Application Guide of Pressure Sensors in the Pulp and Paper Industry: Key Technology to Improve Production Efficiency and Quality

Paper, as one of China's Four Great Inventions, is not only a carrier of human civilization but also an indispensable material in modern industry. The pulp and paper industry is closely linked to the national economy and social development. With the expansion of the global packaging paper market and increasing downstream demand, the industry is experiencing opportunities for improved supply and demand balance. However, the production process is complex, involving high temperature, high pressure, and viscous media, making precise control difficult with traditional methods. Pressure sensors, as key monitoring tools, play a vital role in raw material preparation, processing, and wastewater treatment, helping optimize processes, reduce waste, and improve product quality. Nexisense, with its advanced technology, provides customized solutions for paper enterprises, driving the industry toward intelligent transformation.

The Role and Importance of Pressure Sensors in the Pulp and Paper Industry

Pressure control is integral throughout the paper production process, from raw material preparation to finished product output. During raw material preparation, pressure must be monitored in cooking tanks to ensure uniform fiber separation. In processing, pulp flow is regulated to prevent clogging. In wastewater treatment, precise flow measurement ensures environmentally compliant discharge. Pressure sensors collect real-time data and feed it back to control systems for automated adjustment.

In high-temperature cooking environments, sensors prevent overpressure explosions. In viscous pulp pipelines, they prevent measurement interruptions. These functions not only enhance safety but also reduce energy consumption. Since 2012, industry inventory levels have decreased, supply-demand balance has improved, and sensor applications have accelerated digital upgrades. Nexisense sensors integrate IoT capabilities, supporting remote monitoring, helping enterprises respond to market fluctuations, and achieving efficient production.

Main Advantages of Pressure Sensors

Pressure sensors offer significant advantages in the pulp and paper industry. First, durability. Facing high temperatures and corrosive media, Nexisense products use special materials to extend service life and reduce downtime. Second, precision. Sensor outputs are stable with ±0.5% FS accuracy, aiding fine pressure control and optimizing paper uniformity.

Third, cost control. Real-time data avoids resource waste, such as excessive steam or chemicals, potentially reducing energy consumption by 10-15%. Fourth, environmental contribution. In wastewater treatment, sensors ensure accurate flow measurement, reducing pollutant discharge and complying with national standards. Additionally, strong compatibility with protocols like Modbus facilitates integration with existing equipment. Together, these advantages enhance product quality and market competitiveness.

Types and Characteristics of Pressure Sensors in the Pulp and Paper Industry

Pressure sensors are classified by operating conditions. High-temperature sensors feature heat sinks for cooking processes, with wide measurement ranges capable of withstanding over 150°C. Nexisense high-temperature models use ceramic cores with strong thermal shock resistance.

Flat diaphragm sensors are designed for viscous pulp, with smooth diaphragms to prevent clogging and easy installation and cleaning. The sensor core uses diffused silicon technology for fast response. The Nexisense NPS3051 model is ideal for wastewater treatment, made of 316L stainless steel, corrosion-resistant, supporting real-time configuration such as range adjustment and variable monitoring.

These sensors offer multiple output types, including 4–20mA and RS485, with IP67 protection for reliable operation in humid environments.

Application Scenarios

Pressure sensors are widely applied across the entire paper production chain. During raw material preparation, they are installed in cooking tanks to monitor saturated steam pressure, ensuring efficient fiber separation and preventing overcooking to save energy.

In processing, flat diaphragm sensors are placed in pulp pumps and pipelines to monitor flow pressure in real-time, preventing blockages and improving paper machine speed. In pressing and drying stages, sensors adjust roller pressure to optimize paper thickness uniformity.

Wastewater treatment is a key scenario. The NPS3051 model, paired with flow meters, measures gas, steam, and liquid flow, supporting volume or mass calculations. Paper industry wastewater has high COD; sensors help regulate aeration and sedimentation processes, ensuring compliance. Amid growing global packaging paper demand, these applications enable enterprises to expand capacity while controlling environmental risks.

Measurement Methods and Installation Techniques

Pressure sensors measure based on the piezoresistive effect: medium pressure changes the resistance of the sensing element, amplified and converted into standard signals. High-precision models use laser compensation to ensure linear output.

During installation, high-temperature sensors require heat sinks and placement away from heat sources. Flat diaphragm sensors are in direct contact with media, avoiding dead zones. Pipe installations use G1/2 threads for sealing. In wastewater systems, sensors are installed at differential pressure points to calculate flow. Clear the medium before calibration and set the zero point. Wireless sensors support Zigbee, suitable for large plant deployment. Correct installation improves measurement accuracy and reduces error.

Technical Parameters

Nexisense sensors are designed for pulp and paper requirements. High-temperature models have a range of 0–10MPa, accuracy ±0.25% FS, and operating temperatures from -40°C to 150°C. Flat diaphragm sensors have 200% FS overload capacity and<1ms response.

NPS3051 parameters: 316L stainless steel construction, HART output, supports intelligent linearization. IP67 protection, Ex d IIC T6 explosion-proof certification. Power supply 12–36VDC, suitable for steam measurement. These specifications ensure stability in complex environments and provide reliable data support.

Maintenance and Care

Regular maintenance is key. Clean high-temperature sensor heat sinks quarterly to remove dust; flush flat diaphragm sensors to prevent pulp residue. Calibration is annual using standard sources. Wastewater sensors should be checked for corrosion and data backed up monthly. General care: store in dry locations, protect from vibration. For drift or faults, core replacement may be required. Nexisense provides manuals and online support, extending service life to 8–10 years.

How to Choose the Right Pulp and Paper Pressure Sensor

Assess operating conditions: select high-temperature sensors for cooking, flat diaphragm sensors for pulp. Match measurement range to system pressure and ensure output compatibility with PLCs. Nexisense series offers strong compatibility and customization support. Prefer explosion-proof models for safety. Refer to case studies and certifications to balance budget and performance.

FAQ

How do pressure sensors handle high-temperature stages in paper production?
Equipped with heat sinks or high-temperature models, they withstand over 150°C for stable measurement.

What are the advantages of flat diaphragm sensors?
Anti-clogging, suitable for viscous media, easy installation and cleaning, improving efficiency.

What is the role of the NPS3051 in wastewater treatment?
Supports real-time configuration, measures flow, enables linearized data processing, ensuring accuracy.

How to deal with sensor clogging?
Regular cleaning, flat diaphragm design, avoid dead zones during installation.

Factors affecting sensor price?
Type, material, and communication protocol; entry-level hundreds of dollars, professional models thousands, with long-term returns.

Conclusion

The application of pressure sensors in the pulp and paper industry is driving transformation from traditional to efficient operations. Nexisense high-temperature, flat diaphragm, and NPS3051 series, with excellent parameters and versatile adaptability, help enterprises optimize raw material preparation, processing, and wastewater treatment, improving quality, reducing costs, and strengthening environmental protection. Correct selection, installation, and maintenance are key. With global market expansion, these technologies are core to sustainable development in paper production, enabling Chinese paper industry to continue leading globally.