The story of how a 3D Radar Level Transmitter transformed the operations of a cement plant forever.

A case study is the best way to demonstrate how problems that often appear intractable can be solved with a simple solution by adopting the right technology, which in this case happened to be the 3D Multi Beam Radar.

Background

The Cement Plant Group in discussion is one of India's largest producers of cement with more than 10 integrated cement plants and about 15 grinding units in India with their presence expanding to the Middle East as well.

Challenges

Post Covid lockdown, when we first visited their grinding unit near to our factory, they explained that their Clinker Silos which have a diameter of more than 30 metres have a peculiar problem – no matter how many conventional single beam radars they install, they never get a reliable volume and can never tell the operator the accuracy on volume. On the other hand the operator is never concerned with Level, he always wants Volume to calculate the Yield and Throughput and be sure that the process is running as per his requirement. The other part of the problem was related to dust which was causing the maintenance issues.

Solution

During the discussion we introduced our customer to the world’s first 3D Multi Beam Radar, which not only measures at multiple points inside the silo, but helps provide an accurate level and volume data accompanied with a real time 3D profile of the material inside the silo. The added benefit comes with the 140 GHz frequency of operation which allows the device to work in heavy dust without any air purge, hence zero maintenance.

Results

1. Volume data customer can rely

2. 3D profile of the uneven material

3. Like a camera that works in dust

4. Transforming level -> volume.

The adoption of this solution was so fast that in a matter of 3 years customers have implemented this 3D Radar in almost all the cement plants across India for their clinker application.

EIP at a glance

EIP Enviro Controls was established about three decades ago, since then the company has been able to build its reputation in the field of design/manufacture supply of accurate reliable point level and inventory control system for silos/bunkers and stockpiles which have proven to be in satisfactory operation under harsh environmental conditions. Apart from India EIP products have also been proven in other countries. EIP aims to provide not only a stable operating system but also to re-engineer equipment and systems as per the needs of the customers.

This has been possible due to our wide experience in this field backed by constant technological development and absorption of new technologies developed world-wide. EIP’s strong endeavor to provide the best solution to its customers has gone a long way in introducing the most advanced level measurement technology from time to time.

At a glance...

Challenges

·         Accurate volume not available

·         Uneven surface profile

·         Dust

·         Maintenance issues

Benefits

·         Reliable level and volume

·         Real time 3D profile

·         No more manual dips 

Contact : +91-9818953439/73. Email : info@eipenviroindia.com

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