Loading data

Intelligent solutions for harsh materials in the chemical industry

A variety of plastics for a variety of uses

Intelligent solutions for harsh materials in the chemical industry

A variety of plastics for a variety of uses

Chemicals

Cypol GmbH

The customer was interested in reliable level measurement that was accurate, adaptable to changing conditions and manitenance-free. They were also hoping the solution would decrease their manufacturing downtime, maximize their silo capacity and improve their logistical complexity.
Four of the company’s 30-ton metal silos with conical tank bottoms are used for production and raw material storage. The other two silos are loaded from production and unloaded continuously, with materials moving at speeds of 600 to 800 kilograms per hour. Finished products are loaded into big bags, bags, and boxes. Obstructions inside the silos include leaders, reinforcements, and tubing for pneumatic filling and vacuum emptying. The silo shape and obstructions combine with the challenging environment created by the materials themselves. These compound polymer plastic materials are three to five millimeters in size and create both a dusty atmosphere and occasional high humidity during pneumatic loading.

SITRANS LR560 high-frequency radar provides the accuracy, adaptability to changing conditions, and maintenance-free operations Cypol needed.

“The performance of these transmitters has paid off in so many ways throughout our production, we can depend on SITRANSLR560 for accurate readings and easy upkeep.”

Walter Rauenschwender, Executive Director at Cypol GmbH

Operators easily installed these 78 GHz transmitters on the existing DN 100 process connections using existing two wire power loop cables. Commissioning was also straight forward using the device’s local display—and this entire process took place without a single interruption to production.
Thanks to the transmitter’s Process Intelligence, Cypol can depend on its continuous level measurement even with changing product variables such as density, material size, dielectric constant, and humidity. And dust or buildup? The maintenance-free sensors are supported by an air purge feature integrated on the process seal to keep antenna components clean during the entire production process.
The integrated Easy Aimer means that the narrow four-degree beam will reach all the way to the silo’s conical bottom, maximizing the measuring range and ignoring obstructions along the way.
From decreases in operators’ time spent maintaining or cleaning devices to increased energy savings, SITRANS LR560 has proven itself in Cypol’s operations.
The yearly maintenance savings over the previous sensor equipment for all six silos is around 1,000€. But factor in the cost of production downtime during maintenance on each of the previous devices and the savings add up.
As well, Cypol has noticed a marked benefit in energy consumption since installing the new radar transmitters. With more tank capacity over the time available for filling, operators are able to optimize these processes thanks to accurate and reliable level measurement. As well, decreases in required cleaning saves power, hot steam, and water while also not expending energy to shut down and start up production.
Using Siemens Process Device Manager (PDM), operators can perform remote echo analysis. This involves taking an echo profile of the empty silo and then comparing it to echo profiles once the silo is full to monitor changes to the level sensor. During filling and unloading, PDM monitors surface conditions on the materials to ensure that the radar echo quality remains strong.

Duisburg

Chemicals

Cypol GmbH

Chemicals

Cypol GmbH

Release Year 2022

Building a solid foundation of future-proof instrumentation and control

Completion 2016

An ideal narrow beam radar level transmitter for textile additives

Release Year 2021

4 tips for continuous level measurement selection perfection