Conductivity sensor applications

Use in water treatment

For more than 30 years, EnviroFALK GmbH has been designing and manufacturing water treatment systems for a wide range of industries worldwide. Various ifm sensors are used to monitor the complex treatment process and ensure a permanently high quality of the ultrapure water.
The LDL101 conductivity sensor is also part of the game. It is the right choice whenever the purity of water is crucial for product quality or process reliability. In the process itself, the conductivity sensor monitors the concentration of ions in the water and signals in time when ion exchanger cartridges need to be replaced.

Concentration measurement for efficient AEM electrolysis

Our client ProPuls offers comprehensive services in automation technology, from customised test bench construction to research and development of innovative high-pressure electrolysers in hydrogen technology.

One current project is the construction of a test bench for AEM electrolysis, in which hydrogen is obtained through the electrochemical splitting of water. For efficient hydrogen production, water and electrolyte are mixed in a storage tank. If the electrolyte concentration in the tank is too high, the diaphragms are subjected to greater stress and the risk of corrosion increases. If, on the other hand, the concentration of water is too high, the electrolysis performance decreases, and with it the efficiency of the process.

The LDL400 conductivity sensor is used to ensure the optimum mixing ratio. This monitors the conductivity in the mixing tank. This can be used as an indicator of the quality of the mixture.

H2 Powercell application report

H2 Powercell sees hydrogen as part of a holistic climate solution and has set itself the goal of making hydrogen available to the masses. The start-up develops systems for tomorrow’s energy supply in order to move towards a climate-neutral future together.

One such system is the H2PowerCube. Inside the cube, hydrogen is produced using water electrolysis and stored in a tank. If power is required, this H2 storage medium is used to generate electricity and heat via a low-temperature PEM fuel cell. The only thing needed for an environmentally-friendly energy supply with the Cube is green electricity, which can be obtained from a photovoltaic system, for example. Everything else is taken care of by the system itself, relying on ifm’s sensor technology. For example, the LDL101 conductivity sensor monitors the quality of the ultrapure water required for H2 production. In this way, pure hydrogen can be produced from the purest water – in an entirely environmentally-friendly way.

Residue-free cleaning with ultrapure water

Our customer Maschinenbau Silberhorn GmbH is part of the internationally active Silberhorn Group and specialises, among other things, in the development and construction of systems for industrial parts cleaning.
In some systems, ultrapure water is used in the final rinsing process for best results and residue-free cleaning. For a conscious and careful use of water as a resource, the ultrapure water is stored in a tank from where it is introduced in the process over and over again. To ensure a constant quality of the ultrapure water, an ion exchanger is used that continuously filters the water. The LDL101 conductivity sensor keeps an eye on the filter performance and thus the quality of the ultrapure water. If the sensor signals an increase in conductance, this is indicative of a reduced filter performance and can therefore facilitate the timely replacement of the ion exchanger cartridge.

Sustainable cleaning and resource conservation

MAFAC specialises in aqueous parts cleaning in industry and offers standardised single-chamber machines which can be adapted to the respective cleaning requirements by means of numerous options.
Our LDL220 conductivity sensor can be found in the MAFAC Palma model where it performs an important task. Aiming at resource efficiency, the cleaning agent selected for the cleaning process is reused several times and stored temporarily in a tank. In order for it to be reused, the contamination in the cleaning agent must not exceed a certain level. And it is this level of contamination that the LDL220 monitors. When a previously defined conductance is reached, the cleaning agent is replaced in order to ensure continued thorough cleaning.

Use in cooling water applications and critical supply systems

In the past, our customer used a glycol/water mixture to cool temperature control units. However, salt and limescale deposits resulted in reduced diameters at critical points in the temperature control channel. This, combined with lower flow rates, reduced the cooling capacity at these points, resulting in quality problems with the part being cooled.
Today, the customer uses ultrapure water. With ultrapure water, deposits cannot form and residues are reliably flushed out of the pipe. However, over time, the ultrapure water accumulates residues. This is where the LDL101 conductivity sensor comes in, constantly monitoring the quality of the ultrapure water via the conductance. If the conductance rises, the customer can take early action and feed new ultrapure water into the process.

Condition-based cleaning in the CIP process

Our customer in the cheese dairy relies on modern technologies for processing fresh milk. The ifm LDL220 conductivity sensor is one of the instruments used.
Two process values are the focus here: temperature and conductivity. Temperature is a critical process value, as cleaning cycle times are associated with reaching a predefined temperature. Conductance, on the other hand, provides information about the progress of the last cleaning cycle: rinsing the product lines with water. The sensor detects when the detergent has been completely rinsed out, preventing contamination of the product, e.g. milk.

The result: By implementing condition-based cleaning, the process has been sustainably optimised, reducing water and energy consumption while maintaining a consistent quality.

Increased efficiency with a clear phase separation

A machine supplier, which is mainly active in the food industry, has significantly increased the machine efficiency of its CIP systems with the LDL100 conductivity sensor. As the sensor detects changes in conductance, the process phases can now be clearly identified. As a result, the consumption of chemicals and water in the cleaning process could be optimised.

Controlled fertilisation process in horticulture

Our customer GaTech, based in Lüllingen, specialises in modern horticultural technology and offers solutions in the areas of irrigation, heating and air conditioning technology as well as water and fertiliser systems. The company supports horticultural businesses from planning and installation to maintenance, focusing on energy-efficient and resource-saving technologies.

In horticulture and greenhouse cultivation, the precise dosing of water and fertiliser is essential for healthy plants and their growth. Not only the quantity, but also the concentration is crucial here. If the concentration of fertiliser in the irrigation system is too high or too low, there is a risk that the plants will not grow optimally or even die.

This is where the LDL400 conductivity sensor comes into play. It constantly monitors the conductivity of the fertiliser and ensures that the concentration remains within the desired range. In the event of deviations, a safety valve closes and the fertilisation process is stopped. For maximum safety, an additional LDL400 conductivity sensor is used that serves as a control instance and makes any possible drift visible.

Precise salt concentration for safe fish farming

Our client SENECT develops innovative technology for safe and sustainable fish farming. The portfolio includes IoT controllers, sensors and filters that can be combined to form complete recirculating aquaculture systems. One end customer for whom the planning and implementation of a circular system was carried out is InfiniteSea.

InfiniteSea is the world’s first urban marine fish farm based on a sustainable circular principle. The almost complete reuse of water and short supply chains conserve resources, avoid environmental impact and create optimal conditions for breeding yellowtail.

As a saltwater fish, the yellowtail mackerel requires a specific salt content in the water. To compensate for salt losses due to evaporation and continuous filtration, the water is enriched with brine before it returns to the pools.

The brine itself is mixed in the salt storage tank. Here, the LDL400 conductivity sensor monitors the conductivity of the brine mixture, ensuring the correct salt concentration.

Processing of polymeric flocculant

The company ISV Umwelt from Langelsheim develops mobile biomass dewatering plants for temporary or permanent rental. At the heart of the mechanical dewatering process is a powerful decanter centrifuge that separates sewage sludge from bound bacteria and solids. A flocculant is added to optimise the separation process.

The quality of the flocculant is crucial here: It not only affects drainage results, but also operating costs and environmental performance. To achieve maximum efficiency, ISV Umwelt has developed an innovative solution station that mixes polymer and water in the optimum ratio.

The LDL400 conductivity sensor is used to identify the ideal mixing ratio. Once the defined conductivity value has been reached, the mixture is stored in an intermediate tank and can be removed from there as required.