ACITEK's Ion Selective Electrode

ACITEK G300 Online DO Transmitter + DO6800 High-temperature Dissolved Oxygen Electrode

1. Project Background
A fine chemical enterprise produces 50,000 tons of acrylate annually. Its reaction kettles operate at 80–120℃ and 0.6–1.0 MPa. Dissolved Oxygen (DO) must be strictly controlled within 0.5–1.5 mg/L. Excess DO causes side reactions and reduces product purity, while insufficient DO leads to incomplete chemical reaction and lower output.

The traditional polarographic electrodes suffered severe signal drift above 60℃, with membranes aging every 2–3 weeks. Frequent shutdown for calibration and replacement brought high maintenance costs and disrupted continuous production. The site adopted ACITEK G300 DO Transmitter + DO6800 High-temperature DO Electrode to solve the problems.



2. Product Specifications
ACITEK G300 Online DO Transmitter

Measuring range: 0.00–40.00 ppm, Accuracy: ±0.01 ppm
Working temperature: -10.0–130.0℃, automatic temperature compensation
Output: 4-20mA & Modbus RTU, compatible with DCS system
Protection class: IP65, explosion-proof design







ACITEK DO6800 High-temperature DO Electrode

Temperature resistance: 0–130℃, supports 130℃ SIP sterilization
Housing: 316L stainless steel, acid & alkali resistant
High-temperature resistant membrane, anti-aging and anti-fouling
Response time: t90 ≤ 60 s




3. Installation & Commissioning

Mounted on DN50 side port of reaction kettle, immersed 20–30 cm below liquid level, away from agitator and inlet to avoid bubble interference.
Shielded cabling to prevent electromagnetic interference.
Two-point calibration with oxygen-free water and air-saturated water. Stable performance lasts over 6 months after one calibration.
Linked with DCS: Automatic nitrogen purge when DO below set value; cut off nitrogen supply when DO exceeds limit.

4. Application Results (6-month operation)

Stable measurement: No signal drift at 120℃, DO fluctuation controlled within ±0.1 mg/L.
Low maintenance: Membrane service life extended from 2–3 weeks to 8–10 months. Calibration cycle reaches 6 months, maintenance workload reduced by over 70%.
Quality improvement: Acrylate purity rose from 99.2% to 99.7%, high-grade product rate increased by 12%.
Higher efficiency: Gas consumption cut by 18%. Shutdowns caused by DO faults were eliminated, with annual output increased by 2000 tons.
Durable performance: Continuous trouble-free operation for 180 days, no corrosion orscaling on electrode.

5. Customer Feedback
"This high-temperature DO monitoring solution perfectly solves our pain points of unstable reading and frequent maintenance. The G300 transmitter delivers reliable data and smooth communication. The DO6800 electrode works well under high temperature. It greatly guarantees our continuous production and product quality." — Manager Wang, Equipment Department

6. Applicable Scenarios

Chemical industry: High-temperature reaction kettles, polymerization & oxidation processes, high-temperature wastewater
Pharmaceutical industry: Fermenters with 121℃ SIP sterilization
Power industry: Boiler feed water and condensed water trace oxygen monitoring
Environmental protection: High-temperature industrial wastewater & leachate treatment

Case 1: Thermal Power Plant Boiler Feed Water & Condensate Monitoring
Project Background
A 2×300MW thermal power plant in East China needs full-process monitoring of deaerator outlet feed water, condenser condensate and boiler drain water. Per national power industry standard DL/T 502.29-2019, tiny ion impurities in water will cause boiler scaling and turbine blade corrosion, which may trigger unplanned shutdown and huge economic loss. The original old conductivity sensors had two pain points:


Ordinary 304 stainless steel electrodes corroded rapidly under chloride-containing condensate, measurement drift occurred within 3 months;
Non-standard thread fittings required customized welding bases, high installation cost and difficult later disassembly maintenance.

ACITEK Solution Deployment

Sensor selection: AC58031404 SS316L 2-electrode conductivity sensor (K=1cm⁻¹), 3/4NPT male thread directly matched with pipeline standard 3/4NPT tee joint, no extra custom fittings;
Installation layout: Installed on condensate sampling pipeline, boiler feed water outlet and blowdown pipeline via side pipeline insertion; 44mm insertion length ensures electrode fully immersed in stable fluid, avoiding bubble interference;
System matching: Paired with ACITEK G100 compact DIN rail transmitter, 4-20mA active signal access plant DCS system, RS485 Modbus upload data to SCADA platform; built-in PT1000 automatic temperature compensation eliminates temperature drift error of high-temperature water samples;
Working condition adaptation: SS316L material resists trace chloride ion corrosion in condensate, withstands 17bar working pressure and 90℃ sampling water temperature.

On-site Operation Effect

Measurement stability: After 12 months continuous operation, measurement deviation is always within ±1% (0.02~5000µS/cm) and ±3% (>5000µS/cm), no regular calibration drift phenomenon;
Maintenance cost reduction: Replace cycle extended from 3 months to 12 months, only quarterly simple surface cleaning is needed, saving 70% of annual sensor replacement labor & material cost;
Safety optimization: Real-time conductivity abnormal linkage alarm timely reminds resin regeneration and condenser leakage risk, boiler scaling failure rate decreased by 8%, annual power generation loss risk reduced greatly.

Case 2: Semiconductor Factory Ultrapure Water (UPW) Preparation Line Monitoring
Project Background
A wafer manufacturing enterprise in Shanghai built a 18.25MΩ·cm ultrapure water production line, requiring real-time monitoring of RO reverse osmosis effluent, EDI terminal ultrapure water and cleaning circulating water. The core demand is to capture tiny conductivity rise caused by membrane element damage or ion exchange resin failure, to avoid wafer etching pollution and mass product scrap.

Application Scheme & Configuration

Sensor matching logic: K=1cm⁻¹ wide-range electrode fits full-process water quality monitoring—low-conductivity ultrapure water (0.05~2µS/cm) and medium-conductivity intermediate circulating water (500~5000µS/cm) can be measured by one sensor model, reducing spare parts types;
Installation method: Adopt flow cell pipeline installation, 3/4NPT thread quickly connect small-bore flow cell, compact structure fits narrow space of ultrapure water equipment rack;
Signal transmission: 5m shielded cable anti-electromagnetic interference in clean workshop, matched G100-DIN rail transmitter centralized installed in small control cabinet, multi-point conductivity data unified upload to water treatment PLC;
Customization support: Factory customized 10m long cable for remote sampling points according to workshop layout, realizing unified sensor model for all monitoring positions.

Actual Benefit

Early warning capability: Quickly capture conductivity fluctuation of 0.1µS/cm, advance 3~5 days to judge EDI resin failure, avoid batch wafer contamination loss;
Cost optimization: Single sensor covers all water quality sections, no need to prepare multiple electrode constants for different process sections, spare parts inventory cost cut by 45%;
Stable long-term operation: SS316L electrode will not release metal ions into ultrapure water, meet semiconductor high-purity water monitoring requirements, one-year warranty provides stable after-sales guarantee.

Case 3: Fine Chemical Plant Reaction Kettle & Circulation Cooling Water Monitoring
Project Overview
A fine chemical factory producing pharmaceutical intermediates has multiple reaction kettles and cooling water circulation systems. It needs to monitor electrolyte concentration in synthesis liquid and circulating water conductivity to control reaction conversion rate and prevent pipeline scaling blockage. The medium contains weak organic acid and trace chloride, putting forward high corrosion resistance requirements for electrodes.

ACITEK Deployment Plan

Tank & dual pipeline installation: Reaction kettle side wall 3/4NPT thread interface for sensor insertion; cooling water main pipeline symmetrical installation two sensors to monitor inlet & outlet conductivity;
Material advantage: SS316L electrode effectively resist weak acid and chloride corrosion, compared with plastic-shell electrodes, it is not easy to deform and aging under 80℃ circulating water long-term soaking;
Control linkage: 4-20mA signal feeds back to reaction PLC, automatically adjust raw material feeding amount according to solution conductivity; cooling water conductivity high value triggers automatic dosing & blowdown control to reduce scaling;
Maintenance convenience: Standard 3/4NPT thread can be directly screwed out without stopping production for short-term replacement cleaning, greatly improving production continuity.

Site Feedback

Reaction yield improved: Stable real-time conductivity data optimizes feeding control, intermediate product yield increased by 12%;
Pipeline maintenance cycle extended: Timely cooling water blowdown control reduces scaling frequency, pipeline cleaning cycle from 1 month extended to 4 months;
Wide range adaptability: One sensor continuously measures synthesis liquid (1000~20000µS/cm) and cooling water (50~800µS/cm), equipment procurement cost reduced.

Case 4: Small Factory Sewage Treatment Station Discharge Water Monitoring
Demand Background
Multiple small chemical & food processing factories built decentralized sewage treatment stations, needing online conductivity monitoring of aerobic tank effluent and final discharge water to meet environmental protection real-time upload requirements. The on-site cabinet space is narrow, with limited maintenance manpower, requiring low-cost, easy-to-install & low-maintenance conductivity measurement solution.

Matching Solution

Low-cost integrated system: AC58031404 conductivity sensor + G100 ultra-narrow DIN rail transmitter (12.5mm width), multiple sets side-by-side installed in small control box without cabinet reconstruction;
Immersion installation: 3/4NPT thread matched with stainless steel mounting sleeve, directly put into sewage outlet weir tank, 44mm insertion length avoids sludge sediment coverage at tank bottom;
Signal output dual mode: 4-20mA analog signal access environmental protection data collector, RS485 remote data upload to factory cloud platform, realize unattended monitoring;
Adapt to wastewater medium: SS316L anti-corrosion electrode resists sewage weak acid & alkali medium, not easy to be corroded by organic sewage.

Operation Results

Meet environmental compliance requirements: Continuous 24h online conductivity data meets local environmental bureau monitoring upload standards, no penalty risk due to missing monitoring data;
Labor saving: Only quarterly simple cleaning of electrode surface sludge, no frequent calibration, suitable for unattended small sewage stations;
Space saving advantage: Ultra-thin transmitter + compact sensor solves the problem of small control box insufficient installation space, overall equipment investment reduced by 30% compared with split large display conductivity meters.

Core Product Advantages Reflected in All Cases

Universal 3/4NPT standard thread: Compatible with all industrial pipeline, tank, flow cell common interfaces, no customized fittings, low installation cost and fast construction;
SS316L all wetted material: Excellent corrosion resistance to chloride, weak acid, weak alkali medium, long service life in power, chemical, semiconductor, wastewater industries;
K=1cm⁻¹ ultra-wide measurement range (0.02~50000µS/cm): Cover ultrapure water, intermediate process water, high-salinity sewage, one model for multi-scene use, reduce spare parts inventory;
Built-in PT1000 temperature sensor: Automatic temperature compensation, eliminate measurement error caused by medium temperature change, stable data under high/low temperature working conditions;
Flexible cable customization: Standard 5m cable, support OEM/ODM customized length to adapt long-distance sampling points;
Perfect matching ACITEK G100 DIN rail transmitters: Form compact low-cost online conductivity monitoring system, 4-20mA + RS485 dual signal output, compatible with all mainstream PLC/DCS industrial control systems;
Pressure & temperature resistance: Max 17bar (250psig) pressure, 93℃ medium temperature, adapt high-temperature & high-pressure industrial water sampling pipelines.

Summary
ACITEK AC58031404 SS316L 2-electrode conductivity sensor breaks the limitation of single-scene electrodes. With standard 3/4NPT thread, wide measurement range and reliable corrosion-resistant material, it has formed mature, low-cost and stable monitoring schemes in power, semiconductor, fine chemical and wastewater treatment industries. Whether it is high-standard ultrapure water precision monitoring, high-temperature high-pressure power plant water sampling, corrosive chemical process liquid control or decentralized sewage environmental monitoring, this sensor can meet on-site measurement demands, and combined with ACITEK G100 series compact transmitters, it provides users with space-saving, easy-maintenance and customizable industrial water conductivity full-set measurement solutions.

1. Drinking Water Quality Online Monitoring


Drinking water safety supervision requires continuous tracking of dissolved ion content to judge raw water pollution, treatment efficiency and pipeline secondary contamination, which is the primary application scenario of CR-GS-10.


Application Points



Water plant full-process monitoring

Install CR-GS-10 at raw water intake, sedimentation tank outlet, filter section and finished water pipeline. Abrupt conductivity rise of raw water can warn agricultural chemical infiltration or industrial wastewater leakage; comparing conductivity before and after filtration evaluates the removal efficiency of mineral ions and impurities, ensuring finished water complies with national drinking water standards.
Community & commercial direct drinking water equipment

Mount the sensor on RO direct drinking machines in schools, hospitals, office buildings and shopping malls. Real-time conductivity data reflects filter element aging and membrane attenuation: once effluent conductivity surges, the system triggers maintenance reminder to avoid unqualified drinking water supply.



Matching Product Advantages



Platinum electrode features strong chemical inertness, resisting corrosion from residual chlorine in tap water and long-term stable measurement without frequent calibration;
Compact structure with Pg13.5, G1/2A and NPT multi-thread interfaces, easy to install on small-sized commercial water dispensers and pipeline flow cells;
Wide measuring range (0.05 μS/cm ~ 100 mS/cm) covers both low-conductivity purified water and medium-conductivity tap water.



2. Ion Exchange & Reverse Osmosis (RO) Pure Water Treatment Systems


Ion exchangers and reverse osmosis equipment are core processes for industrial pure water preparation, where conductivity is the key index to judge resin failure and RO membrane desalination performance, making CR-GS-10 an essential online monitoring component.


2.1 Ion Exchange Resin Regeneration Monitoring


Cation and anion exchange resins gradually lose ion exchange capacity during operation, accompanied by rising effluent conductivity. Install CR-GS-10 at the outlet of mixed bed/separate bed ion exchangers:



Set conductivity threshold linkage control; when readings exceed the standard value, the system automatically starts acid-alkali regeneration program;
Avoid manual periodic sampling detection, reduce labor cost and prevent unqualified pure water from flowing into downstream production lines.



2.2 Reverse Osmosis System Operation Control



Monitor primary and secondary RO product water conductivity to judge membrane integrity: conductivity jump indicates membrane rupture, seal failure or scaling blockage;
Install sensors on raw water inlet and concentrated water outlet to calculate water recovery rate, optimize dosing of scale inhibitors, reduce chemical consumption and extend membrane service life.



Matching Product Advantages



Stable operation under 6 bar process pressure, adapting to pipeline pressure of standard RO water treatment equipment;
Wide temperature adaptation (-5~+80°C) fits warm water circulation systems in industrial pure water workshops;
Low overall investment cost, suitable for mass deployment on medium and small-sized pure water equipment manufacturers.



3. Aquarium & Aquaculture Water Quality Management


Household aquariums, commercial ornamental fish breeding farms and hydroponic planting facilities all rely on conductivity to control water mineralization degree, and CR-GS-10 provides economical continuous detection solutions for civilian and small aquaculture scenes.


Application Points



Ornamental fish tank water adjustment

Different fish species have fixed adaptive mineral concentration ranges. CR-GS-10 continuously monitors water conductivity to guide regular water replacement and mineral additive dosing, avoiding fish stress or death caused by excessive or insufficient dissolved solids.
Small-scale aquaculture & hydroponics

Deploy the sensor in indoor hydroponic vegetable planting pools and mini aquatic breeding ponds. Conductivity fluctuation reflects nutrient solution concentration change, helping growers adjust fertilizer dosage in real time to stabilize plant growth environment.



Matching Product Advantages



Small and lightweight design, plug-type installation option without complex pipeline transformation;
One-year warranty reduces post-maintenance cost for aquarium merchants and individual users;
Platinum electrode resists biological adhesion of algae and aquatic microorganisms, maintaining stable measurement in long-term immersion.



4. General Laboratory & Multi-Scenario Routine Water Testing


Beyond industrial and civilian online monitoring, CR-GS-10 also serves as a universal conductivity probe for laboratory daily water analysis, matching small water quality analyzers for offline sampling measurement.


Application Points



Lab daily pure water machine effluent detection, verifying lab-grade purified water quality for chemical, environmental and biological experiments;
Routine sampling testing of surface water, groundwater and domestic sewage, recording conductivity changes as auxiliary pollution evaluation data;
Teaching laboratory demonstration experiments for water quality detection courses.



Matching Product Advantages



Dual-purpose design for online pipeline installation and offline immersion measurement;
K=10 cell constant compatible with mainstream conductivity transmitters and lab meters on the market, convenient equipment matching and replacement;
Robust glass electrode body with impact resistance, suitable for frequent mobile use in laboratories.



5. Universal Municipal & Light Industrial General Water Quality Inspection


CR-GS-10 can be extended to multiple light industrial and municipal auxiliary water monitoring scenarios:



Circulating cooling water monitoring for small factories: control conductivity to adjust blowdown frequency and reduce scaling and pipeline corrosion;
Swimming pool and spa water supervision: track total dissolved solids to assist disinfectant concentration management;
Landscape river and community fountain water quality regular monitoring, timely reflect external pollution input.



Core Product Strengths Supporting Multi-Scenario Application



Platinum electrode core material: Inert metal avoids oxidation and ion precipitation, long service life, minimal measurement drift after long-term underwater immersion;
Ultra-wide measuring range: 0.05 μS/cm to 100 mS/cm covers nearly all conventional clean water and lightly polluted water measurement demands;
Strong environmental adaptability: -5~+80°C temperature range and 6 bar pressure resistance adapt to most normal industrial and civilian water pipeline operating conditions;
Flexible installation compatibility: Three connection modes (Pg13.5 screw head, G1/2A & 1/2"-14 NPT thread, plug connector) match various pipeline sizes and equipment interfaces;
High cost performance: Compact integrated structure, low procurement cost, one-year full warranty, ideal for mass installation in medium and small water treatment projects.



Conclusion


As a versatile platinum two-electrode conductivity sensor, ACITEK CR-GS-10 covers full-chain application from municipal drinking water, industrial pure water preparation to civilian aquaculture and laboratory testing. Its balanced performance of measurement stability, environmental adaptability and cost advantage solves the demand of economical and reliable real-time conductivity monitoring for most conventional water quality scenes. For engineering integrators, water equipment manufacturers and laboratory users focusing on general water detection, CR-GS-10 is a preferred universal conductivity probe with wide compatibility and stable running performance.