Application Value of Monocrystalline Silicon Micro Differential Pressure Sensors in the Chemical and Petroleum Industries

In the chemical and petroleum industries, production processes are highly continuous and complex, and small pressure changes often signal major process fluctuations: filter clogging, pipeline leakage, reduced separation efficiency, and even potential safety risks. Traditional differential pressure measurement devices, when faced with high temperature, high pressure, strong corrosion, and extremely small measurement ranges, often fail due to drift, overpressure damage, or medium corrosion, leading to frequent alarms or unplanned shutdowns.

The Nexisense 800-3051DR monocrystalline silicon micro differential pressure sensor is a dedicated solution developed specifically for these extreme operating conditions. Using a German-imported monocrystalline silicon sensing element as its core, combined with a floating structure and 316 stainless steel isolation design, it achieves high accuracy of 0.1% within micro differential pressure ranges such as -50~50 Pa, while also offering excellent overpressure protection and environmental adaptability. Its reliable value has been proven in numerous refining and chemical installations. This article analyzes its technical advantages, typical applications, and actual benefits to help industry professionals better understand the strategic significance of this type of sensor.

Core Challenges of Micro Differential Pressure Measurement in the Chemical and Petroleum Industries

In petroleum refining and chemical production, differential pressure measurement runs through multiple critical points:

• Filtration systems: a slight increase in filter differential pressure indicates clogging and requires early warning
• Pipeline transportation: small differential pressure reflects flow changes and potential leakage risks
• Separation towers/vessels: tray pressure drop and liquid level differential pressure control separation efficiency
• Reactors: gas-liquid two-phase flow differential pressure affects mass transfer and reaction uniformity

The common challenges in these scenarios are: extremely small differential pressure ranges (often tens to hundreds of Pa), while static pressure can reach several MPa or even higher; media containing sulfur, acids, and hydrocarbons with strong corrosiveness; large on-site temperature fluctuations and frequent vibration and shock. Ordinary ceramic or diffused silicon sensors are easily affected by static pressure under micro ranges, resulting in significant errors, or suffer diaphragm damage due to overpressure impact, leading to measurement failure.

Industry statistics show that differential pressure-related failures account for more than 20% of instrumentation failures in petrochemical installations, directly affecting safety and economic efficiency. Therefore, a sensor that can accurately capture micro changes while maintaining long-term stability under harsh conditions is essential.

Core Technologies and Structural Advantages of the 800-3051DR

The Nexisense 800-3051DR adopts a monocrystalline silicon resonant or piezoresistive sensing element (German imported), using floating encapsulation technology to achieve isolation and protection. Key performance highlights include:

• Measurement range: as low as -50~50 Pa, accuracy ±0.1%FS
• Static pressure range: up to 40 MPa (depending on model)
• Overpressure capability: withstands 1 MPa reverse overpressure impact at a 1 kPa range
• Wetted materials: 316 stainless steel (optional Hastelloy, tantalum, etc.)
• Temperature range: full temperature compensation ensuring minimal drift from -40℃ to +85℃ (or higher)
• Output and communication: 4–20 mA + HART protocol, supporting remote configuration and diagnostics

The floating monocrystalline silicon structure significantly reduces the influence of static pressure on micro differential pressure measurement, while improving resistance to vibration and shock. The 316 stainless steel isolation diaphragm and fill fluid design ensure effective isolation between the sensor and corrosive media, extending service life. The product is also equipped with a 5-digit backlit LCD display, supporting local three-button parameter setting, unit switching, and alarm display, facilitating quick on-site inspection.

The electrical interface adopts cable entry with IP66 protection, making it suitable for harsh environments such as outdoor oil fields and offshore platforms. In abnormal conditions, it can output alarm signals and be integrated into DCS/PLC systems for rapid response.

Application Value in Typical Chemical and Petroleum Scenarios

1. Refinery Filtration and Separation Systems

In units such as catalytic cracking and hydrotreating, filter or separator differential pressure is a key indicator for determining clogging and efficiency. The high-precision micro differential pressure measurement of the 800-3051DR can output reliable signals even when differential pressure changes are only tens of Pa, helping operators adjust regeneration cycles or switch standby paths in advance, preventing pressure buildup or sharp efficiency drops.

2. Pipeline Transportation and Leakage Monitoring

In long-distance pipelines or plant pipe networks, small differential pressure changes can reflect pump performance, valve leakage, or foreign object blockage. The sensor’s overpressure protection capability ensures it is not damaged during water hammer or abnormal impacts, while the 316 stainless steel material withstands sulfur-containing crude oil and acidic gases, ensuring long-term stable monitoring.

3. Separation Towers and Vessel Level / Pressure Drop Control

Equipment such as three-phase separators and distillation towers require precise pressure drop control to maintain separation performance. The monocrystalline silicon sensing element combined with full compensation technology maintains consistency under high static pressure and temperature fluctuations, while the HART protocol supports remote parameter adjustment and fault diagnostics.

4. Reactors and Gas-Liquid Transfer Systems

In continuous chemical reaction processes, gas-liquid two-phase flow differential pressure directly affects mass transfer efficiency. The fast response and anti-interference performance of the 800-3051DR ensure accurate and reliable data, providing precise input for PID control.

Actual Benefits and Industry Feedback

After adopting the 800-3051DR, many petrochemical enterprises reported the following results:

• Improved accuracy of micro differential pressure monitoring, reducing false alarms by approximately 40%
• Significant reduction in overpressure damage incidents, with an average sensor service life exceeding 3 years
• HART remote configuration reduced on-site maintenance frequency, saving labor costs
• Stable operation with no obvious drift on coastal high-salt-spray platforms and northern low-temperature oil fields

These achievements not only improved operational safety but also provided a high-quality data foundation for digital transformation.

Frequently Asked Questions (FAQ)

What is the difference between monocrystalline silicon micro differential pressure sensors and ordinary differential pressure transmitters?
Monocrystalline silicon sensing elements offer higher sensitivity, lower static pressure influence, and stronger overpressure capability, making them especially suitable for operating conditions where micro ranges and high static pressure coexist.

How are highly corrosive media handled?
Standard 316 stainless steel withstands most acids, alkalis, and sulfides; for extremely corrosive environments, Hastelloy or tantalum isolation diaphragms can be customized.

Which communication protocols are supported?
Standard 4–20 mA + HART, supporting remote parameter setting, diagnostics, and configuration, making integration with existing DCS systems convenient.

Is it reliable for use in remote oil fields?
With IP66 protection, full temperature compensation, and vibration-resistant design, it adapts to temperature differences from -40℃ to +85℃ and outdoor vibration and shock.

Conclusion

In the chemical and petroleum industries, precise micro differential pressure measurement is not only a technical requirement for process optimization, but also a key safeguard for safe and continuous production. The Nexisense 800-3051DR monocrystalline silicon micro differential pressure sensor, with its high-precision sensing element, excellent overpressure protection, corrosion-resistant structure, and intelligent communication capabilities, successfully addresses multiple challenges such as high temperature and pressure, strong corrosion, and micro measurement ranges, providing reliable support for critical processes including refining, separation, pipelines, and reactions.

Choosing a sensor that understands the industry and can withstand real-world conditions not only significantly reduces risk and maintenance costs, but also injects strong momentum into intelligent and safety-oriented system upgrades. In today’s pursuit of intrinsic safety and efficient operation, it has become a trusted pressure monitoring partner for many petrochemical enterprises.