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SSSI – Smart SSI Speed Limit Switch

Level Measurement Solutions for Steel Industries

Level-Sensors-Steel-Industry_Sapcon-Instruments

Need for Level Instruments

  • To control overflow of material and to avoid dry run of process in hoppers and bunkers.
  • To regularize material filling
  • To avoid wastage of material
  • Protect from dry run
  • Reduce human dependence

Why Sapcon

  • Appropriation in design and fast switching operation
  • Control over spurious switching in case material deposits on vessel wall; proximity and photoelectric sensors need maintenance in such cases
  • Different types of designs available according to the application
  • Thorough study of steel plant along with good experience in such applications
  • RF-Admittance type & Vibrating Fork Level Switch are the best solutions based on the material characteristics and application requirements

Sapcon manufactures quality products based on the contact type of the level measurement instrument with the material. These instruments work well in various critical and non-critical applications in steel and iron making processes. In contact-type, Sapcon has four measuring principals:

Sapcon’s Capacitance Level Switch utilizing specially designed Immuno Coat Probe offers a solution for level limit detection of fine, coarse, bulky solids, non-sticky slurries and liquids. The probe comprises of a sense electrode, electrically isolated from the metallic tank by means of a suitable insulator. The sense electrode and the vessel wall serve as the two electrodes of a capacitor with the service material as the dielectric. A change in material level causes a change in the dielectric, which in turn causes the value of this tank capacitor to change.

Applications:

  1. Iron Making Process – Iron Ore, Flux and Coal Bunkers
  2. Sinter Plant Area, Dust Collection System
  3. Blast Furnace Area – Dust Catcher Unit at High Temperature
  4. Coke Oven & Coal Blending Process
  5. High Temperature Applications – For ESP and Bag Filter Hoppers
  6. Customized Solutions – Chute Block Detection
  7. Water Level in Coke Oven Batteries – DM Water Level Measurement
  1. Iron Making Process – Iron Ore, Flux and Coal Bunkers

All three materials are the basic raw materials of Iron making process which must have individual storage units requiring point level monitoring.

Sapcon’s Solution

Sapcon provides its RF Admittance rope probe arrangement that is suitable for measuring the desired level in open bunkers, so that the overflow can be avoided.

Unique Features

  •  Sturdy rope probe can withstand impact of heavy and bulky solids
  •  Customised probe length as per requirement
  •  Better coating immunity in case of excessive dust
  •  Operator can see the level at the control area by separate control and local indication units
  1. Sinter Plant Area, Dust Collection System

Iron ore is agglomerated into large porous lumps which is suitable for use in the blast furnace. Sinter dust collection system requires high / low level monitoring with high temperature resistivity.

Sapcon’s Solution

Sapcon recommends its RF-Admittance level switch with extra sturdy rod probe to control high / low level switching points in silos. Sapcon also has solutions for high temperatures (above 300°C).

Unique Features

  • Universal supply options for AC / DC in all models
  •  Customised mounting arrangement like flange, thread as per site condition
  •  Remote location model with 15 (SLA..M) and 50 Meters (SLA..B) with special interconnection cable
  • Sensitivity arrangement and fail-safe selection on site
  1. Blast Furnace Area – Dust Catcher Unit at High Temperature

Blast furnace is a ceramic refractory line reactor for producing hot metal. Here, coke is used for combustion which further generates carbon monoxide which converts iron oxide into molten metal.

Sapcon’s Solution

Sapcon recommends its RF-Admittance level switch with heavy-duty probe and flexible rope probe to control high / low level switching points in dust catcher unit.

Unique Features

  • Universal supply options for AC / DC in all models
  • 12mm Dia GI / SS flexible rope to sustain large particle sized materials like stones / rocks
  • Remote location model of 15 Meters (SLA..M) and 50 Meters (SLA..B) with special interconnection cable
  • High temperature model up to 800°C with cooling fins arrangement
  • Fail-safe selection for High / Low levels on field
  1. Coke Plant & Coal Blending Process

Naturally found coal (FC) contains ash, moisture, volatile matter and other impurities which makes it unsuitable for use in blast furnace. Hence, naturally found coal is converted into coke in a coke plant.

Sapcon’s Solution

Sapcon recommends its RF-Admittance level switch with heavy-duty part ceramic probes to control high / low level switching points in a hopper.

Unique Features

  • Universal supply options for AC / DC in all models
  • 33mm dia sensing and heady-duty construction
  • Remote location model of 15 Meters (SLA..M) and 50 Meters (SLA..B) with special interconnection cable
  • Flexible rope probe to sustain material size greater than 50mm
  1. High Temperature Applications – ESP & Bag Filter Hoppers

A Filtration device is used to eliminate dust and fine particles from gas flowing through an induced electrostatic charge. Hoppers containing dust, fly-ash require high / low level detection.

Sapcon’s Solution

Sapcon recommends its RF-Admittance level switch with extra sturdy rod probes to control high / low level switching points in a hopper.

Unique Features

  • Extra sturdy rod probes suitable up to 150 / 250°C temperature
  • Discharge device to eliminate static charge
  • Remote location model of 15 Meters (SLA..M) and 50 Meters (SLA..B) with special interconnection cable.
  • Special LED / Bar graph on controller to see the gradually increasing levels in the hopper
  1. Customized Solutions – Chute Block Detection

Sapcon also offers customised solutions for various process applications in cement plants. Some of them are to detect level in boot and other for material detection in chutes.

Sapcon Solution

Sapcon recommends its RF-Admittance level switch with disc-type arrangement for material detection in boot and chutes where insertions are generally difficult.

Unique Features

  • Heavy-duty disc-type arrangement suitable for temperatures up to 250°C
  • Suitable for remote location as these come with special interconnection cable
  • Projection and flush-mounted type switches are available
  • Special LED / Bar graph on controller to see the gradually increasing levels in the hopper
  • A more reliable and straightforward replacement to diaphragm-type switches
  1. Water Level in Coke Oven Batteries – Cement Storage & Packing Feed Hopper

Sapcon recommends its conductivity / capacitance level switch for measurement of DM water in coke oven batteries.

Unique Features of Capacitance Level Switch

  • Low power consumption – Less than 5V
  • Ignore build-up of material on vessel wall
  • High temperature durability (Up to 250°C and 600°C for non-conductive liquids)