Understanding ORP Sensors for Industrial Water Systems
Oxidation-Reduction Potential (ORP) refers to the measure of a solution’s capacity to either gain or lose electrons during chemical reactions. It is expressed in millivolts (mV), with positive readings indicating an oxidising environment and negative readings suggesting a reducing environment. Oxidation refers to the process of a substance losing electrons, while reduction involves gaining electrons. For industrial water systems, monitoring the ORP levels ensures that water chemistry remains balanced and that the necessary reactions (such as disinfection) are happening efficiently. Here, we share more insights about how these sensors work.
How ORP sensors work
ORP sensors consist of an electrode that measures the voltage difference between a reference electrode and the solution. This voltage difference gives an indication of whether the solution is in an oxidising or reducing state. In industrial water systems, the sensors are installed to continuously monitor the water’s chemical potential and provide real-time data.
These sensors are often used alongside pH sensors because both pH and ORP play significant roles in water treatment processes. While pH measures the hydrogen ion concentration (acidity or alkalinity), ORP gives a broader picture of the water’s overall chemical reactivity.
Applications of ORP sensors in industrial water systems
The sensors are used in a variety of industrial applications where water quality control is vital. Here are some key uses:
Disinfection control
One of the most common uses of these sensors in industrial water systems is to monitor and control disinfection processes. In industries such as food and beverage, pharmaceuticals and water treatment facilities, maintaining proper disinfection is critical. The sensors help ensure that disinfectants such as chlorine are working effectively by measuring the oxidising power of the water.
A high ORP reading indicates a strong oxidising environment, meaning that the disinfectant is actively killing bacteria and other harmful microorganisms. Conversely, a low ORP reading may signal that more disinfectant is needed or that the disinfectant’s effectiveness has decreased over time.
Corrosion prevention
ORP sensors are also used to prevent corrosion in industrial water systems, such as cooling towers, boilers and piping systems. Corrosion can lead to expensive repairs and downtime if not properly managed. By monitoring ORP levels, engineers can determine whether the water is too corrosive (high oxidising potential) or not protective enough, thus allowing for proper treatment adjustments to protect equipment.
In such cases, ORP readings help maintain the right balance of corrosion inhibitors, ensuring that industrial equipment remains in good condition and operates efficiently over time.
Wastewater treatment
In wastewater treatment, ORP plays an essential role in monitoring the reduction and oxidation processes. They help track the effectiveness of chemical treatments, such as oxygenation and dechlorination, ensuring that the treated water meets environmental standards before being discharged. ORP levels also help in processes such as anaerobic digestion, where reducing conditions (low ORP) are necessary for the breakdown of organic matter.
Chemical dosing control
Many industrial water systems rely on chemical dosing to maintain water quality. ORP analysers can provide feedback on the effectiveness of chemicals being introduced into the system, ensuring that dosages are optimal. This real-time feedback loop helps save costs by preventing overuse or underuse of chemicals while maintaining the necessary water conditions.
Looking for quality ORP sensors?
Explore our ORP analysers. Our ORP analysers are designed for reliable common water quality measurement with a high-strength glass bulb design that enhances durability and performance. The large sensing bulbs provide superior sensitivity to hydrogen ions, ensuring accurate results. Equipped with a ceramic pore electrode, these analysers prevent blockages, making them suitable for CWQM media. The PTFE large ring diaphragm further enhances the electrode’s durability. For demanding applications, we offer options with high alkali/high acid process glass. Our sensors are used in industries, such as industrial water, sewage, general applications and much more.
