INDUSTRY 10

New Energy / Battery Electrolyte

10 / NEW ENERGY

Inline density / concentration for Li copper-foil (CuSO₄), lead-acid (37 wt% H₂SO₄) and lithium-ion battery electrolytes across multiple electrochemical storage systems.

2 applicable products 3 application cases
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Overview

The new-energy / battery-electrolyte industry covers density and concentration measurement across lithium copper-foil electrolyte, lead-acid battery electrolyte, lithium-ion battery electrolyte and nickel-metal-hydride electrochemical storage products.

Copper foil (4.5-8μm ultra-thin) is electrodeposited from a CuSO₄ - H₂SO₄ bath where Cu²⁺ concentration, free-acid level and trace additives (gelatin, thiourea, chloride) drive thickness uniformity, tensile strength and surface roughness. Lead-acid batteries are filled with ≈ 37 wt% sulfuric acid (1.275-1.285 g/cm³); a 1 wt% deviation cuts cycle life by 10-20% and SLI capacity by 5%+.

Process challenges

  • Copper-foil electrolyte: pH < 1 at 50-60°C — PFA / titanium / tantalum wetted parts required
  • Additives at ppm level — beyond resolution of conventional density meters
  • 4.5-6μm foil trend leaves no tolerance for process drift (±0.5μm requires ±1% concentration)
  • Lead-acid 37 wt% sulfuric acid corrodes standard 316L over time — diaphragm rupture contaminates an entire batch
  • Recirculating baths carry fine bubbles — interferes with non-ultrasonic principles
  • Multi-drum / multi-plant lines need unified communication to MES

Recommended solutions

Measurement pointPrincipleModels
Copper foil CuSO₄ concentration (main)Ultrasonic sound velocity + T compPS7020
Copper foil free acid (return)Ultrasonic sound velocity / opticalPS7020 / PS7110
Copper foil additive dosing tankCoriolisPS7200
Lead-acid 37 wt% sulfuric acid mixing tankTuning fork + PTFE coatingPS7400
Li-ion electrolyte (LiPF₆ + carbonates)CoriolisPS7200
Post-treatment surface bathUltrasonic / opticalPS7020 / PS7110
RECOMMENDED PRODUCTS

Products that fit this industry

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PS7020

Sound Velocity Concentration Meter

The PS7020 series ultrasonic sound-velocity concentration/density meter measures the time of flight of ultrasonic waves in a liquid, and—combined with temperature compensation and an extensive library of calibration curves—converts this data in real time to yield the medium’s concentration and density, addressing the low accuracy and susceptibility to interference inherent in conventional measurement methods. Leveraging the fundamental physical principles of the sound-velocity method, this instrument is entirely immune to the effects of liquid color, transparency, electrical conductivity, vibration, noise, and flow velocity, thereby guaranteeing high precision and exceptional stability.
PS7400

Online tuning fork density meter

The PS7400 series online tuning fork density meter monitors liquid density in real time by leveraging piezoelectric excitation and changes in the tuning fork’s resonant frequency, requiring no maintenance while delivering highly accurate, repeatable measurements. Its built-in PT1000 temperature compensation eliminates drift due to temperature variations, making it suitable for diverse industrial applications such as pipelines and storage tanks, and widely used in the petrochemical, chemical, and pharmaceutical industries.
APPLICATION CASES

Cases in this industry

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Sound Velocity Concentration Meter · PS7020

PS7020 Series Ultrasonic Sound Velocity–Based Concentration/Mass Density Meter: Applications in the Food, Brewing, and Sugar-Refining Industries

In the wort mashing, filtration, and fermentation stages of beer brewing, customers face challenges such as delayed wort concentration measurements, bubble interference, and poor performance with dark-colored liquids, resulting in significant batch-to-batch variability and frequent manual sampling. The PS7020 series ultrasonic sound-velocity–based concentration/density meter measures wort °P online with an accuracy of ±0.0005 g/cm³, unaffected by color, bubbles, or CO₂. Equipped with a hygienic clamp‑type quick‑connect and compatible with CIP/SIP, it delivers sub‑second real‑time feedback and seamless integration with MES systems.

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Sound Velocity Concentration Meter · PS7020

Online Monitoring of Electrolyte Concentration in Copper Sulfate + Sulfuric Acid + Additive Solution

In lithium‑battery copper‑foil production, the customer faced significant fluctuations in the concentration of the electrolyte (copper sulfate, sulfuric acid, and additives), along with the drawbacks of time‑delayed offline analysis and frequent damage to instrumentation caused by highly corrosive media. The PS7000 ultrasonic acoustic impedance concentration meter, featuring a fully PTFE‑lined design and a Hastelloy construction, effectively withstands complex corrosive environments while delivering sub‑second response for online density monitoring. Coupled with DCS control, it enables automated, precise replenishment of chemical solutions, reducing CuSO4 concentration variations from ±2.5 g/L to within ±0.5 g/L.

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Online tuning fork density meter · PS7400

37 wt% dilute sulfuric acid feed tank concentration fine control · PTFE-coated ultrasonic tuning fork resistant to acid

In the electrolyte-filling section of lead-acid battery production, the 37 wt% dilute sulfuric acid mixing tank has long relied on manual sampling with a density bottle, resulting in large concentration fluctuations and delayed response, which in turn leads to poor consistency in battery capacity. The PS7400 PTFE-coated tuning fork concentration meter is directly installed on the tank’s side wall, providing density readings and converting them to wt% within seconds, and, when integrated with the DCS, enables closed-loop control of concentrated sulfuric acid and deionized water. As a result, concentration variations have been reduced from ±0.6 wt% to within ±0.08 wt%.

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Industry FAQ

What does lithium-battery copper foil electrolyte monitoring require?

The core electrolyte in the lithium‑battery copper‑foil electroplating process consists of copper sulfate (CuSO4), dilute sulfuric acid (H2SO4), and additives; precise concentration control directly determines the copper foil’s thickness uniformity, grain size, and tensile strength.

Measurement challenges:

  1. The medium is highly corrosive (H2SO4 + Cu2+);
  2. The concentration fluctuation range is very narrow (CuSO4 typically 60–80 g/L, requiring control within ±2 g/L);
  3. The site temperature varies significantly (25–55°C);
  4. The presence of trace additives (gelatin/SPS) affects certain principle‑based instruments.

Recommendations:

  1. PS7100 spectroscopic method—MLR multicomponent modeling enables simultaneous measurement of Cu2+ concentration, H2SO4 concentration, and additive concentration;
  2. PS7020 sound velocity method—single‑component density accuracy of ±0.0005 g/cm³, with a PTFE lining for acid resistance.

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