PROCESS AUTOMATION
Wireless non-contacting radar is particularly well suited to intermediate bulk container level measurement applications
Bulk solids applications
Bulk solids handling and storage is another application where wireless non-contacting radar delivers significant operational benefits. Industries including chemical production, mining and food processing depend on accurate solids level measurements to maintain inventory visibility, optimise production and prevent overfilling. Conveyors, chutes, process vessels and silos containing ore, cement, grain, flour, sugar, polymers, minerals and chemical powders are, however, often distributed across large sites where installing cabling is expensive and impractical. These applications present demanding
measurement conditions, including dust, uneven material surfaces, ratholing and build-up. Non- contacting radar is particularly well suited to these environments because the antenna remains isolated from abrasive products, while minimising the effects of product build-up on the measuring system. Modern 80 GHz radar technology also provides a narrow beam angle that helps to avoid interference from internal structures and maintain reliable performance even in tall or complex silos. Integrated diagnostics can alert operators to antenna contamination or changing process conditions before measurement quality is affected. Combined with wireless communications, this enables reliable inventory monitoring across
remote solids storage without additional cabling or routine manual inspections.
Open ponds and wastewater basins are other applications where wireless non-contacting radar offers clear advantages. Across many process industries, ponds are commonly used for wastewater treatment, stormwater retention and process water storage. These assets are frequently located around the perimeter of facilities or in environmentally sensitive areas where trenching for cables is impractical or prohibitively expensive. Non-contacting radar transmitters measure from above the liquid surface, avoiding contact with contaminated water, sludge and aggressive chemicals, and making them well suited to applications where maintenance requirements must be minimised. Combining this measurement principle with wireless communications enables continuous level monitoring to be installed without extensive civil works, helping operators to prevent overflows, maintain treatment capacity, demonstrate environmental compliance and reduce the need for routine manual level checks.
Operational benefits
While the ability to eliminate power and signal cabling is often the initial reason for adopting wireless non-contacting radar, the greatest long-term value
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frequently comes from the additional operational insight it provides. As existing WirelessHART networks continue to expand across industrial facilities, adding new wireless measurement points becomes increasingly straightforward. Rather than being constrained by wiring infrastructure, engineers can extend continuous level measurement wherever improved process visibility is required. Instead of relying on periodic manual readings, organisations gain continuous visibility of inventory levels and changing process conditions, allowing abnormal trends to be identified before they develop into operational problems.
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OCTOBER 2026 | PROCESS & CONTROL ENGINEERING 15
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