In industrial production, zinc is a key non-ferrous metal. It is used for corrosion protection, in alloys, battery manufacturing, and pharmaceutical applications. Around half of the world’s zinc production is dedicated to protecting metal surfaces from corrosion. During processing, zinc often occurs as a powder or granulate, is abrasive, highly dusty, and demanding for any level measurement technology.
In addition to mechanical wear, fine zinc dust can create an explosive atmosphere. For safe and continuous operation, measurement solutions must provide long-term reliability and meet strict safety standards for use in potentially explosive environments.
Challenge: Excessive Wear Caused by Fine-Grained Zinc Powder
A zinc processing company had been experiencing repeated sensor failures over time. The fine, abrasive zinc powder caused significant wear on seals and moving parts of the existing level sensors. Consequently, the plant experienced frequent maintenance work, unplanned shutdowns, and rising operating costs.
To achieve a stable and low-maintenance solution, the company turned to UWT. The goal was to deploy a robust sensor system that could withstand the abrasive conditions of zinc processing while ensuring reliable operation in a demanding 24/7 production environment.
Solution: UWT Level Limit Sensors Withstand Abrasive Conditions
After detailed analysis and close collaboration with the local UWT team, the plant operator selected two sensor types: Vibranivo® VN 4020 and Rotonivo® RN 6001. Both were installed at various points in the system to ensure reliable limit level detection.
Vibranivo® VN 4020 is a compact vibration level switch with a short stainless-steel probe extension. Its rugged design makes it resistant to mechanical stress, ideal for fine and abrasive bulk solids.
Rotonivo® RN 6001 functions as a rotary paddle switch and performs reliably across almost all types of bulk materials. With pressure-resistant versions, optional explosion protection, and SIL2 certification, it is suitable for safety-critical processes. Both sensors were installed vertically at the top of silos as full detectors, well protected from direct material load and easily integrated into existing process openings.
Operational Results: Stability, Safety, and Reduced Maintenance
Switching to UWT sensor technology significantly improved plant availability:
- Reliability: No more failures caused by abrasive powder – both sensors operate precisely and stably, even in heavy dust conditions.
- Robustness: Stainless-steel components and proven mechanics provide long-lasting resistance to high material stress.
- Safety: Both devices meet the requirements for use in explosive atmospheres, enhancing overall process safety.
- Low Maintenance: No sensor-related downtime, fewer service interventions, and reduced total operating costs.
Result: Improved Process Safety and Lower Operating Costs
The combination of vibration and rotary paddle technology has proven highly effective. Overfilling is reliably prevented, and precise signal output ensure a stable material flow.
The user’s clear conclusion is:
“Since installing the UWT sensors, the system has been running without any disruptions. Maintenance requirements have dropped significantly – a real relief for our operations.”
This application demonstrates how robust sensor solutions from UWT contribute decisively to process safety – even in challenging environments with abrasive, dust-intensive, and safety-critical conditions.
