Pain Points and Challenges of Liquid Level Monitoring in the Electroplating Industry

During the electroplating production process, the corrosion of equipment by corrosive media such as strong acids and strong alkalis has always been an industry challenge. Traditional liquid level sensors use metal materials, and long-term exposure to environments containing sulfuric acid, hydrochloric acid, cyanides, and similar substances can easily lead to problems such as electrode corrosion, diaphragm perforation, and signal drift. This not only reduces measurement accuracy, but may also cause safety accidents. Xi'an Shenghongchuang Instrumentation Co., Ltd. found during field research that a large electroplating enterprise once suffered tank liquid overflow due to sensor failure, causing economic losses of hundreds of thousands of yuan.

In response to this industry pain point, Shenghongchuang's R&D team innovatively applied high-purity alumina ceramic to the core components of sensors. Ceramic materials feature high-temperature resistance, corrosion resistance, and high hardness, and tests show that they can operate stably in extreme environments with a pH value of 0-14. Taking the SSM-P220FS anti-corrosion liquid level transmitter as an example, its ceramic diaphragm and 316L stainless steel housing adopt a special welding process, ensuring that it can still maintain a measurement accuracy of 0.5%FS in concentrated sulfuric acid solution at 80℃.

Three Major Breakthroughs in Ceramic Anti-corrosion Technology

• Material innovation: Made of 99.6% high-purity ceramic, with corrosion resistance more than 3 times higher than traditional PTFE
• Structural optimization: An original honeycomb ceramic diaphragm design, with impact resistance strength reaching 200MPa
• Process upgrade: Vacuum sintering technology enables the airtightness of the ceramic-metal bonding interface to reach the IP68 standard

Practical Application of SSM-P220FS in Electroplating Processes

In the nickel plating production line upgrade project of a well-known electroplating enterprise in Guangdong, Shenghongchuang's engineering team deployed 12 SSM-P220FS anti-corrosion liquid level transmitters. These devices were installed at key positions such as pickling tanks, nickel plating tanks, and recovery tanks, transmitting liquid level data in real time to the central control system through 4-20mA signals. Significant results were achieved after project implementation:

Comparative Advantages Over Other Anti-corrosion Solutions

Compared with anti-corrosion submersible liquid level transmitters such as PTJ302 that use polytetrafluoroethylene wrapping, the ceramic sensing technology of SSM-P220FS demonstrates clear advantages. Comparative tests conducted in phosphoric acid solutions of the same concentration show:

• After a 1000-hour test, the zero drift of the ceramic sensor was only 0.02%
• The traditional PTFE sensor showed diaphragm swelling after 400 hours
• The ion permeability of the ceramic material was lower than 0.001μg/cm²·day

Shenghongchuang Anti-corrosion Sensor Product Matrix

In addition to SSM-P220FS, Xi'an Shenghongchuang has also developed a complete anti-corrosion liquid level monitoring product line to meet the needs of different working conditions:

1. HHY700 series: Specially designed for special media such as hydrofluoric acid, using a multilayer ceramic composite structure
2. ZC-185 series: Suitable for high-temperature alkaline liquid environments, with a maximum temperature resistance of up to 150℃
3. EVT300B series: Intelligent transmitters with a self-cleaning function, capable of preventing electroplating sludge adhesion

These products have all passed ISO9001 quality management system certification and comply with the GB/T17626-2018 electromagnetic compatibility standard. Enterprises can select different models of anti-corrosion submersible liquid level transmitters such as CL192 and DH712 according to parameters including electroplating tank volume, media characteristics, and installation method.

Implementation Case: Upgrade of an Electroplating Wastewater Treatment System

In an environmental protection project in Zhejiang, Shenghongchuang adopted a combined solution of YM-BCYW and YM-QYYW anti-corrosion liquid level transmitters, successfully solving the monitoring challenges of a lead-containing wastewater treatment system. Project features include:

• Treatment capacity: 200 tons/day of lead-containing wastewater
• pH value fluctuation range: 0.5-13.5
• Oxidation-reduction potential: +1100mV to -800mV

After 18 months of system operation, the sensors still maintained their initial accuracy, helping the customer pass the Ministry of Ecology and Environment's special inspection on heavy metal discharge. This case was awarded one of the Top 10 Environmental Protection Technology Application Cases in China's Electroplating Industry in 2022.

The Value of Choosing Professional Anti-corrosion Monitoring Solutions

For decision-makers in electroplating enterprises, adopting industrial-grade anti-corrosion submersible liquid level transmitters such as LMK809-396-1000-B-C-1-1-3-3-DOS can bring three core values:

1. Reduce overall costs: Reduce equipment replacement frequency, with annual maintenance costs decreasing by 40-60%
2. Improve process stability: Precise liquid level control reduces the fluctuation range of plating layer thickness by 30%
3. Strengthen safety compliance: Avoid environmental accidents and administrative penalties caused by monitoring failure

Conclusion and Action Recommendations

Against the backdrop of transformation and upgrading in the electroplating industry, reliable liquid level monitoring equipment has become a key factor in enhancing competitiveness. With more than a decade of professional expertise, Xi'an Shenghongchuang Instrumentation Co., Ltd. has developed anti-corrosion submersible liquid level transmitters such as the SSM-P220FS series, which have been successfully applied in more than 200 electroplating enterprises across China.

If you need a customized anti-corrosion monitoring solution, please feel free to contact our technical consulting team. Based on your specific working conditions, we will provide the optimal configuration solution, including models such as HHY700, ZC-185, and PTJ302, and support on-site installation, commissioning, and regular calibration services. Call 029-89300839 now or visit our official website for online consultation to obtain your exclusive white paper on liquid level monitoring for the electroplating industry.