Contactless radar level sensors success in small turbulent feedstock vessel

The BASF Agricultural Specialities Limited production site in Littlehampton, West Sussex produces industry leading biological pest control products formulated from beneficial nematodes. These products are used by farmers and growers across the globe in agricultural, protected ornamental and home and garden markets. Liquid rhizobium inoculants produced at Littlehampton are also used as seed treatments. Nematodes are naturally occurring microscopic worms, already present in the soil, beneficial nematodes attack and kill targeted garden pests. After application, using a garden hose or watering can, they attack the larval stages of pests and slugs. Once inside, they quickly kill the pest by releasing bacteria that stops it from feeding. The nematodes reproduce inside the dead pest and release a new generation of nematodes, which disperse to hunt down more pests. The research scientists have isolated individual species of beneficial nematodes that target only specific garden pests including slugs, vine weevils, chafer grubs, leatherjackets, caterpillars, and codling moth. The state of the art production facility in Littlehampton produces trillions of nematodes in a form that is easily applied by growers and gardeners.

“The radar works perfectly, even at very close proximity to liquid when the vessel is full” - site Process Development Manager

The production process involves several stages of organism development and growth in special vats, nutritional feedstocks are added to provide perfect conditions to produce the nematode product. As part of this, the feedstock is mixed heated and aerated in a small just over 1m high batching vessel before adding into the process, ready for further growth and development stages. The container has ‘sparge’ pipes which blow air up through the product to mix and aerate, creating a turbulent foaming surface. The lid is hinged and removable for cleaning and inspection, so any long probe guided wave radar would be impractical and prone to damage, as well as causing a cleaning issue. Of course, any pressure based systems would have their level reading affected by the changing density during the process.

A few years ago, it was identified that a contactless device, insensitive to these conditions was needed. A 26GHz radar was previously used, however, there were some limitations on the performance due to the small measuring range when the liquid level was high and surface conditions. Recently, BASF turned to the new VEGAPULS 64 80GHz radar, which has world leading sensitivity to handle both the turbulence and foam on the surface as well as condensation on the antenna of the sensor. It now provides a true level and contents measurement over the whole vessel height, the site Process Development Manager commented, “The radar works perfectly, even at very close proximity to liquid when the vessel is full”. The unit was supplied with the optional Bluetooth communications, which allows set up via Smartphone, Tablet or PC. It was just as well, as during the set up, the Manager also reported, “My computer got destroyed by accident during the setting up of the radars. So I loaded up the VEGA Bluetooth App on an old iOS phone. I have to say I was impressed”. 80 GHz contactless radar is offering new solutions to level measurements that were previously thought impossible with a contactless device. As well as handling these challenging conditions, they are also capable of measuring very low reflectivity hydrocarbons, long ranges, even liquid gases, pure solvents, seeing past complicated vessel internals, long nozzles, even operating through process isolation valves. The customer concluded, “There is always excellent technical support by VEGA, from legacy devices we have had for many years, through to latest innovations like this radar”.

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80GHz level radar solution for agricultural bio-science sector