1.Comprehensive Description of the Project and Products
Shandong Qisheng New Materials’ project-with an annual output of 60,000 tons of rubber additives and supporting formaldehyde, chemical intermediates- is situated in Yuedong New Material Industrial Park, Jiayue Town, Zhucheng City, Weifang. The first phase invests 581.78 million yuan, covers about 132 mu, and includes production workshops, warehouses, storage tank areas and supporting facilities, following the “raw material - metering - reaction - separation - recovery - drying - product” process to boost the company’s development and local economy.
Jiangsu Huahai M & C provides full-process support for it, supplying 40 metal rotameters, 33 vortex flowmeters, 2 Annubar flowmeters, 2 orifice flowmeters, 6 mass flowmeters and 56 magnetic flap level gauges. These instruments work together to underpin the project’s safe production, quality improvement, energy efficiency and accurate cost accounting.
2.Application of Jiangsu Huahai M&C’s products in the Project
2.1 Overall Overview of Full-Process Measurement and Control
These instruments together form the “sensory system” and “nerve endings” of the project. They are responsible for real-time monitoring, accurate measurement, and reliable control of the flow of all materials (liquids, gases, steam) and the liquid level in containers (storage tanks, reaction kettles). They are the cornerstone for ensuring safe production, improving product quality, achieving high efficiency and energy saving, and realizing accurate cost accounting.
2.2 Specific Roles of Each Product in Rubber Addictive Production
(1) Magnetic Flap Level Gauge: The “Eye” of the Process
Role: Visual management and safety early warning.
Application Points: Formaldehyde storage tanks, aniline/phenol raw material tanks, intermediate storage tanks, finished product tanks, reaction kettles, etc.
Functions: Intuitively indicate the liquid level height on site, making it convenient for on-site operators to grasp the situation at any time. After being equipped with a remote transmitter, the liquid level signal is transmitted to the central control room to realize remote monitoring, high and low liquid level alarms, and even interlocking control with feed/discharge pumps to prevent tank overflow or vacuuming, which is the first line of defense for safety.
Magnetic Flap Level Gauge
(2) Metal Rotameter: An “Assistant”for Fine Operation
Role: Accurate feeding of small flow rates and auxiliary process monitoring.
Application Points: Accurately adding catalysts and auxiliaries to reaction kettles; auxiliary pipelines such as cooling water and lubricating oil.
Functions: Intuitively and economically measure and indicate the flow of small-flow liquids or gases. Ensure that a small amount of key additives are accurately added to ensure the smooth progress of the reaction and product quality.
Metal Rotameter
(3)Vortex Flowmeter & Orifice Flowmeter: “Stewards”of Energy and Power
Role: Accurate measurement of steam and gas.
Application Points: Vortex: Heating steam for jacket/coil of reaction kettle, reboiler steam for rectification tower, factory compressed air, nitrogen.
Orifice: High-pressure, high-temperature steam main pipe, or gas flow measurement with special requirements for measurement accuracy.
Functions: Accurately measure the consumption of steam, compressed air, and nitrogen (often used for protection and purging) required for production. Provide key data for energy management, cost allocation, and process optimization. For example, control the reaction temperature through steam flow.
Votex Flowmeter
(3)Annubar Flowmeter: An “Energy-Saving Sentinel” for Large Pipelines
Role: Flow monitoring of public media in large pipelines.
Application Points: Main water return/down water main pipe entering the main workshop, air main pipe at the outlet of large air compressors, boiler air supply/flue gas system.
Functions: Measure the flow of water, air, and other media with extremely low pressure loss in large-diameter pipelines. Realize macro-monitoring and management of the energy consumption of the whole plant's public engineering, which is helpful to discover energy-saving potential.
Annubar Flowmeter
(4) Mass Flowmeter: A “Precision Brain” for Core Processes
Role: Accurate measurement and quality control of key materials.
Application Points:
Functions:
Directly and accurately measure the mass flow of materials without being affected by changes in temperature, pressure, and density.
Ensure the accuracy of chemical reaction ratio, which is the core of stable product quality.
It is used for trade settlement of high-value products to ensure fairness and efficiency.
It can measure the density of the medium at the same time, which is used for auxiliary component monitoring.
Coriolis Mass Flowmter
3.Conclusion
Jiangsu Huahai M&C’s tailored measurement and control instruments fully cover Shandong Qisheng New Materials’ rubber additive production process—from core raw material metering to final product settlement, and from on-site monitoring to remote control. They not only guarantee the project’s safe, stable, and high-quality operation but also provide solid data support for energy conservation, cost optimization, and efficient management, becoming an indispensable technical guarantee for the project’s success.
