Zinc is one of the most important non-ferrous metals worldwide. Around half of the global zinc production is used for corrosion protection, while other applications include alloys, batteries, paints, and pharmaceuticals. In production, zinc is typically processed as a fine powder or granulate – materials that are abrasive, dust-intensive, posing significant challenges for level sensors.
The fine-grained particles cause heavy wear on mechanical components and zinc dust in contact with air can create explosive atmospheres. Therefore, robust and reliable sensor technology is essential to ensure safe, stable, long-term operation.
Initial Situation: Sensor Failures Caused by Abrasive Zinc Powder
A zinc processing plant had been struggling with recurring problems using its existing level sensors. The fine, abrasive structure of the zinc powder caused wear on seals and mechanical components, resulting in frequent maintenance, unplanned downtime, and rising costs.
To resolve this, the plant turned to UWT for a durable, low maintenance sensor solution capable of withstanding harsh conditions and ensuring 24/7 operation.
Level Limit Switches Ensure Process Stability in Abrasive Zinc Powder 24/7 Operations
UWT Solution for Reliable Level Measurement
After detailed analysis and with support from UWT’s US team, the plant selected the and sensors. These level limit switches effectively address the specific challenges of the zinc processing operation.
Finding the right solution together with expertise and application specific consulting
Vibrating fork Vibranivo® VN 4020:
compact level switch for abrasive powders
The vibration level switch with a short stainless-steel probe extension, ideal for abrasive bulk materials. Its compact, mechanically robust design ensures reliable detection even in fine, dusty materials.
Rotary paddle switch Rotonivo® RN 6001:
robust level limit switch for all types of bulk solids
The versatile rotary paddle switch for all types of bulk solids. It resists dust buildup, electrostatic charging, and caking. Its pressure-resistant, explosion-proof housing and SIL2 certification make it suitable for safety-critical processes.
Both sensors are installed vertically as full detectors on top of silos, making integration simple and providing protection against direct material load.
Advantages in Operation: Reliable, Robust, and Safe
Switching to UWT sensors has led to significant improvements for the zinc plant:
Reliability: No more failures caused by abrasive powder – both sensor types operate precisely even in heavy dust environments.
Durability: Made of stainless-steel and engineered for high material stress.
Safety: Certified for use in potentially explosive atmospheres, enhancing overall process safety.
Low maintenance: No sensor-related downtime and significantly fewer service operations reduce the maintenance workload.
Greater Process Safety and Lower Costs
in Zinc Processing
Changing to the Vibranivo® VN 4020 and Rotonivo® RN 6001 has clearly paid off for the zinc plant. Both sensors ensure stable level detection even under the demanding conditions of zinc processing. Accurate high-level alarms prevent overfilling, ensuring process stability, reducing costs and increasing process reliability.
From the user’s perspective: “Since installing the UWT sensors, the operation has been running smoothly and failure-free. The devices are extremely low-maintenance, which has further reduced our operating costs.”
This solution exemplifies how tailored, reliable level monitoring from UWT for abrasive and dusty environments can ensure long-term process stability – tailored for each customer’s needs.
Discover More Applications in the
Chemical Industry
Whether for the storage and processing of powders, granulates, liquids, or aggressive chemicals – UWT offers robust and safe sensor solutions for a wide range of chemical industry processes.
