SolidFlow 2.0Monitoring of solids

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Function

TheSolidFlow2.0sensorusesthelatestmicrowavetech-nology.Thesensorisusedexclusivelyinmetalpipelines.Thespecialintegrationofmicrowavetechnologycreatesthemeasurementfieldtogetherwiththemetalpipeline.Themicrowaveradiationinthepipelineisreflectedbythesolidparticlesandreceivedbythesensor.Thefrequencyandamplitudeofthereceivedsignalsareanalysed.Thesensorworkslikeaparticlecounter,countingthequantityofflowingparticlesperunitoftime.Thefrequen-cy-selectedevaluationsystemensuresthatonlyflowingparticlesaremeasuredwhiledepositsaresuppressed.SolidFlow2.0featuresactivestratificationcompensationwhichcompensatesmeasurementerrorscausedbystrati-fication,inparticularwhilematerialsarebeingpneumati-callyconveyed.Basedonnewprocessingtechnology,themeasurementsignalisconvertedintoitsfrequencyspectrumwhichisusedtodetectthematerial'sflowpattern.Thesensoriscalibratedduringinstallationbyenteringthereferencequantityandpressingabutton.Theillustrationsshowtwofrequencyspectrafordifferentflowconditionswithsimilarmassflows.Asoftwarealgo-rithmensuresthatthemeasuringresultiscorrectevenwithdifferentflowconditions.

ProductInformation

Use

SolidFlow2.0hasbeenspeciallydevelopedformeasuringsolidvolumesconveyedthroughpipelines.SolidFlow2.0isusedforonlinemeasuring:• alltypesofdust,powder,granulates,etc.• withparticlesizesbetween1nmand10mm• whichareconveyedpneumatically• orinfreefallaftermechanicalconveyorsystems

SolidFlow2.0isextremelyeasytoinstallandhasawear-resistantdesign.SolidFlow2.0isthelatestgenerationofmicrowave-basedmeasuringsystemsformeasuringtheflowofsolids.Basedonourmanyyearsofexpertise,SWRhasdevel-opedasecondgenerationversionofthissensor.SolidFlow2.0isareliablesensorwhicheliminatesthedis-advantagesencounteredincurrenttechnologiesavailableonthemarket.

090 200

DopplerFrequencyfD

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DopplerFrequencyfD

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Frequency

Am

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mpl

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Frequency

Spectrumduringstratification

3

• Fuel delivery

Inaboiler,dustisconveyedasfueltothecombustionchamber.Asthereisnoinformationaboutthedistribu-tionoffuelquantitiesinthedifferentsupplylines,settingoptimumcombustionisnotalwayspossible

Benefits:

EachsupplylineismonitoredbyaSolidFlow2.0system,andthesupplyoffuelquantitiesisregulatedineachindividualsupplyline.Thisenablesaccurateanduni-formdistributionoffuelquantitieswhichisanessentialrequirementforoptimumcombustion.

approx. 1.5 t/hGranulation approx. 1 m

Pressure bin1

2

3

DN 50 steel pipe3Combustion chamber2

Fuel (-dust)

Compressedgas

Fluid-Gas (N2) Primary fuel

1

1,5 t/h

ProductInformation

• Compounding plant

Mixturesarecreatedusingthesandwichtechniquewithaweighingcontainer.Theexistingweighingdevicewasnotdesignedfordosingsmallquantitiesofadditionalcomponents,whichmeantthatmeasureddosescouldnotbereproduced.

Benefits:

SolidFlow2.0enablesthedosingofadditionalcom-ponentstobereproducedandbetterbalancingofthequantitiesused.

different types of malt (0,3 – 1 mm Ø)

M111

2

3

1 3 DN 50 stainless steel3Mixer2

Balance

Rotary value

Exhauster

500 kg/h

Applications – Practical Examples

System

Acompletemeasuringpointconsistsofthefollowingcomponents:

• Socketformountingthesensor,includingplugs

• FMSsensorwitha2meter-connectingcable• C-Boxforconnectingthesensorandtransmitter• FMEtransmitterwitharesettabletotalcounter

Thetransmitterisavailableasafieldenclosureversionwithtouchpanelcontrolandadisplay,orinaDINrailversion.WiththeDINrailversion,softwareissuppliedforparametrisationpurposes.

max. 1000 m

C-Box TransmitterSensor

DIN rail transmitter

or

• Granulate dosing system

Theexistingdosingtankistooinaccurateandmeansthattheplantcanonlyoperateintermittently.

Benefits:

SolidFlow2.0enablestransparentmonitoringofthecon-veyedquantitiesandtheprocesscanbeturnedintoonecontinuousoperation.

• Free-fall application

Abeltweigherrecordstheamountofcementconveyed.Thismeasurementisusedasaguidevaluewhenmeter-ingtheadditionofiron(II)sulphate.Thismustbemeteredwithaproportionof0.2…0.3%.

Benefits:

WithSolidFlow2.0,theactualvalueofthemeterediron(II)sulphateisrecordedandregulatedbyadjustingthescrewconveyor'sspeed.Theresultisuniformproductquality.

M

Granulation100 m

Granulation hopper1

12

3

4Mixing chamber3

Proportioning weigher (no longer necessary)2

DN 50 steel pipe4

400 kg/batch

Granulation 40 – 60 m

Iron-II-Sulphate hopper

DN 150 sheet metal pipe

300 kg/h

4

ProductInformation

• Quantity balancing

Thesupplyofmaterialstothegrindingsystemissubjecttosignificantfluctuations.

Benefits:

WithSolidFlow2.0,theprogressofthemassflowcanbemeasuredanddocumented.Ifnecessary,adjustmentscanbemade.Bymeasuringthecoarsegrainbetweenthegrindingsystemandthemill,thegrindingqualitycanalsobemonitored.

Lime hopper

1

1Classifier2

2to the mill

for further processing

40 m DN 150riser,granulationapprox. 5 – 10 m

10 t/h

Mounting and installation

Toinstallthesensor,theinstallationlocationmustbede-terminedaccordingtotherequiredinletandoutletareas.Withpipediameterslargerthan200mm,2or3sensorsareusedpermeasuringpointandthesensorsarear-rangedatanglesof90°or120°toeachother.Infree-fallapplications(forexampleafterscrewconveyorsorrotaryfeeders),aninfeedsection(dropheight)ofatleast300mmisideal.Thesensorbracket(weldedsupport)isweldedonatthespecifiedinstallationlocation.Afterthis,a20mm-bore-holeisdrilledthroughthesensorbracketandthroughthepipewall.Thesensoristhenadjustedtothewallthickness,insertedandfixedwiththeaidofunionnuts.Done!

DN

5 x DN

8 x DN (min. 1 m)

10 x DN (min. 1 m)

8 x DN (min. 1 m)

8 x DN

10 x DN

8 x DN

3 x DN

300

Hopper

1

A

B

2 3A

B

5

Commissioning

ThemeasuringdeviceisstartedupbytheFMEtransmit-ter.Thiselectronicunitenablesconvenientmenu-guidedinputofparameterssuchasmeasuringrange,requiredphysicalunitsormeasuringsignalattenuation.Theavailableoutputsareacurrentoutput,4...20mAandapulseoutput(opencollector).

Theintegratedtotalcounterenableseasycalibration.ThemenulanguageoptionsareGerman,EnglishorFrench.WhenusingDINrailtransmitter,thesystemisoperatedviathesuppliedsoftware.

ProductInformation

Technical data

78

271

90120

244

258

237

12341234Sensor Messumformer

9886

3664

6 EN04/09/2014

Sensor

Housing Stainlesssteel1.4571

ProtectioncategoryIP65,DustExzone20orGasExzone1(optional)

OperatingtemperatureFrontendofsensor:-20…+80°COptional: -20…+200°CSensorelectronic: 0… +60°C

Max.workingpressure 1bar,optional10bar

Workingfrequency K-Band24.125GHz,±100MHz

Transmittingpower Max.5mW

Weight 1.3kg

Dimensions Ø60,Ø20,L271mm

Accuracy ±2…5%incalibratedrange

Transmitter

Powersupply 110/230V,50Hz(optional24VDC)

Powerconsumption 20W/24VA

Currentconsumption Max.1Aat24V

Protectioncategory IP65toEN60529/10.91

Operatingtemperature -10…+45°C[+14…+113°F]

Dimensions 258x237x174(WxHxD)

Weight Approx.2.5kg

Interface RS485/RS232C(ModBus)

Cableglands 3xM16(4.510mmØ)

Screwterminalssection 0.2-2.5mm2[AWG24-14]

Currentoutputsignal4…20mA(0…20mA),load<500Ω

Measurementvaluealarmrelayoutput

RelaywithswitchingcontactMax.250VACat1A

Datastorage Flash

Pulseoutput OpenCollector-max.30V,20mA

C-Box

Size 98x64x35mm(WxHxD)

certificatedaccordingto ATEX

ProductInformation

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SolidFlow 2.0