Conductivity meter and pH meter
Application case of water quality monitoring in high voltage and high temperature production in a large electroplating plant
I，Project Background
In the electrolytic production process of a large electroplating factory, it is necessary to monitor the water quality in real time to ensure the efficiency of electrolytic reaction and product quality. The water used in this process has the following stringent conditions:
• Extreme electrical environment: water voltage up to 1000V, current 500A (for electrolytic reaction);
• High temperature environment: water temperature is maintained at 85-95℃ for a long time;
• High precision requirements: conductivity (reflecting ion concentration) and pH value directly affect the purity and surface uniformity of aluminum foil, and the measurement accuracy of ±0.1% should be achieved.
Traditional instruments often fail due to their weak resistance to electromagnetic interference and insufficient heat resistance, leading to poor production stability and a higher rate of defective products. To address this issue, companies have introduced the FESKS FSEC 5270-X01 four-point conductivity meter and the FSPH 5280 pH-X01 computer. To date, nearly 200 units have been installed, covering all production lines.
2， core challenges
• Strong electromagnetic interference: the large current of 500A generated by the electrolytic cell forms a high intensity alternating magnetic field, resulting in signal distortion of conventional sensors.
• High temperature stability: 90℃ high temperature accelerated electrode aging, ordinary glass pH electrode life is less than one month.
• High voltage insulation risk: 1000V voltage puts forward high requirements for instrument insulation performance, and leakage may cause safety accidents.
3， Solutions and product advantages
FSEC 5270-X01 four-pole conductivity meter
• Four-pole anti-interference design: four-electrode separation technology is adopted to eliminate the interference of electromagnetic field on the measuring electrode through dual driving electrodes, ensuring that the fluctuation of conductivity data is less than or equal to 0.5μS/cm.
• High temperature resistant sensor: ceramic packaged electrode with titanium coating, long-term tolerance of 100℃ high temperature, service life of more than 3 years.
• High voltage isolation protection: IP68 protection class + insulated housing design, through 5000V withstand voltage test, completely eliminate the risk of leakage.
FSPH 5280-X01 pH meter
• Automatic compensation at high temperature: built-in PT1000 temperature sensor, realizing dynamic compensation of 0-130℃ full range, temperature drift error <0.02pH/℃.
• Anti-pollution electrode: open liquid junction and acid and alkali resistant glass membrane are used to avoid the crystallization and blockage of aluminum ions (Al³⁺) in aluminum foil process, and the maintenance period is extended to 6 months.
• Intelligent self-diagnosis: real-time monitoring of electrode status, automatic alarm and data storage when abnormal, reducing the frequency of manual inspection.
4，Implementation effect
Since its deployment in 2023, the instrument system has been operating steadily with key indicators as follows:
metric | Before improvement | Improved | Improve the effect |
Accuracy of water quality data | 78% | 99.5% | The defect rate was reduced by 30% |
Instrument failure rate (years) | 15 times per set | No more than 1 time per set | Maintenance costs are down 80% |
Electrode replacement cycle | One month | 6-8 months | Spare parts cost savings of 60% |
customer feedback ：
"The FESKS instrument is far more stable than expected in high temperature, high pressure and strong interference environments, and the electrolytic cell process water control accuracy
After the upgrade, the surface finish of aluminum foil reaches the military standard, and the annual benefit increases by more than 12 million yuan."
V. Summary
The FESKS FSEC 5270-X01 and FSPH 5280-X01 have successfully addressed the challenge of high-quality water monitoring in the aluminum foil industry by leveraging their anti-interference design, high-temperature and high-pressure resistance, and intelligent operation and maintenance. This case demonstrates their reliability in extreme industrial environments and can be extended to similar fields such as lithium battery copper foil and nuclear power cooling water, helping companies achieve efficient and safe production management.
Technical consultation: FESKS technical team provides customized sensor selection and installation solutions, please contact chinainfo@fesks.com.cn for details
