Case Study: Aggregates Level Monitoring
ABM’s non-contact solids radar level sensor delivers reliability in challenging aggregate silo application
A concrete block manufacturer required a level sensor to measure the inventory of aggregates in a silo. Reliable level measurement was essential to effectively manage, control and optimize the use of raw materials at the plant. ABM’s non-contact, solid material radar level sensor was selected for the project.
Problem
Reliably monitoring the level of aggregates (sand, gravel and crushed stone) in the silos presented several challenges due to the processing conditions and harsh environment.
The material constantly moved in the silos, with emptying and filling conditions happening simultaneously to keep the material level relatively consistent. For this reason, material continuously crossed the level sensors beam. The environment inside the silos was loud and extremely dusty, with build-up and coating common.
Mechanical solutions proved too maintenance-intensive for the application, while alternative continuous-level sensors could not provide consistent, reliable measurements under harsh conditions and required routine cleaning.
Solution
ABM’s non-contact radar level sensor was used to meet the demands of the challenging aggregate silo application. The radar sensor provides reliable measurement under all processing conditions, measuring through heavy dusty and acoustic filling noise without influence. No maintenance is required, as the sensor is unaffected by build-up from aggregate dust on the microwave antenna.
Due to ABM’s innovative self-adjusting sensor design, the echoes are the same amplitude regardless of the distance or dust conditions. This technique makes ABM’s radar sensors reliable, even under the most challenging process conditions. The echo profile from the radar sensor (Fig. 1) displays good operation in the aggregate silo.
Figure 1: Echo profile from ABM self-adjusting radar sensor measuring aggregates.
