obtainable
from lemons and limes. Phosphoric acid is also used as an electrolyte in copper electro-polishing, for burr
removal, circuit board planarization, in cleaners, fertilizers, as an etching solution and many more.

Production process
For industrial production the mineral apatite Ca5(PO4)3 is used. Through the ore-bearing rock, flotation is
first concentrated and then reacted with sulfuric acid:

2
Sulfuric acid
H2SO4

Reaction tank

Flotation tank
Apatite

Ca5(PO4)3

(Mineral)

(Mineral)

1 Phosphoric acid
H3PO4

Calcium sulfate (solid)

CaSO4

Acid Applications

Density and sound velocity:

Quick, safe and accurate acid concentration determination
Whether making batteries, fabrics, explosives, propellants or pickling metals, corrosive acids are used
throughout many industries. The accurate concentration measurement of highly corrosive acids is always
difficult, often dangerous and sometimes impossible, unless you have the right instrument for the job. Anton
Paars Acid Monitor even measures aqua regia (nitro-hydrochloric acid)!
While only the major industrial acids are described in detail, Anton Paar also measures a variety of other acids
and compounds. Our team of application specialists are dedicated to measuring new components and work
closely with existing and potential customers to devise a solution tailored to the customers individual process
needs.

Benefits
Increase quality, production and revenue
High cost savings through more efficient use of resources
Typical life cycle of 170,000+ hours
Continuous, real time data recording
Automatic temperature compensation
Simple to install and maintenance free

Concentration range (aqueous solution)

HCl
HNO3
H3PO4
H2SO4

Accuracy

0.05 % to 0.17 %*

Temperature range HCl and H2SO4:

0 C to 100 C

Temperature range HNO3 and H3PO4:

0 C to 60 C

* dependent on temperature- and concentration range

0
0
0
0

% to 35 %
% to 65 %
% to 100 %
% to 110 %

Acid Applications

Plating baths
The plating process employs electricity and an electrolyte solution of acid, water and metallic salt to coat
metal objects with a thin layer of a different material. The concentration of the acid and salts in the bath is
critical to proper layer thickness and quality.
Typical plating acids are:
Hydrochloric acid

HCl

Sulfuric acid

H2SO4

Phosphoric acid

H3PO4

Combinations of the above and other acids

Sulfomated
polystyrene
cation
exchanger

1
2

H2SO4

Highly
basic
anion
exchanger

H + OH

Highly
basic
anion
exchanger

Demineralized
water storage

WASTE

Evaporator

Plating bath

Save rinse

Rinse

Rinse

Floor drain

Pickling baths
Pickling baths are used to remove iron oxide and other scale created during hot rolling of sheet metal or other
fabrication steps without removing base material. More accurate pickling bath concentration saves resources
and time while improving quality and revenue. The pickling solution used is a ternary system composed of
acid, water and metallic salt (FeSO4, FeCl2 etc.). The acid and salt concentration of the bath is measured.
Common pickling acids are:
Hydrochloric acid

HCl

Sulfuric acid

H2SO4

Phosphoric acid

H3PO4

Combinations of the above and other acids

Steel picking (three-tank arrangement):

TANK A

Treatment: HCl

TANK B Treatment: HCl

TANK C Treatment: HCl

Scrubber brush

9
Direction of strip travel

Acid Applications

Battery manufacturing and recycling

As reliable solutions for monitoring acid concentration, Anton Paars instruments are found in many stages of
battery production and recycling: from the production of new acid, recovery of used acid from old crushed
batteries, control of acid blending for various acid concentrations to the final quality control in the filling process.

Acid Recovery

Plastic
New cases and covers
Plastic pellets recycled
from old battery cases
and covers are used to
produce new cases and
covers.

New battery cases and

covers are produced
from recycled plastic
pellets.
Plastic pellets

Cases and covers

crushed

Transportation
network

Lead

New grids
and lead oxide

Lead ingots recycled

from battery grids and
lead oxide are used to
produce new grids and
components.

Recycled lead is used

for new battery grids,
recovered lead oxide is
also used in new battery
production.

Used batteries

The same transportation

network used to
distribute new batteries
safely carries used
batteries back to Crown
Battery.

Used batteries are

taken to a recycling
facility, broken down
and separated into
components to
begin the recycling
process.

New cases and covers

Lead ingots

Melt grids

New grids, lead oxide

Battery acid

Sodium sulfate crystals

separated from old
battery acid are recycled
and sold for use in
textiles, glass and
detergents.

Sodium sulfate
crystals

Glass, textiles,
detergents

Neutralized battery acid

Battery filling
H2SO4

10

To capping
& washing

New battery

99 % of Crown Batteries
are recyclable and
comprised of previously
recycled materials.

15

3 PVC 80

Electronic
stop

Tilt (30) stage to equalize volume

Overfill stage

Electronic
stop

Approx. 60 % fill stage

Acid Applications

Etching
Various types of etching are found in different industries;
the type of etching greatly depends on the parts
manufactured. These include photochemical machining
(PCM) for smaller sheet metal parts, chemical milling
for printed circuit boards, semiconductors and the
aerospace industry.
The chemicals used vary widely depending on the
application but include:

Chemical etching

Water

rinsing

Sensitization step

Water

rinsing

Activation step

Water

rinsing

Water

rinsing

Activation step

Water

rinsing

Acceleration step
(solution)
Water

rinsing

Electroless plating

Common materials and their etchants

Material

Measurebale wet components

Aluminum

Phosphoric acid + acetic acid + nitric acid

Indium tin oxide

Hydrochloric acid + nitric acid

Chromium

Hydrochloric acid

Gallium arsenide

 Hydrochloric acid
 Citric + hydrogen peroxide water

Organic residues and photoresist

Sulfuric acid + hydrogen peroxide

Silicon

Nitric acid

Silicon nitride

Phosphoric acid

Titanium

Hydrofluoric acid

Titanium nitride

Nitric acid

Tungsten

 Nitric acid
 Hydrogen peroxide

11

NH3

Ammonia

Ammonia is a compound of nitrogen and hydrogen with the formula NH3. It is a colorless gas with a
characteristic pungent odor.

Important facts
Ammonia is a building block, either directly or indirectly, for the synthesis of many pharmaceuticals and is used in
many commercial cleaning products. Although in wide use, ammonia is both caustic and hazardous.
Commercially used ammonia is often called anhydrous ammonia. This term emphasizes the absence of water
in the material. Because NH3 boils at -33.34 C (-28.012 F) at a pressure of 1 atmosphere, the liquid must be
stored under high pressure or at low temperature. Household ammonia or ammonium hydroxide is a solution
of NH3 in water. Household ammonia ranges in concentration from 5 to 10 weight percent ammonia.

Production process
The Haber process, also called the HaberBosch process, is the nitrogen fixation reaction of nitrogen gas and
hydrogen gas, over an enriched iron or ruthenium catalyst, which is used to industrially produce ammonia.
Despite the fact that 78.1 % of the air we breathe is nitrogen, the gas is relatively unavailable because it is so
unreactive: nitrogen molecules are held together by strong triple bonds. It was not until the early 20th century
that the Haber process was developed to harness the atmospheric abundance of nitrogen to create ammonia,
which can then be oxidized to make the nitrates and nitrites essential for the production of nitrate fertilizer and
explosives. Prior to the discovery of the Haber process, ammonia had been difficult to produce on an industrial
scale.
The Haber process is important today because the fertilizer generated from ammonia is responsible for
sustaining one third of the Earth's population. It is estimated that half of the protein within human beings is made
of nitrogen that was originally fixed by this process, the remainder was produced by nitrogen fixing bacteria and
archaea.

Steam

Waste
heat
boiler

Water

Concentration range:
Temperature range:

0 % to 100 %
0 C to 60 C

Accuracy:

0.15 %*

N2, H2, NH3

Cooler
Reactor

H2, N2

N2, H2

AMMONIA
(fluid)

12

* dependent on temperature- and concentration range

Ammonia Applications

Increase revenue and profit with improved accuracy

Ammonia is used across numerous industries and is commonly referred to as anhydrous ammonia in
commercial use and ammonia hydroxide in household cleaners. Accurate inline ammonia measurement can
save resources, increase production, ensure process and product quality and raise revenue, all the while
ensuring a safe work environment.
Roughly 83 % of the worlds ammonia is used as fertilizer and is directly or indirectly the precursor of most
nitrogen-containing compounds. Used to increase the yield of crops, ammonia is a significant component of
the worlds chemical production.

Fertilizer
Nitrogen fertilizer production routes

Ammonia Plant
Natural gas | Water | Air

Carbon dioxide

Ammonia

Urea Plant

Nitric Acid Plant

Water | Air

Ammonium Nitrate Plant

Nitric Acid

Ammonium nitrate

Nitrophosphate Plant

Phosphate Rock

Calcium Nitrate Plant

Potash

Phosphoric Acid Plant

Phosphate Rock

1
Sulfur

NPK Fertilizer Plant

Sulfuric Acid

Sulfuric Acid Plant

Ammonium Phosphate Plant

13

NH3

Ammonia Applications

Refrigerants
Anhydrous ammonia is often used for industrial refrigeration because of its high energy efficiency, low cost
and tell-tale smell if there is a leak. Proper ammonia concentration is important for efficient refrigeration and
cost savings.

Cleaning agents
Ammonia is one of the most common components of cleaners, especially for glass, porcelain, stainless steel
and oven cleaners. An accurate ammonia concentration is key to saving costs and ensuring product quality.

Water

Ammonia

Additive

Mixer

Nitrogenous compound production

Ammonia is directly or indirectly used as the precursor to most nitrogen containing compounds and the
starting point for nitric acid used in fertilizer, catalysts and explosives, to name just a few.

14

(NH4)2HPO4

Diammonium Phosphate

Diammonium phosphate (DAP or (NH4)2HPO4) is one of a series of water-soluble ammonium

phosphate salts which can be produced when ammonia reacts with phosphoric acid.

Important facts
DAP is used as a fertilizer in many applications and can also be used as a fire retardant. It lowers the
combustion temperature of the material, decreases maximum weight loss rates, and causes an increase in
the production of residue or char. DAP is also used as a yeast nutrient in winemaking and brewing mead;
as an additive in some brands of cigarettes, purportedly as a nicotine enhancer; as a flux for soldering tin,
copper, zinc and brass; and to control precipitation of alkali-soluble and acid-insoluble colloidal dyes on wool.

Production process

Ammonia
unloading
stations

Enclosed
work area

Phosphoric
acid unloading
stations

DAP storage tank

To product
loading stations

15

Cl

Chlorine

At standard temperature and pressure, two chlorine atoms form the diatomic molecule Cl2. This is a
yellow-green gas that has a distinctive strong odor, familiar to most from common household bleach.

Important facts
Chlorine is a component of various compounds such as table salt. It is the second most abundant halogen
and 21st most abundant chemical element in the Earth's crust. The great oxidizing potential of chlorine
led to its use as a bleaching agent, a disinfectant and an essential reagent in the chemical industry. As a
common disinfectant, chlorine compounds are used in swimming pools to keep them clean and sanitary. In
the upper atmosphere, chlorine-containing molecules such as chlorofluorocarbons have been implicated in
ozone depletion. Elemental chlorine is extremely dangerous and poisonous to all life forms; however, chlorine
is necessary to most forms of life, including humans, in the form of chloride ions. The major inorganic
compounds include HCl, NaCl, CaCl2, etc.

Cl2 production process

The electrolysis cell is divided into two "chambers" by a cation permeable membrane acting as an ion
exchanger. Saturated sodium (or potassium) chloride solution is passed through the anode compartment,
leaving at a lower concentration. Sodium (or potassium) hydroxide solution is circulated through the cathode
compartment, exiting at a higher concentration. A portion of the concentrated sodium hydroxide solution
leaving the cell is diverted as product, while the remainder is diluted with deionized water and passed through
the electrolysis apparatus again. Anton Paar instruments can be used for concentration measurement of the
reaction substances NaCl as well as NaOH.

The membrane cell chlorine process

Anode

2Cl-

Cl2 + 2e-

(This reaction happens

at the anode)

Cathode

2H2O + 2e-

Power
supply
Chlorine gas
(CI2)

Hydrogen gas
(H2)

Lid

Depleted
brine

33 % caustic
soda (NaOH)

OH-

Cl2

30 % caustic
soda (NaOH)

H2

Cl

Na+

1
Saturated
brine
(H2O & NaCl)

OH-

Cl2

33 % caustic
soda (NaOH)

Na+

Cl
(Na+)

Cl2

16

H2 + 2OH-

(This reaction happens

at the cathode)

Sodium ions
pass through
membrane

Caustic soda
(NaOH)
Pure water
(H2O)

dilluted brine
(H2O & NaCl)

Non-permeable
ion exchange
membrane

dilluted caustic
soda (NaOH)

Chlorine Applications
Water

HCl production
In the chlor-alkali industry, brine (mixture of sodium chloride and
water) solution is electrolyzed producing chlorine (Cl2), sodium
hydroxide and hydrogen (H2). The pure chlorine gas (Cl2) can be
combined with hydrogen (H2) to produce hydrogen chloride (HCl
gas).
As the reaction is exothermic, the installation is called an HCl oven
or HCl burner. The resulting hydrogen chloride gas is absorbed in
deionized water, resulting in chemically pure hydrochloric acid (HCl
in water). This reaction can result in a very pure product, e.g. for
use in the food industry.

HCI gas

HCI in water

Cleaning agents
Chlorine is also a very common component of cleaning agents.

Water

Chlorine

Detergent

Mixer

Pharmaceuticals
Some 85 % of pharmaceuticals contain or are manufactured using chlorine chemistry, including products
to treat AIDS, allergies, arthritis, cancer, depression, diabetes, heart disease, hypertension, infections,
pneumonia and ulcers. One example is the natural antibiotic vancomycin, an effective medicine in fighting
hospital staphylococcus infections.
Chlorine-containing compounds are also important intermediates in the manufacture of vitamin C.

17

90 Years
of Innovation
Measurement solutions from Anton Paar are developed*
and produced entirely in-house. In the fields of density
and concentration measurement, rheometry and CO2
measurement, Anton Paar is a global market leader.
From the first hint of an opportunity to the final touches before
shipping, over 1460 people with diverse talents, skills and
mindsets join forces to provide you with results of relevance.
Investing 20 % of its turnover into Research & Development,
and closely cooperating with external scientific partners,
Anton Paar continuously strives to find new solutions and to
further improve existing ones to meet your present and future
needs.

A companys responsibility
Producing solutions for your applications, Anton Paar is
aware of its responsibility to guarantee you lasting success.
This responsibility goes hand in hand with another: Every
companys social responsibility for its employees and society
in general. At Anton Paar, this is a tangible reality a promise
made measurable.

The Santner Foundation

Anton Paar GmbH is owned by the Santner Foundation, a nonprofit organization exclusively and directly aimed at charitable
work and serving the public good. Its proceeds are targeted
at financing research in the fields of natural science and
technology, as well as addiction prevention and rehabilitation.

18

* Developed in cooperation with Labor fr

Messtechnik Dr. H. Stabinger GmbH, Graz

Instrument name
1

Density

Instrument specs

DPRn 407

Temperature: -25 C to 125C

Pressure: max. 10 bar
U-tube material: Borosilicate glass
Flow rate: 100 - 500 l/h

DPRn 417

Temperature: -25 C to 125C

Pressure: max. 50 bar
U-tube material: SS 1.4571
Flow rate: 100 l/h - 500 l/h

DPRn 427

Temperature: -25 C to 125C

Pressure: max. 50 bar
Application dependent U-tube materials: Hastelloy
C276, Tantalum, Incoloy 825
Flow rate: 100 l/h - 500 l/h

L-Dens 437

Temperature: -40 C to 125C

Pressure: 125 bar at max. 80 C
115 bar at max. 125 C
U-tube material: Hastelloy C276
Flow rate: 100 l/h - 500 l/h

Sound

SPRn 4115

Temperature: -25 C to 125C

Pressure: depending on flange and material
up to 100 bar
Application dependent sensor materials:
SS 1.4571, Hastelloy, Monel, gold coated
Flow rate: max. 6 m/s

Density
& Sound

DSRn 427

Temperature: -25 C to 125C

Pressure: max. 50 bar
U-tube material: Hastelloy C276
Flow rate: 100 l/h - 500 l/h

Density &
Conductivity

DPRn 4X7

Temperature: -25 C to 125C

Pressure: max. 50 bar

(DPRn type dependent)
U-tube material: application dependent
Flow rate: 100 l/h - 500 l/h

Conductivity Sensor
(not by Anton Paar)

Temperature: -20 C to 125C

Pressure: max.16 bar,

0 mS/cm - 2000 mS/cm

Evaluation Units

Evaluation Units
mPDS 5

mPDS 1100

For DPRn or SPRn or DSRn

and/or conductivity sensor

For DPRn or SPRn

Inputs
1 analog input

4 to 20 mA passive

1 digital input

Frequency < 100 Hz,

e.g. filler stop

External product selection

5 bits, 32 products

Outputs
2 analog outputs

4 to 20 mA passive,
accuracy 0.1 % FS (for DC
24 V max. 500 Ohm circuit
resistance)

2 relays for limit monitoring

24 V / 0.7 A

Computer serial interfac

RS 232, 1200 to 9600

Baud; Option: Profibus DP
adapter

Display

4 x 20 character LCD

CPU board

Ethernet

(LAN) interface (to Davis 5)
2
 USB interfaces Backup, update
DC
 24 V connection
CAN

interface
(for AP smart sensors)

Transducer
board

Transd.1/Transd.2

DPR(n), SPR(n),
DSRn
2
 analog inputs 4 to 20 mA active/
passive
12
 digital inputs/outputs or counter
e.g. filler stop, bottle counter, limit
alarms

Input/Output
board

4
 analog outputs Connection to PLC
3
 analog inputs
4 to 20 mA active/passive
12
 digital inputs/outputs or counter
e.g. filler stop, bottle counter,
product selector
2
 relay outputs
Alarms

Fieldbus
boards

PROFIBUS DP, PROFINET IO, Modbus

TCP and EtherNet/IP Interface

LCD

Color touch screen

640 x 480 pixel

Power
supply

DC 24 V

Temperature range ambient

10 40 C

22

Anton Paar GmbH

Anton-Paar-Str. 20, A-8054 Graz
Austria - Europe
Tel.: +43 (0)316 257-0
Fax: +43 (0)316 257-257
E-mail: info@anton-paar.com
Web: www.anton-paar.com
Specifications subject to change without notice. | 01/12 XDPIP003EN-A