Building materials

The building materials and mining industry places extremely high demands on the durability, quality and cost-efficiency of the sensors. IPTech sensors deliver absolutely reliable measurement data in the mining, transport, processing and storage of all raw materials and finished products.

Applications

Application

The large boulders are extracted from the solid bedrock with blasting. This very first stage in the process is needed to enable these very large rocks to be crushed by smaller, secondary jaw and roller crushers, which create the smaller sizes for screening to produce the basic building materials like gravel, grit or sand. To enable efficient, continuous operation and keep wear on the crusher as low as possible, level measurement and point level detection are required.

Your benefit

Reliable

Reliable measurement ensured even in noisy environments

Cost effective

Uninterrupted operation thanks to optimal process feed

User friendly

Simple installation and setup

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Crusher

Measuring range up to:

5 m

Medium:

Stones

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Strong noise and dust generation, extreme abrasion

Application

After being crushed, screened and sorted into different grain sizes, the gravel and sand are transported on conveyors and stored in large stockpiles. To automate the stockpiling levels and enable the optimum area to be filled, a reliable level measurement is essential.

Your benefit

Reliable

Reliable measurement is ensured in all weather conditions

Cost effective

Optimum utilization of stockpile capacity

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement

Measuring point:

Stockpile

Measuring range up to:

50 m

Medium:

Stones, gravel and sand

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Weather conditions such as rain, snow and wind

Application

The transport of coarse and fine bulk solids within a stone processing facility takes place in most cases via conveyor belts. To achieve an even throughput and compensate for volume fluctuations during transport, belt transfer points are integrated in the conveyor line. The incoming bulk material is briefly stored in a buffer silo to prevent belt overfilling. This is the point where the level and the point level must be monitored.

Your benefit

Reliable

Reliable monitoring of silo filling

Cost effective

Optimal utilization of conveyor belt capacity

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

5 m

Medium:

Stones, gravel and sand

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Extremely noisy and dusty environment, abrasion

Application

Bulk aggregates are fed into production processes via conveyor belts or screw conveyors. For effective feed control to and from these processes, or inter-production unit billing, the mass flow of the conveyed bulk material must be measured. A reliable belt-weighing scale system and mass flow rate ensures accurate measurement and smooth operation of the plant.

Your benefit

Reliable

Reliable measurement despite changing belt tension and vibrations

Cost effective

Optimal mass flow measurement allows exact accounting of bulk solids

User friendly

Maintenance-free operation

Process data

Measuring task:

Throughput measurement

Measuring point:

Conveyor belt

Measuring range up to:

10,000 t/h

Medium:

Bulk solids

Process temperature:

-40 … +60 °C

Process pressure:

0 … 0 bar

Special challenges:

Vibrations, dirt, changing material size

Application

To ensure continuous production, even if material production is interrupted, the raw materials are stored in large bunkers with heights of over 30 m and diameters of up to 20 m. The large dimensions of the silos require the filling and emptying to take place at multiple points. Uniform filling and emptying of the bunkers is achieved through level measurement at various points in the bunker.

Your benefit

Reliable

Reliable measurement even in dusty and noisy environments

Cost effective

Optimal filling of the silos

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

40 m

Medium:

Mineral rock, gravel and stone powder

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Extreme dust generation, filling noise

Application

After crushing and screening, the different aggregates are transported via conveyor belts and distributed among the silos. Before further processing, the stones, gravel or rock flour are stored in buffer and production silos. To ensure optimal material storage, a precise level measurement is required.

Your benefit

Reliable

Reliable measurement even in dusty and noisy environments

Cost effective

Optimal storage capacity

User friendly

Maintenance-free operation of the facility

Process data

Measuring task:

Level measurement

Measuring point:

Silo

Measuring range up to:

30 m

Medium:

Stones, gravel and rock flour

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Noise, dust and abrasion

Application

Dust-free, closed loading systems are needed for fine aggregates and finished products such as cement. Automated loading of trucks is preferred in the industry and, while the load quantity is determined with a weighing system, it must be ensured that the truck is in the correct place and not overfilled. Reliable point level detection and vehicle positioning shortens loading times, increases throughput and improves the efficiency of the entire system.

Your benefit

Reliable

Reliable measurement under tough operating conditions

Cost effective

Optimal filling of silo vehicles

User friendly

Simple setup and commissioning

Process data

Measuring task:

Point level detection

Measuring point:

Silo truck

Medium:

Gravel, grit and cement

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Harsh environment, extreme dust generation

Application

In order to process building materials such as mortar, plaster or grout effectively, they are delivered directly to the construction site in transport silos. There, water is added as required and the building material is processed immediately. Level measurement ensures that there is enough material in the silos.

Your benefit

Reliable

Reliable measurement of a wide variety of media

Cost effective

Optimal material supply

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement

Measuring point:

Silo

Measuring range up to:

8 m

Medium:

Mortar, grout, plaster

Process temperature:

-25 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Buildup, dust generation

Application

A lime kiln is used to produce quicklime through the calcination of limestone. Here the furnace is filled from the top and the calcined limestone (quicklime) is collected at the bottom of the furnace. Accurate level measurement ensures optimal charging and hence efficient operation of the furnace.

Your benefit

Reliable

Reliable measuring results even at high process temperatures

Cost effective

Accurate charging of the lime kiln

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement

Measuring point:

Lime kiln

Measuring range up to:

4 m

Medium:

Burnt limestone

Process temperature:

+800 … +1000 °C

Process pressure:

0 … 0 bar

Special challenges:

High temperature

Application

After the calcined lime is cooled, it is sorted into different sizes and stored for further processing. Most of the lime is further processed to lime powder. For optimum production planning, a reliable level measurement is a must.

Your benefit

Reliable

Reliable measurement ensured under all operating conditions

Cost effective

Optimal storage of the product

User friendly

Wear and maintenance-free

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

25 m

Medium:

Fine lime

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Extreme dust generation and product buildup

Application

Bitumen is an important ingredient in asphalt production. It binds stone aggregates together to form the finished asphalt. To enable cost-effective asphalt production, reliable level measurement and overfill protection in the storage tank is required.

Your benefit

Reliable

Reliable measurement and detection even at high temperatures

Cost effective

Optimal utilization of storage capacity

User friendly

Simple setup and commissioning

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

5 m

Medium:

Bitumen

Process temperature:

+120 … +200 °C

Process pressure:

0 … 0 bar

Special challenges:

Buildup, high temperatures and condensation

Application

Different qualities are required from the asphalt depending on the usage and climatic conditions, so every asphalt mixture varies depending on the application. Asphalt is always extremely viscous, hot and highly adhesive. Due to these properties and the numerous different asphalt mixtures, reliable level measurement and point level detection methods are essential.

Your benefit

Reliable

Reliable measuring results even at high temperatures

Cost effective

Optimal utilization of storage capacity

User friendly

Simple installation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

15 m

Medium:

Asphalt

Process temperature:

+150 … +200 °C

Process pressure:

0 … 0 bar

Special challenges:

Very heavy buildup and high temperatures

Application

Materials such as concrete and mortar are needed in widely different compositions depending on the application. The various raw materials are stored in segmented towers, which then blend cement, lime and other aggregates according to specific requirements. In each individual segment, reliable level measurement and point level detection ensure the constant availability of the raw materials and cost-effective operation of the plant.

Your benefit

Reliable

Reliable measurement in all types of media

Cost effective

Optimal material storage

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

25 m

Medium:

Sand, gravel and grit

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Abrasion, dust and large struts

Application

In the manufacture of stucco with special insulating properties, Styrofoam is also added to the traditional sand, lime and cement mixture. With a bulk density of only a few grams per litre, Styrofoam balls are extremely light and therefore very difficult to measure. For cost-effective storage, reliable level measurement and point level detection are required.

Your benefit

Reliable

Reliable volume measurement of very lightweight media

Cost effective

Optimal use of storage capacity

User friendly

Maintenance-free operation

Process data

Measuring task:

Level measurement and point level detection

Measuring point:

Silo

Measuring range up to:

25 m

Medium:

Styrofoam

Process temperature:

-40 … +50 °C

Process pressure:

0 … 0 bar

Special challenges:

Extremely low bulk density

Application

Diesel is stored in tanks on construction sites to supply the construction vehicles with fuel directly on site. A sufficient supply of diesel fuel is essential for optimal construction site operation. Exact level measurement, in combination with wireless data transmission to a central location, ensures automatic, optimal provisioning of mobile containers at all times.

Your benefit

Reliable

Security of supply, thus no construction delays due to lack of diesel fuel

Cost effective

Optimisation of the logistics and procurement process thanks to reliable measurement

User friendly

No external power supply required for the sensor

Process data

Measuring task:

Level measurement

Measuring point:

Tank

Measuring range up to:

3 m

Medium:

Diesel

Process temperature:

-20 … +60 °C

Process pressure:

0 … 0 bar

Special challenges:

Change in density due to temperature fluctuations

Application

During the winter season the highways and road maintenance departments safeguard the roads, public squares and pedestrian paths by clearing off snow and ice. The quantities of road salt required are stored in silos and when needed, loaded onto snowploughs. Reliable level measurement is necessary for the optimal and adequate stocking of the salt. The stock level information is transmitted to the central control centre.

Your benefit

Reliable

Ensures the supply of salt

Cost effective

Efficient and simple planning of deliveries

User friendly

Simple installation and commissioning

Process data

Measuring task:

Level measurement

Measuring point:

Silo

Measuring range up to:

25 m

Medium:

Road salt

Process temperature:

-40 … +80 °C

Process pressure:

-1 … +2 bar

Special challenges:

-1 … +2 bar

Application

Safe filling and timely routing of tanker trucks is essential for reliable bitumen supply. The medium is hot and viscous and places high demands on both handling and safety. Accurate level measurement, in combination with wireless data transmission to a central location, guarantees optimal automatic refilling of these mobile containers.

Your benefit

Reliable

High availability via mobile inventory monitoring

Cost effective

Savings in fuel and operating costs through optimal logistics

User friendly

Automated supply chain via continuous, maintenance-free inventory monitoring

Process data

Measuring task:

Level measurement

Measuring point:

Tank

Measuring range up to:

5 m

Medium:

Bitumen

Process temperature:

+3 … +120 °C

Process pressure:

0 … +5 bar

Special challenges:

Humid environment, foaming