Electrical conductivity as an indicator for early warning detection systems in chemical reactors

Early Warning Detection Systems (EWDS) are essential for preventing runaway reactions in chemical reactors by providing timely alerts before uncontrolled exothermic events. Conventional EWDS rely predominantly on temperature monitoring; however, industrial temperature sensors often suffer from delayed response and are highly dependent on sensor positioning, limiting their effectiveness during rapid or localized thermal excursions. This study introduces an alternative detection strategy based on electrical conductivity monitoring, which offers faster response times and higher sensitivity—especially in reactions where ionic or charged species are released at the onset of runaway. A theoretical framework is presented to demonstrate how this method can overcome key limitations of temperature-based systems, enabling more accurate and responsive detection. Compared to the benchmark divergence method, the conductivity-based approach detects runaway onset within 2 °C of the true temperature (vs. ∼ 3 °C deviation with temperature sensors), and anticipates the event 200–300 s before peak temperature. This allows earlier intervention and significantly reduces the maximum temperature rise at onset (by 30%–40% compared to temperature-based detection). Integrating advanced conductivity sensors into existing EWDS infrastructures could markedly improve reactor safety and control. This work lays the foundation for future experimental validation and broader adoption in chemical reaction engineering safety systems.