Fly ash storage level monitoring in thermal power

—Precision Measurement Practice with KLD806 High-Frequency Radar Level Meter in a 12m Fly Ash Silo

I. Project Background

A 300MW coal-fired power plant in Foshan, Guangdong, utilizes a 12-meter-high, 8-meter-diameter fly ash silo to store pulverized coal ash (particle size: 1–150 μm, bulk density: 0.6–0.9 t/m³). The original capacitive level meter faced critical issues:

1. Low Accuracy: Dust adhesion caused dielectric constant drift, resulting in ±8% measurement error.
2. High Maintenance: Monthly electrode cleaning required 4 hours per session.
3. Signal Interference: Pneumatic fluidization devices triggered false alarms (3 daily on average).

II. Solution: Technical Advantages of KLD806 Radar Level Meter

1. High-Frequency Narrow Beam Design:
   • 80GHz millimeter wave with 3° beam angle, ideal for compact 12-meter silos.
   • Customized range: 0.3–15m, blind zone: 0.3m, full coverage.
2. Anti-Interference Performance:
   • Dynamic Noise Suppression Algorithm (DNIR 3.0) filters false echoes from fluidization airflow.
   • IP68-rated 316L stainless steel housing withstands airflow impact (20m/s velocity).
3. Smart Diagnostics:
   • HART protocol outputs echo curves (local/remote diagnostics).
   • Automatic dielectric constant compensation (dust adhesion impact <0.1%).

 

 

III. Implementation Process

1. Installation & Commissioning:
   • Location: 0.8m below silo top
   • Parameter Configuration ：
     • Range=0.3-12m
     • False Echo Suppression=Enabled (blocks fluidization pipe interference)
     • Output Damping=0.2s (matches pneumatic fluidization cycle)
   • Accuracy Verification: ±5mm error vs. laser rangefinder.
2. System Integration:
   • Integrated into plant DCS via 4-20mA+HART (compatible with existing I/O modules).
   • New functionalities:
     • High/low level interlock control (auto-stop at >90% level).
     • Level change rate alerts (>1m/h indicates blockage risk).

IV. Performance Outcomes

Client Feedback:

“The KLD806’s narrow beam solved measurement challenges in our compact silo. Millimeter-level accuracy at 12m range and zero airflow interference are game-changers.”

V. Key Takeaways

1. Compact Installation Tips:
   • Use short horn antenna
   • Top eccentric mounting
2. Parameter Optimization:
   • Enable “Dust Mode”
   • Set dielectric tracking interval=30min (adapts to humidity changes).
3. Maintenance Protocol:
   • Biannual lens cleaning with KC Sensor toolkit.
   • Download health reports monthly via KC Sensor Cloud.

VI. Broader Applications

Validated for small/medium silos (8–15m), ideal for:

• Biomass Power Plants: 10–15m ash silos.
• Industrial Steam Hubs: Precise small silo measurement.
• Cement Plant Calibration Silos: High-accuracy batching.

Technology Extension:
KC Sensor’s new Multi-Silo Coordination System (supports 16 KLD806 units) enables regional smart ash management, reducing transport costs by 15–20%.

Resource

• FAQs about using radar level gauges
• Do you know how to install and measure radar level gauges?
• Ultrasonic, Radar, Capacitive Level Sensors: Which is the best choice for level measurement?
• Radar Level Sensors: An In-Depth Guide