Barselona’daki Cementos Molins S.A., çimento üretiminde çevreci ve ekonomik bir yol izleyerek alternatif yakıtlar (AFR) kullanıyor. Bu yakıtlar; plastik, kâğıt, tekstil, hurda lastikler gibi atıklardan oluşuyor ve kömür kadar yüksek kalorifik değere sahip. Ancak bu atıklar ön işlem görmeden kullanılamaz: Özellikle Tetrapak gibi ambalajlarda bulunan alüminyum metal parçacıkları, ölçüm cihazlarında parazit sinyallere neden olabiliyor.
Challenging Silo Conditions:
• A continuously operating blade mixer is in use.
• Approximately 1 ton of waste material is discharged every hour.
• Dense dust clouds, constant vibration, and the sticky nature of the material make level measurement extremely difficult.
• Older 26 GHz radar sensors failed in this environment. Dust adhering to the antenna resulted in incorrect measurements.
Cementos Molins made the right decision by directly installing the VEGAPULS radar level sensor series, which operates at the 80 GHz frequency range. Despite heavy dust, vibration, and metal particles, the device continues to deliver uninterrupted and reliable 24/7 measurement.
Dust Penetration Accuracy: Reliable Level Measurement Even in Harsh Silo Environments
Cementos Molins S.A. has been working with VEGA for twelve years at its Barcelona facility. Numerous VEGA sensors are now in use, including pressure transmitters, capacitive measuring devices, and vibrating level switches. A custom solution was needed for a storage silo filled with alternative fuels (AFR), measuring over 20 meters high and 9 meters in diameter. Approximately 35% of the fuel needed for cement production at this facility is supplied by alternative fuels.
At the base of the silo is an unconventional mixer with sharp, vibrating blades that continuously grind the waste. Trucks arrive at all hours to fill the silo, with roughly one ton of AFR material discharged per hour The main challenge in this process stems from the necessity of fully unloading the waste-laden trucks. Therefore, the silo must always have enough capacity to accommodate an entire truckload. Level measurement is critically important not only to prevent overfilling but also to issue empty warnings. Complete emptying could damage the mixer. Therefore, a reliable, continuous measurement process is required 365 days a year.Zorlu Koşullar ve Radar Sensöründeki Ölçüm Güçlükleri
Challenging Conditions and Measurement Difficulties with Radar Sensors
Conditions in the construction materials industry are generally harsher than those in other sectors. In this cement plant, the challenges are even more unique. Firstly, AFR materials are highly variable and sticky. During unloading from trucks into the silo, massive dust clouds form, making measurement extremely difficult and causing heavy buildup on the sensors. During the mixing and grinding process, material waves up to 2 meters high can form in front of the mixer blades. Alongside vibrations, a constantly shifting dust cloud forms inside the silo.
Previously used 26 GHz radar sensors with horn antennas from another manufacturer never performed reliably. Dust adhered to the horn, resulting in inaccurate readings. The 26 GHz transmission frequency alone, combined with the dust cloud and vibration, failed to provide a reliable signal. In addition, metal particles from Tetrapak packaging caused further interference signals in the sensor.
Accurate Measurement Through Dust Clouds
The VEGAPULS radar level sensor series from VEGA, operating at 80 GHz, offers reliable level measurement even under challenging conditions like those at Cementos Molins. Its high focusing capability allows measurement accuracy of ±5 mm without being affected by interference signals. Thanks to a narrow 3° beam angle, the sensor can take accurate readings without being affected by internal structures or buildup. Made of PEEK material, the device is resistant to dust, dirt, and high temperatures. It features an adjustable mounting bracket and a smartphone app for quick and accurate alignment during installation.
No Signal Loss with the Latest in the Series: VEGAPULS 6X
VEGAPULS 6X, with its powerful signal focusing and high dynamic range, easily penetrates dense dust clouds using its 80 GHz frequency. Its air flushing connection allows any buildup on the sensor surface to be easily removed. Despite potential interference from metal particles originating from Tetrapak, it ensures accurate measurement.
A remote display installed at eye level and the PLICSCOM interface allow service personnel to access all data without having to climb to the top of the silo.
• Dust clouds, the internal mixer, and metal reflections do not impact measurement performance.
• The PEEK body and lens antenna are resistant to dust and chemical exposure.
• The standard air flushing connection makes the sensor easy to clean.
• Measurement accuracy reaches up to ±1 mm.
• The smart mounting bracket and mobile application ensure easy sensor alignment.
• The remote display on the silo eliminates the need for maintenance personnel to climb to the top.
