Challenge: 

An incorrect dew point can lead to several issues that affect both production efficiency and product quality. The dew point is the temperature at which the air’s relative humidity reaches 100%, causing water vapor to condense into liquid. When the dew point is not properly controlled, specific problems can arise:

• Condensation on equipment: A high dew point can result in moisture condensing on machinery, equipment, or surfaces. This may cause rust, corrosion, and electrical issues, potentially leading to equipment failure or downtime.
• Product quality issues: In many manufacturing processes, such as food or pharmaceutical production, controlling humidity and temperature is critical to maintaining product quality. An incorrect dew point can result in products being too moist or too dry, affecting their shelf life, appearance, and performance.
• Steam Explosions in Metalworks: Alloys introduced to molten metal with moisture present can cause dangerous steam explosions, posing risks to both equipment and personnel.
• Harmful working conditions for employees: An incorrect dew point can create a high-humidity work environment, leading to discomfort, reduced productivity, and potential health problems, especially in warm conditions.
• Energy efficiency: An incorrect dew point can reduce the efficiency of air conditioning and ventilation systems. Improper humidity control can force cooling systems or humidifiers to work harder to achieve desired temperature and humidity levels, increasing energy consumption.
• Microbial growth: A low dew point (very dry air) can cause issues like static electricity, while a high dew point can encourage the growth of mold, bacteria, or fungi, which can harm both products and health.

Solution:

By monitoring temperature and relative humidity with our Neuron Humidity Sensor in combination with our Neuron Virtual Sensor, the dew point temperature can be calculated using the following formula:

• R = Relative humidity (%)
• T = Air temperature (°C)

• Dew point temperature (for R > 50%*) in °C:
• M = Material temperature (°C)

• Deviation from material to dew point temperature:

*Source: The Relationship between Relative Humidity and the Dewpoint Temperature in Moist Air: A Simple Conversion and Applications. Bulletin of the American Meteorological Society, Volume 86, Issue 2 (2005).

See a dedicated article here: https://el-watch.no/neuron-virtual-sensor/

Benefits:

Monitoring the dew point offers several key advantages, particularly in processes involving humidity, temperature control, or energy consumption. Some of the main benefits include:

• Preventing condensation: Knowing and controlling the dew point can prevent condensation on equipment, pipes, or other surfaces. Condensation can lead to corrosion, mold growth, or electrical faults, damaging equipment and disrupting production.
• Optimizing humidity: In many industrial processes, such as food production, pharmaceuticals, or chemical processing, controlling humidity is essential. The dew point provides a measure of air moisture and helps adjust the environment to achieve the desired production quality and stability.
• Energy efficiency: Controlling the dew point helps optimize energy use in air conditioning and drying processes. Avoiding unnecessary moisture and overheating reduces energy consumption and costs.
• Enhanced Safety in Metalworks: Continuous monitoring ensures moisture does not compromise alloys used in molten metal processes, averting dangerous and potentially catastrophic steam explosions.
• Protecting products from damage: In processes requiring precise temperature control, such as cooling products or storing materials, a high dew point can cause unwanted moisture that damages products. Dew point control protects product quality.
• Enhanced process control and product quality: In processes involving gas or liquid phase equipment, such as dryers, compressors, or refrigeration units, precise dew point control improves process stability and ensures desired product quality.
• Preventing corrosion and rust: High humidity can cause condensation on surfaces, leading to rust and corrosion. Controlling the dew point reduces this risk, extending the life of machines and equipment.
• Safety: In certain industrial environments, such as chemical or pharmaceutical production, excessive humidity or condensation can trigger dangerous reactions or reduce the efficacy of specific chemicals. Controlling the dew point mitigates these risks.
• Controlling the dew point leads to increased operational reliability, improved product quality, reduced maintenance, lower energy costs, and a safer workplace.

Products in use

Neuron Humidity

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