Innovative Breakthrough: The PS7000 Series Ultrasonic Acoustic Impedance Concentration Meter Helps Huadian XX Power Plant’s Flue‑Gas Desulfurization Wastewater Zero‑Discharge Project Achieve Compliance and Upgrade
October 15, 2025 – Against the backdrop of the nation’s “dual carbon” goals and increasingly stringent ultra‑low emission standards, good news has recently emerged from the flue‑gas desulfurization wastewater zero‑discharge renovation project at Huadian Group’s XX Power Plant: by deploying the PS7000 series ultrasonic acoustic impedance density meter independently developed by Xi’an Pisonics Information Technology Co., Ltd., the plant has successfully achieved real‑time, precise control of slurry density in its limestone‑gypsum wet desulfurization system. Effluent discharge levels of COD, suspended solids, and heavy metals now comprehensively exceed the requirements of the “Emission Standard of Air Pollutants for Thermal Power Plants” (GB 13223‑2023), with each unit reducing annual wastewater discharge by more than 12,000 tons.
Directly Addressing Pain Points: Traditional Differential Pressure Density Meters “Fail” in Highly Corrosive, High‑Bubble Conditions
The original desulfurization system at XX Power Plant’s two 660 MW ultra‑supercritical units relied on differential pressure density meters to monitor the density of gypsum slurry and the wastewater concentration pond. However, during actual operation, three major challenges arose:
- Poor Wear Resistance: The wastewater has high density and solid content, leading to severe wear on the pressure sensor diaphragm.
- Measurement Blind Spots: When the slurry’s air bubble content exceeds 15%, the pressure signal becomes severely distorted, causing concentration fluctuations of ±5%.
- Corrosion and Fouling: With probes continuously immersed in acidic slurry at a pH of 4.5–5.5, scaling and failure occur within half a year.
The PS7000 “Black Tech” Takes the Stage: Non‑Contact, Bubble‑Resistant, with ±1% Accuracy—Steady as a Rock
In June 2025, XX Power Plant’s technical team, together with a certain instrumentation supplier, replaced equipment at three critical points—the outlet of Unit #1’s desulfurization absorber, the inlet of the gypsum hydrocyclone, and the feed line to the wastewater triple‑effect evaporator—with the PS7000 (DN200 flanged) ultrasonic acoustic impedance density meter. Key highlights include:
Application Node | Measured object | Real-time concentration | Control Objective |
|---|---|---|---|
Absorption tower outlet | Limestone slurry | 18%~22% | Flue-gas desulfurization efficiency ≥ 99.5% |
Cyclone inlet | Gypsum slurry | 45%~55% | Dewatering rate ≥ 98% |
Wastewater feed pipe | Concentrated wastewater | 8%~12% | Evaporation Load Optimization |
Linear Frequency‑Modulated Acoustic Impedance Algorithm penetrates bubble layers, eliminating multiple‑reflection interference; the PTFE‑ceramic composite probe maintains zero contact with the slurry and withstands Cl⁻ corrosion at concentrations exceeding 5,000 ppm; the 5D+2D direct‑in‑pipe installation requires no full pipe, enabling accurate measurement even with small wastewater flows.
Data Speaks: 72 Hours of Continuous Operation, with Concentration Fluctuations of Only ±0.3%
Post‑renovation results from on‑site manual sampling comparisons show:
- Gypsum Slurry Density Control Accuracy: Improved from ±4.8% to **±0.7%**;
- Wastewater Evaporation System Feed Concentration Stability: Fluctuation narrowed from ±6% to **±0.3%**;
- Annual Energy Savings: Optimized variable‑frequency operation of the slurry circulation pumps, cutting electricity consumption per unit by **280,000 kWh** annually;
- Gypsum Dewatering Rate: Increased by 2.1%, boosting production of high‑quality gypsum by **3,600 tons** per year.
Chief Engineer Praises: “This Is Truly Maintenance‑Free Instrumentation!”
“After three months of commissioning, the PS7000 density meter has shown zero scaling, zero drift, and no radioactive source. Its OLED screen supports Chinese‑English switching, and operators can master it in just five minutes. We have already planned to retrofit Unit #2 in parallel.” — Mr. Zhang, Director of the Production Technology Department, XX Power Plant
Density meters, concentration meters, ultrasonic density meters, acoustic impedance density meters, acoustic attenuation density meters, sound velocity density meters, tuning fork density meters, Coriolis force density meters, optical concentration meters, differential pressure density meters, Na22 density/concentration meters, microwave density meters/moisture analyzers, conductivity density meters, and clamp‑on density meters—please stay tuned and contact Xi’an Pisonics Information Technology Co., Ltd. Company website: https://www.pisonics.cn; English website: https://www.pisonics.com/
Contact: Manager Cui; Phone: 15902932017; Email: info@pisonics.com
