We have developed a combined ionic conductivity and temperature
sensor package for multiphase chemical reactors, key elements of SmartChip,
a flow following, data logging sensor. The initial application of
the sensor is to monitor the process inside the hot and caustic chemical
environment of a kraft pulp digester (pH ∼ 13, temperatures
from 25 to 175 °C, reaching a maximum of 180 °C and pressures
up to 2 MPa). The sensor package consists of a 1000 Ω platinum
resistance temperature detector (RTD) enclosed in a stainless steel
container and a four-electrode conductivity sensor consisting of stainless
steel electrodes and installed on a polyetheretherketone (PEEK) package.
The sensor package is designed ultimately to move within the kraft
pulp digester and record sensor data. The sensors were tested at temperatures
of up to 140 °C in NaOH concentrations of 10–100 g/L as
Na2O with and without the presence of wood chips. Changes
in concentration were clearly discernible as changes in conductivity.
The presence of chips reduced conductivity as expected, and this reduction
depended on the degree of cooking. Although further calibration work
is needed to quantitatively determine concentration inside a digester,
process variations should be readily detectable. The average power
consumption of the sensors is 5 mW, which is sufficiently low to enable
autonomous operation of the sensor under battery power. The sensor
packages were tested for a full kraft pulping cycle and survived with
no signs of corrosion. The demonstration of conductivity measurements
represents an important step toward the successful implementation
of flow following measurements in the kraft pulping processes to aid
process optimization and design.