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Continuously Measuring Corn Surge Hopper Level

PROBLEM:
What continuous level measuring product is ideal for challenging applications, such as a corn surge hopper in an Ethanol facility where the material level is constantly changing and internal vessel environment extremely dusty?

EXPLANATION:
The process of making Ethanol fuel from corn involves using a surge hopper.  A surge hopper typically is used to absorb the peaks and valleys of the raw material requirement during the continuous processing of the grain to make Ethanol.  As material continuously is fed into the hopper and the process draws off the required raw material to process, the levels of corn rise and fall and dust from the grain and field is ever present.  This makes the surge hopper a challenging application for a continuous level measurement sensor.

SOLUTION:
Monitor recommends our continuous level measurement technology, Flexar® guided wave radar, which is unaffected by airborne dust, bulk density and temperature changes. The Flexar guided wave radar unit uses TDR (time domain reflectometry) technology to make accurate measurements at a distance of 100ft (30m) in solids and 200ft (60m) in liquids.  The TDR microwave pulses are guided to the material surface along a continuous stainless steel cable of 0.31" (8mm) diameter.  The microwave pulses reflect off the material surface and the time of flight results in the distance measurement of empty space.  Ignoring any and all dust particles.  The unit calculates the material level based on the height of the surge hopper and transmits this data via a 4-20mA output signal to a remote receiving device such as a control system or digital display meter, or via RS485 communications for use with Monitors’ SiloTrack inventory management system.

Flexar® guided wave radar continuous level sensors are a proven radar technology installed in thousands of bulk solids applications worldwide. Monitor Technologies is the leading supplier of level measurement and monitoring solutions for powder and bulk solids applications.

Give Monitor Technologies a call and let us put our creative solution to work for you!

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