Cement Americas

FALL 2017

Cement Americas provides comprehensive coverage of the North and South American cement markets from raw material extraction to delivery and tranportation to end user.

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www.cementamericas.com • Fall 2017 • CEMENT AMERICAS 15 FEATURE A variety of issues affect accurate continuous lev- el measurement in cement plants. The most criti- cal concerns are dust, heavy build-ups, low-reflective media, and uneven surfaces in conical and/or air-inject- ed silos with internal objects. Now, new frequency-modulated continuous-wave (FMCW) radar technology, combined with high signal dynamics, offers a way to accurately and reliably mea- sure product levels. One example of this new technol- ogy is Krohne's OPTIWAVE 6300 C non-contact radar level. Within its measuring range of 262 ft. (80 m), the device provides a ±1/8 in. (3 mm) standard accuracy. Moreover, due to its small antenna beam angle, tank internals or low reflective media are no longer an is- sue. To control the production and secure the sup- ply of cement, the level sensor's measuring signal is transmitted to the control room; there the silo's level can be continuously monitored. The technology im- proves the supply inventory of remote cement silos and minimizes inefficient loading and costly delays for the end-user. Lower Operating and Installation Costs Installation and operating costs are significantly lower with the new non-contact radar level technology. The two-wire radar needs less wiring, significantly reducing installation and operating costs. The level sensor is equipped with Pactware software; an installation wizard simplifies configuration. The de- vice software uses dedicated algorithms to adapt each instrument to its specific application, making it partic- ularly suitable for measuring uneven product surfaces. Expensive antenna aiming kits are no longer required. In addition, the drop antenna's shape and smooth sur- face made of polypropylene (PP) or polytetrafluoro- ethylene. (PTFE/Teflon), minimizes build-ups. As a result, the 3- or 6-in. (80- or 150-mm) antennas need less cleaning and do not require expensive purging systems. Application in the cement industry. The new level measurement technology is being used in several cement industry applications, including level measurement in cement silos, cement dust level mea- surement and fly ash measurement. Level Measurement in a Cement Silo A cement silo's level must be continuously measured to control production and ensure the supply of cement to downstream products. At one cement plant, where ce- ment is stored in a large silo with a holding capacity of several thousand tons, operators found that the level did not decrease evenly as cement was removed from the bottom of the silo. Instead, deep pits formed and large chunks adhered to the silo walls. Moreover, the combination of a dusty atmosphere and low reflectivity (the dielectric constant was 1.8-1.9 Σr) presented issues for the ultrasonic level measurement being used. Level With Me New Radar Technology Offers Accurate Continuous Level Measurement in Cement Plants. By Joe Incontri

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