VEGA level transmitters in open-cast mining: Precise measurement under harsh conditions with 80-GHz radar

Do you know what melaphyre is? This fine-grained basalt rock is used by industry as a raw material for building materials, concrete and road aggregates. Melaphyre processing is a multi-stage process that requires precise measurement at many points. At the Tłumaczów open-cast mine operated by Regnars in Lower Silesia, Poland, level measurement of the material in crushers, mills and silos is extremely important. The ultrasonic measuring instruments previously used for this purpose were error-prone and unsuitable for the harsh operating conditions. The solution to these problems came in the form of VEGA level transmitters, in particular, transmitters of the VEGAPULS BASIC series.

The 80-GHz radar technology used by VEGA enables non-contact measurement, keeping the transmitter at a safe distance from the actual measuring point. This minimises the risk of damage or interference from the production processes themselves. What is more, VEGA radar transmitters are unaffected by temperature fluctuations, vacuum, or pressure, and totally non-sensitive to dirt and dust. 

While dust, vibration, stone chips and changing weather conditions greatly afflict ultrasonic transmitters and cause malfunctions, such conditions are no problem for VEGAPULS BASIC level transmitters. The instruments are robust and hard-wearing, and operate with great accuracy – around the clock. Thanks to the high frequency of 80 GHz, the radar beam can be focussed very tightly and directed with pinpoint precision onto the bulk solid material. This allows VEGA radar transmitters to measure even in narrow shafts, through dust clouds or in vessels with internal fixtures. Even dust-covered antennas have little effect on the measuring result.

The VEGAPULS BASIC radar transmitters demonstrated their strengths in practical testing at Regnars. To ensure smooth operation, they measure the level of melaphyre in the crushers and buffer silos. Whether as wire-connected VEGAPULS C 21 and VEGAPULS C 23 in the silo or as VEGAPULS 11 and VEGAPULS 31 with local display, the transmitters provide transparency and keep the process running.

VEGA offers plant operators a wide range of accessories and various mounting brackets that greatly simplify installation of the radar transmitters. And simple setup and commissioning ensures smooth integration of the VEGAPULS transmitters into existing processes. To make it as easy as possible to access measured values and parameters, the transmitters can be operated both locally and remotely – the latter conveniently via Bluetooth communication with a smartphone or tablet. This feature is particularly useful for installations that are difficult to access, like those located in Ex hazardous areas or under harsh environmental conditions of open-cast mining, such as in Tłumaczów.

Regnars has been using VEGAPULS BASIC transmitters since the summer of 2023. The results speak for themselves: Trouble-free and precise measurement of the required levels under difficult conditions. VEGA level transmitters not only ensure the required product quality by guaranteeing efficient, stable and uninterrupted mine operation. They also protect the life and well-being of the mine workers.