Mining and Metal Production
Mining and metal production operates in extreme conditions with high temperatures, abrasive materials, and corrosive atmospheres. Reliable instrumentation is critical for production continuity, worker safety, and energy cost optimization.
Overview
Mining and metal production operate in some of the most demanding industrial environments, with extreme temperatures, abrasive materials, heavy vibration, and corrosive atmospheres. From ore extraction and processing through smelting and refining, reliable instrumentation is critical for maintaining production continuity and worker safety. Level measurement in ore silos, slurry tanks, and molten metal vessels must withstand conditions that would quickly degrade standard sensors. Pressure monitoring throughout grinding, flotation, and thermal processes enables operators to optimize throughput while managing energy costs, which represent a significant share of total operating expenses in this sector.
Industry Challenges
Key challenges we help address
Operating instruments in extreme heat near blast furnaces
Measuring slurry and ore levels with high solids content
Preventing crusher and conveyor blockages in real time
Monitoring toxic gas levels for worker safety underground
Managing corrosive chemicals in flotation and leaching
Tracking vehicle and equipment safety in open-pit operations
Solutions for This Industry
Use Cases
Explore specific scenarios and challenges in this industry
Additive silos
Mining and Metal Production
Depending on the manufacturing process and the type of metal being produced, various additives such as lime are required. The products are stored in silos or concrete bunkers and usually fed to the process via conveyor belts. For cost-effective storage of these materials, level measurement in the silo contents is essential.
Alumina powder silo
Mining and Metal Production
The alumina powder is kept ready in storage and day silos for subsequent smelting. Aluminium smelting is carried out in the fused salt electrolysis process, where pure liquid aluminium is extracted from aluminium oxide. Optimal storage is ensured by level measurement and point level detection.
Alumina powder stirring tank
Mining and Metal Production
The extraction of Aluminium from natural deposits of bauxite requires complex and expensive processes. In the ‘Bayer process, the bauxite is first mixed with sodium hydroxide, autoclaved and then stirred. After that, it is fed into the calciner (high temperature kiln), where it dehydrates to a fine white powder, aluminium oxide (Al2O3). Level measurement in this tank ensures optimal operation of the process.
Blast furnace
Mining and Metal Production
Burden (iron-bearing materials) and coke are transported from the bunker to the top of the blast furnace. The charging of the furnace is done via conveyor belts or small aggregate wagons. To ensure an optimal distribution of the burden and coke layers, exact level measurement is required.
Buffer tank
Mining and Metal Production
In the smelter, above the fused salt electrolysis bath there are small buffer tanks that are pneumatically fed via pipelines. The alumina powder is dispensed into the melt bath in small quantities from these tanks. The filling of the buffer tank is controlled by the feed pressure. Full and empty alarms ensure optimal charging of the powder.
Bulk storage tanks
Mining and Metal Production
Dependable storage is not only the basis for reliable production and supply, it also protects against raw material shortages and price volatility. In addition to regulations on the use of overfill protection or safety instrumented systems, large storage tanks are also often subject to hazardous area codes of practice in conjunction with level measurement.
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