Miniaturised Flow Meters for Ethanol

Miniaturised flow meters from DDM Sensors are designed to precisely record small flow rates of low-viscosity media such as ethanol.

Challenges in Ethanol Flow Measurement

The flow measurement of ethanol poses special requirements for measurement technology due to the aggressive media properties. High measurement accuracy and repeatability are required, while compact and easily integratable designs are simultaneously needed. A significant challenge also consists of ensuring the long-term stability of the sensor components against the medium.

Specialised Flow Meters for Ethanol from DDM Sensors

DDM Sensors offers a portfolio of flow meters specifically developed for use with demanding fluids such as ethanol. The range includes various technologies such as ultrasonic flow meters, turbine flow meters, oval wheel meters and, for simple applications, pelton wheel flow meters. The focus is on a combination of miniaturisation and high performance, achieved through the use of validated, chemically resistant materials and reliable measurement technology for critical processes.

Core Features of DDM Sensors Ethanol Flow Meters

Specification	Ultrasonic Flow Meters	Turbine Flow Meters	Oval Wheel Meters	Vane Wheel Flow Meters
Measuring Range	2 ml/min to 20 l/min	0.05 to 1,200 l/min	0.01 to 500 l/min	0.02 to 160 l/min
Accuracy (Linearity)	±1.0% of measured value	±0.1% (system accuracy with Flow Computer)	0.5% to 1.0% (depending on model and medium)	1.0% to 2.0% of full scale
Repeatability	±0.1%	±0.025% of measured value	±0.1%	±0.1%
Max. Operating Pressure	10 to 30 bar	25 to 500 bar	10 bar (PEEK) to 700 bar (stainless steel)	10 to 15 bar (option up to 40 bar)
Temperature Range (Medium)	-10 °C to +110 °C	-40 °C to +150 °C	-20 °C to +150 °C (depending on seal)	-25 °C to +125 °C
Output Signals	Pulse (NPN/PNP), Analog (4-20mA, 0-5/10V), USB	Frequency (TTL)	Pulse (NPN, reed contact, Namur)	Pulse (NPN or PNP)
Wetted Parts	PEEK, stainless steel or borosilicate glass, O-rings of choice	Stainless steel, ceramic hybrid bearings	Stainless steel, PEEK, O-rings of choice	PVDF, stainless steel, sapphire bearings, O-rings of choice

Highest Material Compatibility and Tightness

The material compatibility of the wetted parts, including the housing and sensor elements, is crucial for measuring ethanol. Highly resistant materials are used depending on the sensor type:

For ultrasonic flow meters, materials such as PEEK as well as stainless steel or borosilicate glass are used. The turbine flow meters consist of stainless steel with ceramic hybrid bearings. For our oval wheel meters, we use stainless steel and PEEK, and the vane wheel flow meters from DDM Sensors are manufactured from PVDF and stainless steel with sapphire bearings. Ethanol-resistant O-rings made of materials such as FKM, EPDM, FFKM, and PTFE are available for sealing. 

Precise Measurement Principle for Ethanol

The measurement technology from DDM Sensors used for ethanol is characterised by high resolution and a fast response time. The measurement principle is designed to ensure stable and reliable measurements even at very low flow rates, which is of decisive importance for dosing applications.

High Measurement Performance and Reliability

Flow meters from DDM Sensors cover a wide measuring range from small flow rates of 2 ml/min up to 1,200 l/min. They are characterised by low measurement deviation from the actual value as well as integrated temperature compensation to stabilise the measurements. Another central feature is the high repeatability of the measurement results, which is essential for process reliability.

Seamless System Integration

To ensure seamless system integration, the flow meters are designed in a miniaturised and space-saving form. The flow meters from DDM Sensors feature the following standardised mechanical connection options:

• BSP, NPT in sizes from 1/4″ to 2″

• AN thread with 37° flare

• Ermeto cutting ring fittings

• Hose connections

• Push-in solutions such as John Guest

For specific integration requirements, manifold assemblies for OEMs or bespoke connection options are also available.

In addition, a wide range of electrical interfaces and output signals are available to enable flexible connection to higher-level control and data acquisition systems. 

The flow meters with pulse output provide precise digital  pulses in NPN, PNP or TTL logic, Namur signals and voltage-free contact outputs via reed switches. In addition, linear analogue outputs (4–20 mA, 0–5/10 V) as well as digital interfaces such as USB with ASCII streaming or CAN bus communication. The electrical connection is reliably implemented using industry standards such as M12 sensor connectors or compact push-pull connectors

Typical Application Areas for the Measurement of Micro-Quantities of Ethanol

The precise measurement of minute quantities of ethanol is required in numerous high-tech sectors. Typical areas of application include:

• Fuel cell technology and reformers

• Laboratory and analytical technology

• Dosing and mixing systems in the chemical industry

• Test benches for engines and components

• Semiconductor and pharmaceutical industry processes

Installation and Commissioning

An upward installation position is recommended to ensure that the flow meter does not run empty. Depending on the measurement principle and application, compliance with defined inlet and outlet runs may be necessary. The electrical connection must be made according to the specifications, and the use of suitable filters is recommended to protect the sensor from particles in the medium. 

Durability and Maintenance-Free Operation

The flow meters are designed for continuous operation through a robust construction and are characterised by high longevity. Depending on the chosen measurement principle—for example, with ultrasonic flow meters—the devices manage without moving parts, which minimises wear. Overall, this leads to very low maintenance requirements during operation.

Development of Custom Solutions for Ethanol Flow Measurement

In addition to standard products, the team at DDM Sensors also develops customer-specific custom solutions for ethanol flow measurement. Development includes the adaptation of mechanical connections and housing dimensions, the execution of specific calibrations for special operating conditions, and the modification of electronics and signal outputs according to the application requirements.

Delivery Times and Availability

For our standard models, the average delivery time is 3 to 4 weeks. For customer-specific solutions, transparent delivery times are communicated, which can be around 10 weeks depending on the effort involved. Project-related stocking is also possible for series applications.

Get Advice on Ethanol Flow Meters Now

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