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Technical Analysis of the Chlorosulfonic Acid Valveless Pump Control System (CX-ZS-1-8)

 

I. System Compatibility Verification

 

Media Compatibility

Chlorosulfonic Acid Characteristics: Highly corrosive (pH ≈ -1), with a viscosity close to that of water at room temperature, but corrosion may accelerate at high temperatures or in the presence of impurities.

 

Material Compatibility:

 

Zirconium Oxide Valve Plug: Suitable for strong acid environments, but the presence of fluoride ions in the chlorosulfonic acid must be verified (if fluoride is present, PTFE or silicon carbide should be used instead).

 

SS316 Housing: Standard 316 stainless steel can withstand chlorosulfonic acid at room temperature, but the temperature must be kept ≤40°C for long-term use (to avoid localized overheating that may accelerate corrosion).

 

PTFE Seal: Fully compatible with chlorosulfonic acid, but the sealing surface must be smooth (Ra ≤ 0.4μm) to prevent permeation.

 

Flow Accuracy and Stability

 

Plunger Pump Structure: Suitable for micro-dosing (12.5ml/min), but the pump head dead volume must be verified (≤0.5ml recommended) to reduce residual volume. Adjustment range of 10-20: If the flow rate adjustment range is 1.25-2.5 ml/min, pulse width modulation (PWM) or stepper motor microcontroller control is required through a PLC.

 

1-control-8 synchronization: Flow rate deviation when connected in parallel must be verified (recommended ≤ ±2%). Closed-loop control can be achieved through flow sensor feedback.

 

II. Hardware Configuration Optimization Recommendations

 

PLC Module

 

The Siemens S7-1200 (with 8 high-speed pulse outputs) or Mitsubishi FX5U (supporting floating-point operations) is recommended to ensure independent control of multiple channels.

 

A temperature monitoring module (such as a PT100 sensor) is required to prevent flow rate drift caused by pump head overheating.

 

Touchscreen and Communication

 

A touchscreen with a size of 7 inches or larger (such as the Weiluntong TK6071iP) is recommended, supporting multi-page switching to display individual flow rates, accumulated flow, and alarm information.

 

If remote monitoring is required, a 4G/WiFi module (such as the Siemens CP1243-1) can be added, or Modbus RTU protocol can be used to connect to a host computer via RS485. Key Parameter Settings

Flow Calibration: Each pump must be calibrated individually (using an electronic balance or high-precision flowmeter is recommended) to establish a flow-to-pulse frequency curve.

Temperature Control: Even if the medium is at room temperature, heating of the pump head may affect flow stability. It is recommended to add housing temperature monitoring and a cooling fan.

Cleaning Function: An automatic cleaning program (such as flushing the pipeline with ethanol) should be configured to prevent chlorosulfonic acid crystals from clogging the pump head.

 

III. Potential Risks and Improvement Solutions

 

Corrosion Risk

Risk Point: After long-term operation, SS316 threaded connections may experience stress corrosion cracking.

Improvement Solution: Use Hastelloy C-276 or PTFE-lined pipes to reduce metal-to-metal contact.

Seal Failure

Risk Point: PTFE seals may wear and leak under high-frequency reciprocating motion.

Improvement Solution: Use a double O-ring seal structure or a hydraulically driven diaphragm pump (such as the ProMinent Concert series) to completely isolate the medium from the seal.

Flow Drift

Risk Point: Wear or temperature changes in the plunger pump may cause flow rate degradation. Improvement: Add a flow compensation algorithm (such as temperature-based PID auto-tuning) or perform periodic automatic calibration (such as daily zero-point calibration).

 

IV. Recommended Configuration List

Component Model/Specifications Notes

Valveless Pump CX-ZS-1-8 (Plunger Type) Pump Head Material: Zirconia + SS316 + PTFE

PLC Siemens S7-1214C DC/DC/DC 8-channel high-speed pulse output (200kHz)

Touch Screen Weiluntong TK8071iP Supports multi-language and recipe management

Flow Sensor Sensirion SLI-1000 (Switzerland) Range 0-20 ml/min, Accuracy ±0.5%

Communication Module Siemens CP1243-1 4G/WiFi Dual-Mode, Supports MQTT Protocol

Control Cabinet IP55 Protection Rating Includes Cooling Fan and Temperature Control Module