Background

A sand and gravel quarry located in a mining area in Sichuan Province, China, primarily provides materials for construction, including sand and stone. The quarry uses multiple silos to store large amounts of sand, gravel, and raw materials. Due to factors such as dust, material pile angles, and material buildup inside the silos, traditional level measurement methods are often interfered with, leading to inaccurate measurements. The quarry needed a level measurement solution that could adapt to the complex environment and ensure accurate material monitoring.

Challenges

  1. Dust Interference: The quarry environment contains significant amounts of dust, which often causes traditional level sensors to produce errors due to dust accumulation, affecting measurement accuracy.
  2. Pile Angle and Buildup: The pile angles and material buildup inside the silos vary greatly, affecting the accuracy of the level sensors, especially when the material is piled high.
  3. Automation and Remote Monitoring Requirements: The quarry sought to automate the level monitoring process and enable remote control, reducing manual intervention and increasing operational efficiency and safety.

Solution

To address the level measurement challenges at the quarry, Kacise provided the KLD806 radar level sensor solution. The KLD806 is capable of overcoming dust, pile angle, and material buildup effects, delivering high-precision level monitoring.

  1. KLD806 Radar Level Sensor: The KLD806 uses high-frequency radar wave technology that can penetrate dust and gas interference to accurately measure the material height inside the silo. Even in cases of high material buildup or thick material layers, the sensor provides stable and reliable measurements.
  2. Resistance to Pile Angle and Buildup Effects: The KLD806 sensor boasts excellent stability and precision, adapting to various material shapes stored in the quarry and remaining unaffected by pile angle changes, ensuring reliable data output.
  3. Remote Monitoring System Support: The KLD806 is compatible with the quarry’s intelligent monitoring system, transmitting real-time level data to the monitoring platform, allowing operators to stay updated on the material levels in the silos. When integrated with a PLC control system, the system can trigger external alarm devices if the level exceeds the preset range, ensuring safe operation at the quarry.
  4. Durability and Stability: The KLD806 radar level sensor is highly durable and can work stably for extended periods in dust- and moisture-heavy quarry environments, minimizing maintenance requirements.

Results and Benefits

  • Improved Level Measurement Accuracy: By adopting the KLD806 radar level measurement technology, the quarry can precisely monitor the material storage levels inside the silos, providing more reliable production data.
  • Reduced Manual Intervention: The intelligent remote monitoring system greatly reduces the frequency of manual inspections, enhancing operational efficiency at the quarry.
  • Enhanced Safety: Through real-time monitoring and data analysis, quarry management can take timely action to prevent material overflow and equipment damage, ensuring the safe operation of the quarry.
  • Increased Production Efficiency: Accurate level measurements help the quarry optimize resource utilization and material scheduling, improving overall production efficiency and material management.

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