AL-DCIK A/C Conductivity Sensor

Slurry Conductivity Sensor
AL-DCIK A/C

Rugged Process Analysers for the Minerals Processing Sector

Ceramic Toroidal Conductivity Sensor

AL-DCIK is a ruggedized in-line connectivity sensor that provides continuous real-time conductivity data. AL-DCIK is an erosion/wear resistant toroidal conductivity sensor specifically designed for the alumina industry to provide alumina to caustic ratio measurements (A/C ratio or R/P).

The AL-DCIK conductivity meter uses a standard toroidal conductivity element that has been used in the chemical, mining and food industries for decades.  With inductive conductivity, the sensing element (electrode coils) does not come in direct contact with the process. These matched coils are encapsulated in the steel/ceramic casing protecting them from the adverse effects of erosion.

EROSION RESISTANCE

The AL-DCIK A/C conductivity probe is made using a stainless-steel sensor body with a PSZ ceramic core.  The steel body can erode away without any effects on the measurement.  The ceramic core does not erode at all maintaining the correct internal sensing area dimensions to eliminate drift. During times of low flow, scale can build up on the sensor. You simply remove the sensor, de-scale it and return it to service. Under normal process flow, the conductivity probe should erode away with no cause to maintain the device until it fails.  The life expectancy of the conductivity sensor is about 4-8 years.

FEATURES AND BENEFITS:

• Accurate, stable and repeatable real-time in-line measurement of conductivity in
  any process line size with almost any velocity
• A rugged sensor designed specifically for harsh slurry environments
• Flexible communications and repeatable calibration procedure
• Enables process automatisation of alumina to caustic ratio control
• Allows the user to install the sensor directly in the main process pipe eliminating
  the need for costly high maintenance side streams and sample lines
• Uses proven technology extensively utilized in minerals processing
• Reliance on manual sampling is reduced and control lag is eliminated

APPLICATIONS

The AL-DCIK conductivity meter from Precision Light and Air has been specifically designed for alumina process slurries and the like, where PEEK, Teflon and epoxy bodies suffer from erosion and subsequently frequent, expensive replacements.  The AL-DICK conductivity meter is directly installed in the main process pipe eliminating the need for costly high maintenance side streams and sample lines. For some time, small bore ceramic conductivity sensors known as “flow-through”, have been used in side-streams. Now, with the AL-DCIK conductivity probe, you can get an accurate, stable and repeatable measurement of conductivity in any process line size with almost any velocity.

The AL-DCIK inline conductivity measurement allows the Process Engineers to see process changes in between lab samples so they can react faster. This, in turn, enables the plant to push the A/C target higher allowing more bauxite charge into digestion as your certainty is higher. As we all know, one A/C point is around one million US dollars per train for a standard sized one million tonne alumina refinery. Therefore, the instrument pays for itself in weeks.

The below trend compares the conductivity measurement from the lab to the measurement from the AL-DCIK for a one week period. The R2 is extremely good. The P value of the conductivity is extremely significant.