FEATURE FLOW & LEVEL CONTROL THE SWEET SMELL OF SUCCESS


VEGA’s 80 GHz radar level sensor is changing the way people perceive contactless level measurement, as demonstrated by its successful installation at British Sugar in Newark


A


s the sole processor of the UK’s beet sugar crop, British Sugar work in


partnership with 3,500 growers and customers to deliver a product that is made to the highest standards every day. The innovative approach to manufacturing also enables British Sugar to create a range of co-products from power generation and bioethanol, to animal feed and much more. Sugar beet processing is a complex and demanding process, requiring continuous innovation and process enhancements to produce a consistently high quality product. An area recently improved at its Newark


production site is the production and mixing of milk of lime. This is an essential formulation for use in sugar production when purifying the juice from beet or cane. Typically, 125kg of limestone is consumed in the production of one ton of sugar, so it is a significant process input. Sugar beet is sliced up and passed through a diffuser to extract the sugar juice. Lime, produced from calcium limestone, is used in the next stage of the production process. It is converted into milk of lime and this is used to capture and remove impurities in the juice of sugar beet. A high quality lime-water mixture is


required in the sugar process to ensure an efficient, high quality sugar juice purification stage. Being such a versatile product, lime is


not just used to purify raw materials, it is also often used to clean and neutralise wastewater produced by sugarbeet. The resulting by-products are useful too, as it contains a mixture of lime and organic residues, which are commonly re-used in agriculture as a soil additive and conditioner. Most of the sugar-processing plants have their own lime kilns, and they require good, high purity limestone to burn. This ‘high calcium’ limestone is converted into quicklime in lime kilns, at a temperature of 900°C. To obtain milk of lime, the ‘calcined’ lime is mixed into water and it is during this process that an accurate, reliable level measurement ensures consistent production. Originally a differential pressure transmitter was used with a modified back-pressure bubbler system, to try to maintain a clear level measurement. However, maintenance was unpleasant and running costs were still high. The exothermic reaction of mixing the alkali and water also produces heavy condensation inside the tank. The process area requires a high level of


The VEGA 80 GHz radar level sensor has been installed very close to the edge of the milk of lime mixing vessel, not an ideal position for a contactless level sensor, but it handles the situation with ease


safety as the lime is harmful and an irritant to both skin and eyes. Tank overflows and any consequential clean-up are unpleasant and hazardous. For these reasons, British Sugar were keen to look for a new measurement solution. The result is the installation of a new 80


PEACE OF MIND FROM A LIFETIME WARRANTY


Premier Control Technologies has launched a local UK service department to support the Lifetime Warranty offered by Alicat Scientific for its range of mass flow and pressure measurement/ control instrumentation. Many manufacturers make excellent products and back them with a


12 month Warranty. Alicat Scientific, however, has increased this to an impressive 36 month Warranty. What’s more, beyond these initial three years, customers can retain peace of mind from the Alicat Limited Lifetime Warranty. Premier Control Technologies and Alicat Scientific have worked


closely together to provide the UK with local service and support facilities that complement this Alicat Warranty and provide customers and users alike with an Approved and Certified addition to the Global Service Network. Alicat Gas Mass Flow Meters, Gas Mass Flow Controllers, Liquid Meters/Controllers, Pressure and Vacuum Metering and Control products are all covered under this Warranty (https://www.pctflow.com/our-products/flow- meters/miscellaneous/alicat-limited-lifetime-warranty/). Post-Brexit industry in the UK will require a local certified and knowledgeable support infra-structure that


will eliminate the time, cost and logistical complications of shipping goods either across the Atlantic or even just to the mainland of Europe. Perhaps even more important is the need to provide a reliable standard service that ensures engineers can work within known shut-down periods. Furthermore, an element of flexibility must be possible to fulfil those unforeseen emergencies that sometimes happen. Premier Control Technologies offer standard service turn-around times of 3-5 days with a Gold Service of 1


day available upon request. This service supports Alicat customers and maintains the Lifetime Warranty. Premier Control Technologies


T: 01953 609930 www.pctflow.com


GHz radar from VEGA, which has been successful in following the liquid level, despite the turbulent surface and steamy environment producing high levels of condensation; as well as build up and splashing on the antenna from the milk of lime solution. All outer surfaces of the device are either plastic or stainless steel in construction with a fully encapsulated PTFE antenna system, which means minimal corrosion and a longer operating life for the sensor in this highly alkaline environment. Another challenge was the ideal mounting position: to minimise splashing and build up on the sensor, it was better situated quite close to the vessel wall – but not an ideal position for a contactless level sensor as the proximity of the wall and any build up will interfere and compromise both performance and accuracy. The unit installed, uses 80 GHz frequency, which means its DN80/3” flange only has a 3 degree beam angle. This means it handles the situation with ease, the more focused sensor signal beam bypasses the vessel wall and any build up, following the level confidently. VEGA 80Ghz radar offers 120dB


sensitivity, combined with the enhanced focussing and signal processing software, so creates a formidable package. These abilities enable it to cope with challenges like mounting close to vessel edges (through valves or long nozzles), coping with heavy condensation and build up on the sensor face to deliver a reliable measurement, even with a turbulent or agitated process surface. British Sugar at Newark are very happy


with the results from this application – an improved reliability in level measurement, better quality milk of lime and less maintenance time lost working on instruments or clean ups in the lime mixing plant.


VEGA Controls www.vega.com


40 SEPTEMBER 2018 | PROCESS & CONTROL / PROCESS&CONTROL


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