Level Detector for Zinc+Al Bath

Well there are a number of high-tech solutions that may work but how about a good old float sensor. With a little more effort an analog signal level could be obtained rather than a digital one. How about using load cells to measure the bath weight. Sometimes the simplest ideas are the best after all.

What type of signal do you require? Accuracy? Is it to be used for monitoring or for process control? How wide and deep is the bath? Can you monitor product flow going into the bath instead?

What is the application?

Anyone out there know how they implement this in the aluminium smelters?

Yours is the best and simplest idea

SS FLOAT+SS thinbraided wire>spring loaded payoff 2-turns ropeon pulley>Shaft angle encoder> direct encoded Digital output or Rotary Potentiometer Analog output ---at a cool place>will work forever--set up only after a maintenance shutdown.

You will never need any greater accuracy- you will get easily +/_ 2mm accuracy.

I will use a radar type level sensor from Fisher Rosemount or any other non contact type

Dear CaballoLoco,

can you tell me its Model number of that Fisher Rosemount radar type?

thanks&regards.

I have successfully measured the level of oil by bubbling a small amount of air throught the liquid. The amount of pressure in the air line is proportional to the level of fluid above the air outlet. The beauty of this system is that it is very robust.

There are a lot of mini explosions in a galvanising bath (trapped air, water etc) so any equipment mounted above it would need to be protected from the hot zinc.

Best of luck

There are several methods to use. one, weight, you can use a pressure sensor to get the weight in order htat you can transfer into height. 2] generally you can use a UT sensor to measure its height directly. you can choose high temperature proble. 3] you can use x-ray gauge to get the value. but this is very expensive. if you hve naother problem we are more than help to respond as more detail as we could.

Whats wrong with the simple approach, how about 2 electrical probes that conduct a current via the molten bath when the level is at a certain set-point. you could even use carbon rods and measure resistance if an analogue is required.

yes you can use simple method for measureing. its good and welcome, but there may need much precision electric bridge gauge and you still get a very crude reading between its change values. you even cannt identify theri reading sometimes. is it right?

Dear Abu,

If you need level detection for limit switching, a simple method that comes to mind is a conductivity type level limit switch. You can use a SS ceramic insulated Rod probe as the sensing element and another SS rod permanently dipped in the molten metal as a reference probe. The reference probe should be mounted at a distance from the sense element to avoid formation of a bridge between the two probes. The two probes should have ceramic terminations and should be connected to the evaluation unit via Teflon insulated wires to withstand the environmental temperature close to the molten bath. If you need further information you may visit www.sapconinstruments.com. They manufacture a wide range of level controllers. You may email dimentional details of your specific problem to sales@sapcon.in or info@sapcon.in for their recomendation.

Hope this solves your problem

Vijay

Hear is one thing I did learn about molten zinc and steel inside of it.

If using Carbon Steel, you want as high of a Silicon content as possible.

I say "Mind Your English"

In 1988, in Ontario Canada, English was made a required course for engineers. Before that, things were REALLY rugged as far as engineering reports/memos etc. were concerned.

It's all a matter of personal priorities. Would you rather have no response from an engineering mind just because the English may be a bit rugged here and there; or can you value the engineering contribution well enough over and above the languaging content to rise above your daily preferences with regard to the language/expression in order to value the contribution.

There's no contest. The engineering mind is vastly more important than the spelling and grammar mistakes.

[Sometimes even the spell check feature doesn't help because it only recognizes individual words, not the context in which they may be used.]

If you want the contribution, you take it as it comes, and be mighty grateful for it, too.

Mark

When I was a kid, the baths were well below eye level. When one started to get low, according to the eyeballed distance between the liquid level and the top of the tank, more plating material was added to raise the level.

Mark