Reliable Solutions for Liquids and Bulk Solids in the Chemical Industry
Reliable level measurement is the foundation for safe and efficient chemical processes – for both liquids and bulk solids.
UWT sensor solutions deliver stable measurement results even in aggressive media, dust, foam or buildup conditions.
Your benefits at a glance:
• Safe overfill protection and dry run detection
• Reliable measurement for liquids and bulk solids
• Stable performance despite foam, dust, vapour and buildup
Typical Challenges in the Chemical Industry
In chemical processes, both liquids and solids are handled under demanding conditions:
• Aggressive media such as acids and alkalis
• Dust generation in solids handling
• Foam formation and vapour
• Buildup and deposits
• High safety requirements (e.g. overfill protection, explosion protection)
Reliable measurement results are essential for safe plant operation and stable processes.
Reliable Level Measurement –
for Liquids and Solids
Modern level measurement technology enables stable measurements across different media and process conditions.
Depending on the application, different technologies are used:
For liquids:
• Radar for continuous level measurement
• Capacitive sensors for level and interface measurement
• Vibrating level switches for reliable point level detection
For solids:
• Radar for dust-intensive applications
• Rotary paddle switches for reliable point level detection
• Electromechanical lot systems for continuous level measurement in silos
The right technology ensures maximum process safety and long-term stable measurement results.
Typical Applications in the Chemical Industry
UWT solutions cover the entire process chain – from liquids to solids:
Tank storage (liquids)
Safe overfill protection and continuous inventory monitoring
Silos (solids)
Reliable level detection for powders, granules and dusty materials
Reactors
Stable measurement even under dynamic process conditions and media changes
IBC containers
Safe level monitoring without direct contact with the medium
Filling and dosing systems
Accurate empty detection for liquids and bulk solids
FAQ – Level Measurement in the Chemical Industry
Which sensors are suitable for solids in chemical processes?
The selection of the appropriate level measurement technology strongly depends on material properties and process conditions. In the chemical industry, powders, granulates and dusty solids are commonly used – often under demanding conditions such as dust, buildup or hazardous areas.
Rotary paddle switches (e.g. Rotonivo®)
Ideal for reliable point level detection in silos and vessels.
- Powders, granulates and solids with medium to high bulk density
- Applications with consistent material movement
- Robust standard applications in dusty environments
Vibrating level switches (e.g. Vibranivo®)
Suitable for light, fine or uneven solids.
- Low bulk densities
- Changing material properties
- Challenging process conditions with buildup
Radar sensors (e.g. NivoRadar®)
For continuous level measurement – even under difficult conditions.
- Large silos and vessels
- Dust-intensive processes
- Applications with internals or long measuring distances
Electromechanical lot systems (e.g. NivoBob®)
For precise continuous level measurement in solids silos.
- Very high silos
- Changing material surfaces
- Accurate inventory measurement independent of dust or material properties
In many applications, a combination of continuous measurement and point level detection is used to ensure maximum process safety.
Which sensors are suitable for liquids in chemical processes?
The selection of the appropriate level measurement technology for liquids depends on the media properties and process conditions. In the chemical industry, aggressive, conductive, viscous or foaming media are common, placing high demands on measurement technology.
Capacitive sensors (e.g. Capanivo®)
For point level and interface measurement in liquids.
- Conductive and non-conductive media
- Applications with buildup or coating
- Interface measurement, e.g. oil/water
Radar sensors (e.g. NivoRadar®)
For continuous, non-contact level measurement in tanks and vessels.
- Aggressive media such as acids and alkalis
- Applications with vapour, temperature or pressure
- Large tanks and changing process conditions
Vibrating level switches (e.g. Vibranivo VN 7®)
For reliable point level detection independent of media properties.
- Liquids with changing properties
- Insensitive to buildup, flow, turbulence and air bubbles
- Safety-critical applications such as overfill protection
In many applications, a combination of continuous measurement and point level detection is used to ensure maximum safety and plant availability.
How does overfill protection work in chemical tanks and silos?
Overfill protection is typically implemented using a separate point level sensor that operates independently of the continuous level measurement. Once a defined maximum level is reached, the sensor triggers a signal to the control system. This helps prevent overfilling at an early stage and increases process safety.
Which technology is suitable for dust, foam or buildup?
This depends on the medium, vessel geometry and measurement task. Radar is often suitable for continuous measurement in conditions with dust, vapour or changing environments. For point level detection, vibrating, capacitive or rotary paddle sensors are used depending on the application. The key is selecting the right technology for the specific process.
