Reactor online viscometerIt is an intelligent sensing device used for real-time, continuous, and non sampling monitoring of the viscosity of materials in reaction vessels during production processes such as chemical, pharmaceutical, food, and polymer materials. Compared with traditional offline sampling and testing methods, online viscometers can accurately grasp the rheological changes of materials in key reaction stages such as polymerization, condensation, emulsification, and crystallization without interrupting the process flow, providing key data support for process control, endpoint judgment, and product quality consistency.
This device usually adopts the principles of rotary (such as shaft cylinder, cone plate or paddle), vibration (such as tuning fork or torsional vibration) or ultrasonic measurement, where rotary is suitable for medium high viscosity systems, and vibration is more suitable for clean or low to medium viscosity media. The probe is directly inserted or flange installed on the side wall or bottom of the reaction vessel, which can withstand high temperature, high pressure, strong corrosion, and high shear conditions. The material is mostly 316L stainless steel, Hastelloy alloy, or PTFE lining to ensure long-term stable operation. The built-in high-precision temperature sensor can synchronously compensate for the influence of temperature on viscosity, improving measurement accuracy.
Reactor online viscometerIts main characteristics are as follows:
1. Truly online, real-time continuous measurement
Directly installed inside the reactor or in the external circulation pipeline, without the need for sampling, dilution, or process interruption.
It can respond to viscosity changes in seconds to realize dynamic tracking of reaction process (such as polymerization, cross-linking, gel).
2. Adapt to harsh working conditions
High temperature resistance (up to 300 ° C or above), high pressure resistance (up to tens of MPa), suitable for high-pressure hydrogenation, high-temperature condensation and other reactions.
The materials are mostly 316L stainless steel, Hastelloy alloy, ceramic coating, etc., which are corrosion-resistant, wear-resistant, and compatible with strong acids, strong alkalis, organic solvents and other media.
Explosion proof design (Ex d/Ex i), meeting the safety requirements of explosion-proof areas such as chemical and pharmaceutical industries.
3. High precision and wide range
The measurement range is wide, covering from 1 mPa · s (aqueous) to millions of mPa · s (paste, melt).
The accuracy usually reaches ± 1% to ± 3% of reading, and some high-end models have temperature compensation function to improve accuracy.
4. Strong intelligence and integration capabilities
Supports industrial communication protocols such as 4-20 mA, Modbus, Profibus, HART, Ethernet/IP, etc.
It can be seamlessly integrated with DCS/PLC/MES systems to achieve viscosity temperature mixing rate linkage control.
Some devices are equipped with self diagnostic and self-cleaning functions (such as blowback and ultrasonic cleaning) to reduce maintenance.
5. Improve process control and product quality
Realize accurate judgment of the end point (such as the molecular weight of polymerization reaction reaching the standard, resin gel point early warning).
Avoid over reaction or under reaction and reduce batch scrap rate.
Support PAT (Process Analysis Technology) and comply with GMP and FDA requirements for continuous manufacturing.
6. Easy maintenance and long lifespan
No complex optical or precision mechanical structures (especially vibration type), low failure rate.
Quick installation interface design, easy to disassemble, clean or calibrate.
Some models support online calibration (using standard oil or known viscosity reference points).