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LiquiSonic® enables a reduction of labor cost through the elimination of manual process steps

H2SO4 in Copper MiningLiquiSonic

Copper is obtained by the extraction of copper sulfide ores, which have a copper content of ~ 2 wt%. The raw metal production includes a wide variety of process steps. The processing of copper sulfide ores is carried out by flotation. Thereby, crushed copper sulfide ores are enriched with water and a foaming agent, to skim quartz or silicates. The obtained copper concentrate has a copper content of 20 - 40 wt%.

In the pyrometallurgical extraction, SO2 is generated which is oxidized with atmospheric oxygen to form sulfur trioxide SO3 (contact process). What remains is a copper content of approx. 96-99 wt%. In order to reach a purity of 99.99 wt%, a electrolytic refining takes place subsequently. Otherwise, the impurities strongly influence the thermal and electrical conductivity and quality of copper.

In the pyrometallurgical extraction, the copper concentrate is slagged by adding SiO2 in the furnace at 1200 to 1400 °C. The melt of copper and iron sulfide is removed as the so-called copper matte from the slag phase.

The liquid copper matte is poured into a converter and the iron sulfide reacts with air to sulfur dioxide SO2. Resulting SO2 is oxidized to sulfur trioxide SO3 (contact process), which SO3 is directed into sulfuric acid (96 wt%). In the absorber, sulfuric acid in high concentrations by adding water or oleum is generated. In the blending process, the H2SO4 is diluted on desired target concentration.

pyrometallurgical Each process step can be both monitored continuously by the inline LiquiSonic® measurement technology and optimally set. The high dependency on sonic velocity enables an accuracy of +/- 0,05 wt% for sulfuric acid.


Customer value

The LiquiSonic® analyzer provides a precise inline H2SO4 and oleum concentration measurement with real-time monitoring.
The robust sensor construction and the optional special materials, like Hastelloy C2000, promote long process life.

 LiquiSonic® enables a reduction of labor cost through the elimination of manual process steps:

- time saving: 1 h per day cost per hour: 50 € (60 $) total cost savings: 10.000 € (12,000 $) per year

- In comparison to conductivity and density measurement, LiquiSonic® generates a clear signal in the concentration range from 80 to 100 wt% and provides at every time reliable process information.

- Amortization: approx. 2 years

LiquiSonic Velocity


The LiquiSonic® immersion sensor is easily installed into pipelines after absorber or sulfuric acid production and blending.

By using the LiquiSonic® controller 30, up to four sensors can be connected, allowing the simultaneous monitoring of several measuring points.

Typical measuring range:
- concentration range from H2SO4: 80 to 100 wt%
- temperature range: 20 to 90 °C
- concentration range from oleum: 0 to 10 wt%
- temperature range: 10 to 60 °C



LiquiSonic 30

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