Industry Specific Process Diagram and Product Features for Mining Operations

Process lines followed by most mining operations are similar, starting from removal of minerals or rocks in large quantities from the ground and processing them all the way through to a final product. ABB’s well established level products are tested and proven to perform level measurements across the entire process.

Non-contact technology is highly advantageous owing to the fact that almost all minerals are abrasive, crushing, or corrosive. Ultrasonic transmitters are able to measure most liquid applications, whereas lasers are suitable for use in non-dusty environments over long distances.

ABB also supplies a comprehensive portfolio of contact transmitters and switches to address the challenging level requirements in mining applications. The application of point level measurement, continuous level measurement, and non-contact continuous level measurement at different stages of the mining process is illustrated in Figure 1.

Level Measurement of Mining Operations

Figure 1. Level measurements at different stages of the mining operation

ABB’s Point Level Measurement Products

RS85 Vibrating Level Switch (Figure 2) detects liquid level and is immune to low to medium coating or build-up on sensor. It features special alloy sensors and field selectable parameters with external magnet or internal push buttons (fail safe, density). It has extended probe lengths of up to 3048mm. KCAP400 RF Capacitance Level performs level measurement for liquids and dry bulk solids in pumps and silos. With single setpoint, dual setpoint and pump control features, there are many different two-element sensing probes available up to 450°/3000psig.

RS85 Vibrating Level Switch

Figure 2. RS85 Vibrating Level Switch

TX Thermal Dispersion Switch (Figure 3) can be setup for interface level, liquid level, gas or liquid flow, or temperature. With 316L stainless steel all welded construction standard, the TX Thermal Dispersion Switch is explosion proof with no moving components. The temperature range is -195ºC to 482ºC and pressure range is up to 10,000psig. Chute Master Point Level Detector (Figure 4) performs blocked chute detection for many different bulk solid materials. It is unaffected by particle or dust build up. With 10m range, Chute Master Point Level Detector comes with configurable relay output with on/off delay.

TX Thermal Dispersion Switch

Figure 3. TX Thermal Dispersion Switch

Chute Master Point Level Detector

Figure 4. Chute Master Point Level Detector

SP60 Vibrating Level Switch (Figure 5) detects solid levels in liquids. Adjusted sensitivity, 316 stainless steel wetted parts, IP67 enclosure are the other features of SP60 Vibrating Level Switch. GP50 Vibrating Level Switch (Figure 6) performs point level detection of granulars, powders and solids. It does not require calibration and has robust fork design. It is self cleaning and features patented piezo crystal sensing element.

SP60 Vibrating Level Switch

Figure 5. SP60 Vibrating Level Switch

GP50 Vibrating Level Switch

Figure 6. GP50 Vibrating Level Switch

ABB’s Continuous Level Measurement Products

MT5000/MT5100 Guided Wave Radar Transmitters (Figure 7) measure levels of solids, slurries and liquids. They are free from false echoes because of the travel of radar signals is along the waveguide. They yield reliable level measurement over a variety of process conditions. With distance range of 2-200 ft., they provide true level measurement irrespective of the changes in temperature and pressure. They are available in different material and probe options.

MT5000/MT5100 Guided Wave Radar Transmitters

Figure 7. MT5000/MT5100 Guided Wave Radar Transmitters

AT500 Magnetostrictive Level Transmitter (Figure 8) performs level measurements of different liquid chemicals. It is highly accurate (0.02% of full scale) and can be mounted from the top of a tank. It is loop powered to 4876mm probe length with process pressures to 1800psig and process temperatures to 121ºC. It comes with stainless steel enclosure.

AT500 Magnetostrictive Level Transmitter

Figure 8. AT500 Magnetostrictive Level Transmitter

ABB’s Non-Contact Continuous Level Measurement Products

VM3D (Figure 9) performs volumetric measurement of bulk solid materials in stock piles and silos. Highly visible level indication and 3D surface profiling are the other features of VM3D. LM80/LM200 Laser Level Transmitters (Figure 10) are capable of measuring position, distance, and level over long ranges in extreme environments.

Being powerful laser transmitters, they can measure surface at any angle with narrow beam. They are free from false echoes as there is no beam divergence. LM80’s long range is up to 60m, whereas LM200’s long range is up to 150m. LST400 Ultrasonic Transmitter performs ore level measurement in silos and bins and liquid level measurements in sumps and silos. It can also measure levels of acids and other liquids.


Figure 9. VM3D

LM80/LM200 Laser Level Transmitters

Figure 10. LM80/LM200 Laser Level Transmitters

LST400 Ultrasonic Transmitter

Figure 11. LST400 Ultrasonic Transmitter

About ABB Level Measurement Products

ABB is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 150,000 people.

ABB Level Measurement Products is a leading manufacturer of state-of-the-art level and volume instrumentation for liquid and bulk solids detection. ABB products have demonstrated versatility in numerous applications, affording our customers a variety of practical and innovative solutions for their installation needs.

Our company designs, manufactures, and markets rugged, accurate and reliable equipment addressing numerous applications such as: mining and construction, aggregates, fertilizers, chemical processing, power generation, food and beverage, pulp and paper processing, upstream oil & gas, and downstream oil & gas.

Specifically, the ABB family of non-contact laser level and volume products (LM80, LM200 and VM3D) as well as ultrasonic transmitters, Rf, tuning fork and paddle wheel switches, provide solutions for accurate measurement in the following applications: inventory in bunkers, blending hoppers, reactor vessels, level control, volumetric measurement, and various dry bulk solids and opaque liquids in silos.

This information has been sourced, reviewed and adapted from materials provided by ABB Level Measurement Products.

For more information on this source, please visit ABB Level Measurement Products.


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