Viscometers benefits
A process viscometer can contribute to saving energy in industrial processes in several ways:
By optimizing Process Conditions:
Continuously monitoring viscosity, a process viscometer provides real-time data on fluid flow behavior. This information allows operators to adjust process parameters such as temperature, pressure and mixing ratio to maintain or reach the desired viscosity. Optimizing these conditions ensures that the process operates within an efficient range, reducing energy consumption.
By reducing Overprocessing
Overprocessing refers to the unnecessary use of energy and resources in a process. With a viscometer, operators can accurately determine the endpoint of a process based on or correlated to viscosity measurements. This prevents overprocessing by ensuring that the desired viscosity or consistency is achieved without exceeding the required specifications. By avoiding unnecessary processing steps, energy consumption is minimized.
By a more efficient Pumping and Mixing
Fluid viscosity has a significant impact on pumping and mixing requirements. With a process viscometer, operators can monitor and control viscosity in real time, allowing them to adjust pump speeds and mixing parameters accordingly. By optimizing these operations based on actual viscosity measurements, energy consumption is reduced by avoiding excessive pumping or mixing efforts.
By allowing proper Equipment Sizing
The viscosity of a fluid affects the selection and sizing of equipment such as pumps, agitators, and heat exchangers. Accurate viscosity measurements obtained from a viscometer in the pilote phase enables engineers to properly size and select equipment that matches the fluid’s viscosity characteristics. Proper equipment sizing ensures that energy is not wasted on oversized or undersized equipment, leading to energy savings.
By detecting Anomalies and Maintenance Issues
Changes in viscosity can indicate potential issues with fluid degradation, contamination, or equipment malfunction. By continuously monitoring viscosity with a process viscometer, operators can detect anomalies early on and take corrective actions. Addressing these issues promptly helps maintain process efficiency, prevents energy waste due to process deviations, and avoids costly equipment failures.
By adjusting the viscosity of the product
Giving the product its perfect viscosity ensures it is used in the best possible and efficient way. In spray drying for example, right viscosity will warrant the optimum size of droplets and then heat and mass transfer efficiency allowing the best drying yield and energy savings.
By saving raw materials
Making the product in its exact desired viscosity, manufacturers have better control of the final product.
Overall, a process viscometer assists in optimizing process conditions, avoiding overprocessing, enabling efficient pumping and mixing, aiding in proper equipment sizing, and detecting anomalies for timely maintenance. By implementing these measures, energy consumption can be reduced, leading to energy savings in industrial processes.
Sofraser viscometers
Sofraser’s MIVI is the perfect solution for saving energy. For example, in a combustion application, our process viscometer provides 1% or more fuel consumption savings.
The installation of a MIVI on your process:
- accurately provides and controls your fluids at a specifically set point
- adjusts for variations in quality
- optimizes the process
- reduces maintenance
Installations in combustion applications for example proved process optimization savings ranging between 1 and 2%: A combustion process burning 10,000 tons of HFO can expect a savings of 67,000 USD per year.
The Sofraser MIVI viscometer provides fast ROI within a few months.
