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Environment and Recycling

Environment and Recycling

The environment and recycling sector manages diverse waste streams while recovering valuable materials and protecting natural resources. Reliable instrumentation handles challenging conditions to maximize recovery rates and ensure emissions compliance.

Overview

The environment and recycling industry is central to managing waste streams, recovering valuable materials, and protecting natural resources. Processing facilities handle diverse and often unpredictable input materials ranging from municipal waste to industrial byproducts. Reliable instrumentation is essential for monitoring sorting processes, controlling material recovery operations, and ensuring emissions compliance. Level measurement in storage bunkers, processing vessels, and output silos must handle challenging conditions including dust, moisture, and highly variable material properties. As circular economy principles gain momentum, recycling operations require increasingly precise process control to maximize recovery rates and minimize environmental impact.

Industry Challenges

Key challenges we help address

Monitoring hazardous waste levels in enclosed storage areas

Preventing landfill leachate contamination of groundwater

Managing incinerator feed rates for complete combustion

Tracking emissions to meet increasingly strict regulations

Measuring material purity in recycling sorting processes

Operating sensors in corrosive flue gas environments

Use Cases

Explore specific scenarios and challenges in this industry

Dewatering column

Dewatering column

Environment and Recycling

The waste oil is heated to a temperature of 105 °C in the lower section of the column. Here, the water evaporates and is pumped away after it condenses. After reaching the appropriate temperature, the oil is transported through pipes to the upper part of the column, where the remaining water vaporises. For optimal dewatering, a defined level is required in the column. As the oil surface is very turbulent due to the action of pumps and heating, making level measurement directly inside the column practically impossible. For that reason it is done in a bypass tube.

Dewatering wells in open cast mining

Dewatering wells in open cast mining

Environment and Recycling

In open cast mining, the groundwater levels must be continuously reduced to protect the mining area from flooding and the excavation walls from instability due to water pressure. A large number of dewatering wells with submersible pumps are kept in operation for this purpose. A continuous water flow prevents the pump shaft from blocking due to the effects of hardening clay/iron oxide deposits. To regulate the pump output, precise level measurement is required in each of the up to 750 m deep wells.

Flue gas scrubber

Flue gas scrubber

Environment and Recycling

Flue gas from waste incineration must be cleaned before it is released into the environment. Flue gas scrubbers do this by removing acidic gas components such as sulphur dioxide. Lime water is used as the washing solution and it is sprayed in against the flow of the gas. The lime deposits filtered out of the washing water are used as gypsum, e.g. for the production of plasterboard. To ensure a continuous scrubbing process, a constant level in the scrubbing tower is required.

Gauge station

Gauge station

Environment and Recycling

Accurate monitoring of the river level is an important prerequisite to be able to react quickly and correctly in the event of a flood. Visual, on-site level monitoring requires great effort, particularly for facilities in remote areas.

Incinerator

Incinerator

Environment and Recycling

To ensure that the waste burns completely, temperatures up to 1000 °C must be maintained. For this purpose, large amounts of primary air from below and secondary air from above are blown in. Air quantity and air pressure must be precisely measured. Also an optimum waste layer thickness on the combustion grate is required for uniform combustion.

Incinerator feed chute

Incinerator feed chute

Environment and Recycling

After the crane system lifts the waste from the waste bunker and drops it to the feed chute, in the lower part of the chute, a hydraulic piston pushes the waste onto the combustion grate. It is important that waste in the chute is always at an optimal level and uniformly distributed. This prevents air from leaking into the furnace and ensures a constant supply of fuel for combustion. For that reason the minimum level in the feed chute has to be monitored and the resulting data displayed to the crane operator.

Intermediate hazardous waste storage tank

Intermediate hazardous waste storage tank

Environment and Recycling

Both chemical and thermal processes are used to treat hazardous waste. For efficient processing, the flow rate through the processing facility must be kept constant. To facilitate this, hazardous wastes such as varnishes, paints and thinners are buffered in tanks. Agitators prevent clumping and settling of the solids contained in the mixture. Reliable level measurement ensures continuous waste processing is maintained.

Leachate well

Leachate well

Environment and Recycling

Pollutants contained in the waste are partly washed out over time by rainwater, posing a significant threat to groundwater and surface water. For that reason, leachate is caught in drains within the ground seal or liner, collected in wells and fed to a multistage treatment plant. To control the submersible drainage pumps, a level measuring system is needed inside the leachate well.

Plastic granule silo

Plastic granule silo

Environment and Recycling

Complete plastic windows can be recycled by means of a special process. The recycling process results in a final product of high-quality, pure-grade PVC granules, which serve as a raw material for new windows. It is stored in large silos that are fitted with tubes for uniform colour mixing. For optimal control of production and supply, the contents of the silo have to be determined, which is usually via level measurement.

Pyrolysis chamber and ash container

Pyrolysis chamber and ash container

Environment and Recycling

Waste incineration converts domestic and commercial waste into combustible gases and ash. Pyrolysis is carried out in the absence of air at temperatures up to 500 °C. The intermediate product, charcoal, is then further burned by adding air. Ash and synthesis gas with high thermal content are the end products. For continuous operation, the vessel must be loaded and emptied automatically. To this end, the level of material in the pyrolysis chamber and in the ash pan has to be measured.

Reactor

Reactor

Environment and Recycling

In a recycling company, oil sludge, oil/water mixtures and emulsions from many industrial processes are collected and treated. The objective is to separate the oil and water for recovery, purification and reuse. This process takes place in several steps. Firstly the oil/water mixture is centrifuged, hydrogen peroxide is added and mixed in a stirring reactor, then finally it is centrifuged again. Continuous level measurement is required in the reactor stage to enable automated operation. It’s very important for there to be an absolutely reliable and accurate measurement even at low liquid levels, right down to the vessel bottom.

Receiving tank for hazardous waste

Receiving tank for hazardous waste

Environment and Recycling

Hazardous waste can include lacquers, paints and thinners, as well as acids, alkalis and mixtures. At hazardous waste treatment facilities, environmentally harmful substances are converted into environmentally safe ones. Before treatment, the liquid hazardous waste is collected in receiving tanks. Level measuring systems ensure the automated, monitored operation of the facility, thereby protecting human health and the environment.

Silo for crushed glass

Silo for crushed glass

Environment and Recycling

Glass is made of quartz sand, lime and soda, which are melted together at extremely high temperatures up to 1600 °C. This melting process is very energy intensive and for that reason, more easily melted waste glass is also often added into the mix. After delivery, the waste glass is first crushed and freed from impurities. The material, known as cullet, is then transported and filled into a silo, where it is fed to the melting process. To ensure a continuous supply of material to the furnace, a reliable level measurement in the cullet silo is required.

Stripping column for landfill leachate

Stripping column for landfill leachate

Environment and Recycling

In the stripping column process, the nitrogen and carbon compounds are decomposed by various microorganisms. Special carrier materials are packed in the central part of the reactor, which improve the biochemical reaction processes. To ensure an optimal operating point inside the stripping column, an exact level measurement at the base of the column is required. Because the surface of the medium in the reactor is very turbulent due to air flowing in from below, the level measurement has to be carried out in a bypass tube.

Tsunami warning system in the harbour

Tsunami warning system in the harbour

Environment and Recycling

Tsunamis travel quickly and cause great damage when they hit land. So it is vital that tsunami warnings are issued early. Tsunami information centres continuously evaluate simultaneous data from seismic and sea level measuring stations. Such a sea level measuring station is operated by an oceanographic centre in a ferry and cargo-ship terminal. The measurement has to reliably and accurately detect the sea level and forward the data directly to the central monitoring system.

Waste storage bunker

Waste storage bunker

Environment and Recycling

The waste storage bunker in the reception hall is an important part of the EFW incineration plant. Its purpose is to provide a place to store, buffer and uniformly mix the delivered waste and ensure a continuous supply of waste to the incinerator. A grab crane transports the waste to the feed chute of the furnace. To ensure efficient operation of the plant, a reliable and accurate level measuring system is required in the waste storage bunker. In addition, the level in the feed chute must be monitored to protect against a blowback of flue gas.

Wet deslagger

Wet deslagger

Environment and Recycling

The hot, burned-out slag falls into the water quenching bath of the deslagger. A mechanical discharge mechanism pushes the slag out and, while doing so, presses out most of the entrained water. Evaporation and slag removal cause a steady loss of water. For that reason the water level in the deslagger has to be measured and replenished as required.

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