Application Fundamentals, Issues, Sensors Solutions, Q&A

Common Wastewater Treatment Applications

Municipal/Industrial Electroplating Mining

Poultry/Meat Chemical Manufacturing

Processing
 Municipal/Industrial Wastewater Application Notes:
Background: In the wastewater treatment industry
(including sewage), wastewater is treated prior to
discharge. Chlorine is used to remove microorganisms.
Both pH and ORP are monitored to ensure adequate
effluent control and neutralization prior to discharge.
ORP or FCL sensors can be used for monitoring free
chlorine. Dissolved Oxygen is monitored in aeration
Measurements: basins and activated sludge.

pH Issue: Wastewater contains many aggressive

ORP/REDOX chemicals and solids that can damage / accumulate on
Dissolved Oxygen pH and ORP electrodes, resulting in erroneous readings.
Free Chlorine DO sensors need to be durable and low maintenance.

Sensorex S8000 Series pH and ORP electrodes are designed to

Application Keys: handle these challenges of in-line installations.

• Aeration Process Sensorex DO sensors are durable and require very little
important maintenance. mV and 4-20mA models are available.
• pH/ORP compliance
prior to discharge
 Electroplating Wastewater Treatment
Application Notes:
Background: In the electroplating industry,
wastewater is generated after plating and rinsing of
parts. The key component in electroplating waste is
Chrome VI (Cr+6). Rinse water from parts cleaning need
to be kept as clean as possible.

Issue: Chrome VI (Cr+6) must be reduced to Chrome

III (Cr+3) before it is discharged into the sewer system
Measurements:
or other waterways. The pH and ORP must be
pH monitored. Electrodes often get fouled with chrome
ORP waste and have short life. Rinse water conductivity is
Conductivity measured to ensure parts are rinsed with the cleanest
possible water.

Application Keys:
Sensorex S8000 Series pH, ORP and conductivity
sensors are designed to handled these challenges
• Use pH and ORP to of in-line installations.
verify all Cr+6 is
converted to Cr+3
 Mining Wastewater Application Notes:
Background: In the mining industry gold is extracted
using cyanide which is poisonous. Cyanide in the
wastewater must be treated (cyanide destruct) before
discharging the wastewater.

Issue: Cyanide is treated in a 2-step process. First,

the wastewater pH is adjusted to >10pH with caustic to
prevent dangerous gas formation then oxidizer is added.
Measurements: ORP is used to monitor reaction progress. Next the
cyanate produced in the first step has pH adjusted to 8.5
pH - 9 and more oxidizer is added. ORP is monitored for
ORP/REDOX
increase until the endpoint is reached.

Application Keys: Sensorex S8000 Series pH and ORP electrodes are

designed to handled these challenges of in-line
• Use pH and ORP to
verify all Cyanide is installations.
converted to Cyanate
then CO2 and Nitrogen
 Poultry/Meat Processing Wastewater
Application Notes:
Background: Poultry/Meat processing generates a
large amount of wastewater. To reduce the BOD, large
amounts of water and chlorine are used in the various
stages of processing.

Issue: pH is first adjusted down to a pH of about 3 to

Measurements: break emulsions. Next pH is raised to about 8.5 and
flocculent is added to precipitate solids. Wide pH range
and emulsions can coat pH electrodes.
pH

Application Keys:

• Minimize sensor Sensorex S8000 Series pH electrodes are designed

coatings to handled these challenges of in-line installations.
• Minimize water use
 Chemical Manufacturing
Wastewater Application Notes:
Background: Chemical plants make wastewater in
their manufacturing processes. The wastewater can
contain many different kinds of chemicals and is often
acidic or basic and must be treated prior to discharge.

Issue: Electrodes need to be rugged and have good

Measurements: chemical compatibility. Recommend use of double
junction sensor designs due to the aggressive chemicals
pH that maybe present in the effluent.

Application Keys:
Sensorex S8000 Series pH electrodes are designed
• Regulatory Compliance to handled these challenges of in-line installations.
• Chemical Resistance
 Sensorex Sensor Solutions
pH: A complete selection of flat surface –self cleaning technology
featuring our modular S8000 product line as well as general
purpose electrodes.

ORP (REDOX): Our process line of flat surface ORP electrodes, including
our latest S8000 platform, are available as ORP electrodes.

Conductivity: Sensorex offers a comprehensive selection of process

conductivity sensors. Choose from inductive non-
contacting or contacting 316SS cells.

Free Chlorine: The FCL series Free Chlorine sensors are available for real
time 0 – 2 / 5 / 10 ppm measurements. An isolated 4-20mA
output offers versatility in interfacing these sensors.

Dissolved Oxygen: The DO6400 series dissolved oxygen sensors are available for real
time DO measurements. Sensors provide mV or isolated 4-20mA
output.
S8000 Modular pH and ORP Platform:
Next generation flat surface self cleaning double junction pH
and ORP (REDOX) Electrodes.

• Flexible

• Expandable

• Long Life

• Low Maintenance

• Future Ready
How to Configure Your S8000 Series Solutions
1. Choose Electrode
2. Choose Mounting Hardware
3. If needed, choose electronic interface
4. Choose Cable Assembly
Cable
5. Optional Flow Cells for in-line Assembly

Electronic
Interface

Mounting
Hardware

Electrode Flow Cell

 Typical Sample Configurations S8000

Basic Submersion ATC Submersion or In-Line ATC System With Electronic Module
 pH/ORP General Purpose Solutions
This series of electrodes are designed to provide an economical
multi-purpose solution for in-line or submersion pH measurements.
Based on our proven flat surface pH glass technology, these rugged
and durable electrodes are available in PPS nipples with 1/2" or 3/4"
NPT threads.

General Purpose pH Electrodes:

S272CD-P1K General purpose pH Electrode w/ ATC ¾” NPT

S272CD General Purpose pH Electrode ¾” NPT
S269CD General Purpose pH Electrode ¾” NPT

General Purpose ORP Electrodes:

S272CD-ORP General Purpose ORP Electrode ¾” NPT

S269CD-ORP General Purpose ORP Electrode ¾” NPT
 Conductivity Measurement Solutions
Sensorex offers a comprehensive selection of process conductivity sensors.
Choose from inductive / non-contacting / toroidal, contacting low cost graphite
or a variety of 316SS cells for boilers and sanitary applications.

Which electrode should I choose?

– Choose stainless steel versions for:
• Boilers, ultra pure & high purity water
(CS675 & CS676 Series)
– Choose epoxy model with graphite pins for:
• low to moderate temperature
(CS150 & CS200 Series)
– Choose Toroidal sensors for:
• Heavy coating applications
• Concentrated acid or caustic
Free Chlorine Measurement Solutions
• Amperometric Sensor Technology
• Real Time On-line Measurement 24/7
• Multiple Ranges Available 0 – 2/5/10 ppm
• Integral 4 – 20mA Isolated Output
• Built-In Temperature Compensation
• Large Electrolyte Reservoir (Long Life)
• Replaceable Membrane & Electrolyte
• Ease of Installation
• Ease of Use
Sensors
FCL-402 Free Chlorine Sensor; 0 – 2 ppm Full Scale
FCL-405 Free Chlorine Sensor; 0 – 5 ppm Full Scale
FCL-410 Free Chlorine Sensor; 0 – 10 ppm Full Scale

Flow Housing
FC72 Flow Cell for FCL Sensors

Flow Meter
FM001 Flow Meter, 0.1-1.0 GPM

Accessories
FCLA-4015 Refill Solution, 2ea, 30ml
FCLA-4016 Replacement Membrane Cap (0-5, 0-10ppm)
FCLA-4026 Replacement Membrane Cap (0-2ppm only)
 FCL System Configuration

FCL
Sensor
OUTLET

FC72 Flow Cell

FM-001
Flow Meter

INLET
 Dissolved Oxygen Measurement Solutions
The Sensorex line of Industrial Dissolved Oxygen probes are fast response
galvanic sensors. They have a large reservoir of electrolyte and available with
either mV or 4-20mA outputs.

o DO6400 Series, ppm measurements

o DO7400 Series, ppb / ppm measurements
o Optional 4 – 20mA output
o Built-In Temperature Compensation
o Large Electrolyte Reservoir (Long Life)
o Replaceable Membrane & Electrolyte
o Ease of Installation
o Ease of Use
Possible Expansion of Amperometric Sensor Line

Total Chlorine, Bromine, Ozone, Chlorite , Peracetic Acid

Sensor Customization
•Extensive application and parameter customization

•Concept to final product design and implementation

•Extensive sensor mold design and development

•Majority of Sensorex sales are to OEM businesses often

requiring custom packaging
 Sensorex is an OEM Liquid Analytical Sensor Manufacturer.
We specialize is customizing sensors for OEM applications.

 Focused exclusively on Sensors, producing 250,000 sensors

per year.

 Measurements: pH, ORP(REDOX), Conductivity, Chlorine,

Chlorine Dioxide and other Specialty Sensors.

 Current Status: Tier 1 Sensor Supplier to Nalco

 ISO9001:2008 Certified

QUESTIONS?
For more details, visit our website at:

www.sensorex.com