SensorsONE

Chemical Resistant Hydrostatic Liquid Level & Pressure Sensors

Durable hydrostatic liquid level and pressure sensors designed for harsh chemical environments. Ideal for storage tanks and process applications requiring high corrosion resistance.

This range of chemical-resistant hydrostatic liquid level and pressure sensors is specifically engineered for reliable measurement in environments containing aggressive or caustic media where standard metallic sensors would rapidly corrode and fail. Featuring robust plastic housings made from materials like PVDF, PVC, or PP, and advanced semi-flush ceramic diaphragms, these instruments offer exceptional compatibility with a wide array of corrosive chemicals. Designed for engineers and technicians in chemical processing, storage, wastewater treatment, and research, these sensors ensure accurate and durable performance for critical hydrostatic level monitoring in tanks or direct process pressure measurement, preventing mechanical failure and maintaining operational safety.

Find out more about Chemical Resistant Hydrostatic Liquid Level & Pressure Sensors to determine which product options and capabilities will best meet your application requirements.

When measuring hydrostatic liquid level or process pressures in applications involving aggressive or caustic chemicals, the material integrity of the sensing element and its housing is paramount. Standard metallic pressure transmitters and transducers are often susceptible to rapid chemical corrosion, particularly affecting thin metal diaphragms which can be quickly eroded, leading to premature sensor failure and potential safety hazards. For instance, common industrial chemicals like concentrated sulfuric acid, sodium hypochlorite, or hydrofluoric acid can degrade even robust metals like stainless steel over time, necessitating specialized sensor designs.

To address these challenging environments, pressure sensors constructed from chemically inert materials are essential. These often feature robust plastic-based bodies and advanced ceramic diaphragms. Ceramic, typically high-purity alumina oxide (Al2O3), is selected for its exceptional resistance to a wide spectrum of aggressive chemicals, including strong acids, alkalis, and solvents, even at elevated process temperatures. Unlike metals, ceramic does not rely on a passive oxide layer for protection, making it inherently more stable in diverse chemical matrices. The inert nature of ceramic also prevents leaching or contamination, which is critical in high-purity applications such as pharmaceutical manufacturing or semiconductor fabrication.

A key design feature in many chemical-resistant pressure sensors is the semi-flush ceramic sensing diaphragm. This configuration minimizes cavities or dead volumes at the sensing face, preventing the accumulation, crystallization, or solidification of viscous or particulate-laden media. This is particularly beneficial in applications like wastewater treatment facilities handling sludges, or in chemical processing plants where product build-up could lead to inaccurate readings or blockages. The semi-flush design also facilitates easier and more effective cleaning, crucial for maintaining measurement accuracy and extending sensor lifespan in batch processes or when switching between different media.

The selection of sensor housing material is equally critical and must be carefully matched to the specific chemical composition, concentration, and operating temperature. Common housing materials include PVDF (Polyvinylidene Fluoride), known for its outstanding resistance to halogens, strong acids, and organic solvents, making it suitable for demanding applications such as bulk chemical storage tank level monitoring for chemicals like bromine or concentrated nitric acid. PVC (Polyvinyl Chloride) offers a cost-effective solution with good resistance for many common industrial chemicals like ferric chloride used in water treatment. PP (Polypropylene) provides a balance of chemical compatibility and mechanical strength, often used in chemical dosing systems or plating baths. While plastic housings are prevalent, some designs may incorporate stainless steel for the external body to provide enhanced mechanical protection, especially in harsh industrial settings, with the wetted parts still being composed of the necessary corrosion-resistant plastics and ceramics.

The principle of hydrostatic level measurement (P=ρgh) relies on the pressure sensor being submerged or connected to the lowest point of a tank. The sensor measures the pressure exerted by the liquid column, which is directly proportional to the liquid level. In such direct immersion scenarios, not only the diaphragm and housing but also the cable sheath material (if applicable) must withstand prolonged chemical exposure. For example, in a sump containing a mixture of unknown industrial effluents, a sensor with broad chemical resistance is vital for reliable level monitoring and overflow prevention. Similarly, for process pressure measurement within reactors or pipelines carrying corrosive fluids, such as in fertilizer production or metal etching processes, the chemical inertness of these specialized sensors ensures accurate process control and system integrity.