A practical example from South America shows how this challenge can be solved reliably, even under high-temperature conditions.
Challenge: High-temperature process with internal installations in the reactor
An internationally active manufacturer of specialty chemicals was looking for a suitable level measurement solution for a reactor. In this process, a liquid medium is heated to temperatures of up to 260 °C (500 °F) and subsequently processed as an additive for fuels and lubricants.
In addition, the internal design of the reactor made the measurement task more complex. An agitator with a centrally positioned paddle creates continuous movement in the medium and at the same time represents a potential source of signal interference.
The requirements for the measurement technology were clearly defined:
- Reliable measurement at high temperatures
- Use in hazardous areas
- Non-contact measurement to minimize maintenance effort
- High accuracy despite internal installations and dynamic process conditions
Conventional measurement technologies quickly reach their limits under these conditions – particularly due to thermal stress, vapor formation, build-up and interference reflections caused by internal structures.
Solution: Non-contact radar level measurement with NivoRadar® NR 8500
The solution was the NR 8500 in its high-temperature version, a free-space 80 GHz radar sensor specifically designed for extreme process conditions.
The radar measuring principle ensures reliable level detection without direct contact with the medium. This enables stable and maintenance-free operation, even at elevated temperatures and under demanding process conditions.
Technological advantages in operation
The NivoRadar® NR 8500 is designed for high-temperature and high-pressure applications and enables reliable level measurement even under extreme process conditions. The sensor is equipped with a robust stainless steel horn antenna, ensuring stable signal transmission even in demanding media and complex installation environments.
Thanks to high-quality materials such as stainless steel, ceramic and graphite, as well as reliable sealing, the sensor operates precisely at process temperatures of up to 450 °C (842 °F) and pressures of up to 160 bar (2320 psi). This provides sufficient thermal and mechanical reserves for applications such as the additive production described here.
A key advantage is the use of 80 GHz radar technology. The very narrow beam angle of just 3° allows the signal to be precisely focused on the product surface. Interference reflections caused by the centrally positioned agitator paddle or other internal structures are significantly reduced.
Any remaining interference signals can be specifically suppressed. Using the UWT LevelApp, false echoes, for example those caused by the agitator, can be identified and filtered out using integrated interference signal suppression. This significantly increases measurement reliability, especially in applications with moving surfaces and complex internal installations.
The non-contact measurement principle further contributes to operational reliability. As there are no moving parts in contact with the medium, the sensor remains unaffected by thermal stress, vapor or build-up. This reduces maintenance requirements and increases long-term plant availability.
In addition, the sensor meets the requirements for use in hazardous areas. With international approvals such as ATEX, IECEx and INMETRO, the NivoRadar® NR 8500 is suitable for operation in explosion-risk zones.
Commissioning and parameterization are carried out via standard tools such as the UWT LevelApp, an integrated display or PACTware. This enables fast integration into existing systems and flexible adaptation to different process conditions.
Stable processes and reliable measurement results
By implementing the NivoRadar® NR 8500, level measurement in the reactor was sustainably stabilized. The operator benefits from:
- Increased process safety
- Reduced maintenance effort
- Reliable measurement results even at high temperatures and with moving media
Non-contact radar level measurement has thus proven to be a reliable solution for high-temperature applications in the specialty chemicals industry.
Conclusion
In the chemical industry, especially in high-temperature processes with internal installations such as agitators, robust and precise measurement systems are essential. The NR 8500 demonstrates how modern 80 GHz radar technology enables reliable and cost-effective level measurement, even under demanding conditions.
