Ash density isn’t just a number, it’s a key parameter that influences combustion, heat transfer, and chemical recovery. Every percentage point in solids content impacts fuel efficiency and steam stability.

With real-time measurement, operators can optimize continuously rather than reactively, reducing auxiliary fuel consumption, improving power generation, and stabilizing the entire process.

Consider the cost of inefficiency: even a 1% improvement in recovery performance can translate into substantial savings on chemicals and energy.

Add the hidden cost of downtime – $50,000 to $200,000 per day when a recovery boiler goes offline – and the argument becomes compelling. Online density measurement helps prevent common failure points like plugged burners, smelt bed upsets, and tube fouling.

Avoiding just one or two unplanned shutdowns per year can mean hundreds of thousands saved, making this one of the highest ROI investments in process instrumentation.

When it comes to separation processes, the measurement after the centrifuge isn’t just another data point – it’s the one that matters most. This is where operators gain the clearest picture of performance and where small adjustments can deliver big savings.

Real-time density readings at this stage unlock four major benefits:

• Separation Efficiency Monitoring: Detect performance drifts and equipment issues before they escalate.

• Dregs Handling Optimization: Decide if further thickening is needed, avoiding unnecessary processing costs.

• Chemical Loss Prevention: Minimize valuable chemical losses through optimized washing strategies.

• Environmental Compliance: Ensure accurate waste characterization for disposal and regulatory reporting.

The real value comes when plants turn this data into action. Real-time measurement after the centrifuge enables proactive control, helping optimize separation, reduce chemical losses, and maintain compliance before small deviations become costly problems.

By linking density readings to specific operational responses, facilities shift from reactive troubleshooting to predictive, data-driven optimization.

Here’s how smart plants turn insights into action:

• If the dregs density < target, increase bowl speed, reduce feed rate, or adjust differential speed.

• If the dregs density after washing > target, increase wash water flow or check washing equipment performance.

• If clean liquor density is too low, chemicals are being lost – improve separation or increase washing.

These proactive steps prevent inefficiencies before they become costly problems.

Optimizing centrifuge performance and reducing chemical losses isn’t just good practice, it’s good economics. Real-time ash density measurement at this point turns routine monitoring into measurable outcomes: lower auxiliary fuel use from steadier combustion, fewer makeup chemicals through tighter recovery, and less unplanned downtime thanks to early detection of separation drifts.

Plants see smoother steam and power generation, cleaner operation with fewer upsets, and easier compliance through accurate waste characterization and reporting.

With payback often counted in months – not years – this is one of the smartest instrumentation investments a plant can make to strengthen reliability, cut operating costs, stabilize quality, and protect margins.

In short: more control, fewer surprises, and a faster, clearer path to ROI.