In high-risk industries such as petrochemicals, pharmaceuticals, and energy metallurgy, the accuracy and safety of level measurement are directly related to production efficiency and personnel safety. The high-frequency explosion-proof radar level gauge, with its high precision, strong anti-interference ability, and intrinsic safety characteristics, has become the core equipment for monitoring the level of liquids, slurries, and solid particles in flammable and explosive environments. This article will analyze from two dimensions: technical characteristics and selection points, providing a scientific selection guide for industrial users.

1、 Core technological advantages of high-frequency explosion-proof radar level gauge

1. High frequency electromagnetic wave technology: breaking through the limitations of complex working conditions

High frequency explosion-proof radar level gauge adopts26GHzor80GHzElectromagnetic wave technology, beam angle only3°~5°Strong focusing ability can effectively avoid interference from obstacles such as tank walls and agitators. For example, in petrochemical storage tanks,80GHzThe radar level gauge can penetrate steam concentrations up to90%Accurate measurement of crude oil level in the environment. Its penetration advantage is particularly prominent in the fermentation tank covered with foam or the pulverized coal bunker filled with dust, and the measurement stability is improved compared with the traditional low-frequency radar40%The above.

2. Explosion proof certification system: adapted to global hazardous area standards

Equipment passes throughATEXTheIECExTheCNExWaiting for international certification, explosion-proof level coverageEx ia IIC T6(intrinsic safety type) andEx d IIC T6(Explosion proof type), suitable forZone 0/1(Gas) andZone 20/21(Dust) hazardous area. For example, in the monitoring of liquefied gas storage tanks, intrinsic safety design can prevent explosions caused by electric sparks, while explosion-proof enclosures can withstand internal explosion impacts, ensuring that the equipment is in good conditionextremeSafe operation under working conditions.

3. Intelligent signal processing: adaptive to complex environments

The built-in adaptive filtering algorithm can automatically suppress false echoes, such as interference signals generated by mixers and heating tubes. The alcohol storage tank project of a pharmaceutical company shows that this function reduces measurement errors±10mmdrop to±1mmThe validity of the data is achieved99.8%At the same time, the self diagnostic system can monitor abnormal states such as antenna contamination and temperature drift in real timeHARTProtocol output fault codes to shorten maintenance time60%The above.

4. Durable design: Suitable for harsh industrial environments

The antenna material is adopted316Lstainless steel+PTFECoating or ceramic, improved corrosion resistance3Suitable for highly corrosive media such as hydrochloric acid and sodium hydroxide.IP67/IP68Protection level supports devices in-40℃~200℃Temperature range and95%Stable operation in a humid environment. A high-temperature molten metal level monitoring project in a metallurgical enterprise has confirmed that a radar level gauge with a cooling jacket can be used in800℃Continuous operation under working conditions2yearfault-free.

2、 Selection Strategy for High Frequency Explosion proof Radar Level Gauge

1. Explosion proof level matching: based on the classification of hazardous areas

Before selecting, it is necessary to clarify the explosion-proof zone of the application scenario. For example,Zone 0The area (where explosive gases persist) must be selectedEx ia IIC T6Intrinsically safe equipment, andZone 1Areas (occasionally containing explosive gases) can be selectedEx d IIC T6Explosion proof type. Priority should be given to selecting explosion-proof levels for dust environmentsEx tD A21The model.

2. Antenna type selection: Balanced range and accuracy

Cone antenna: universal design, suitable for range0.1~30Conventional storage tanks for rice.

Parabolic antenna: beam angle only1°Suitable range30~70Long distance measurement of meters, such as large crude oil storage tanks.

Array antenna: Through multi beam coverage, it effectively suppresses signal attenuation in high dust environments and is suitable for monitoring cement plant silos.

3. Process connection and output signal: compatible with existing systems

Process connection needs to match container interface and flange connection（DN50/DN80）Suitable for high-pressure storage tanks, threaded connections（G1½'）Suitable for small containers. In terms of output signals,4-20mA+HARTThe protocol is compatible with traditional methodsDCSThe system, andRS485/ModbusorPROFIBUS PAThe interface is suitable for digital factory renovation.

4. Maintenance convenience design: reduce the total lifecycle cost

Prioritize modular design devices, such as detachable antenna components, for quick replacement and maintenance. A case study of a chemical enterprise shows that modular design enables single maintenance time to be reduced from4Shorten hours to0.5Hours, reduced annual maintenance costs75%At the same time, attention should be paid to whether the equipment supports remote calibration function to reduce on-site operational risks.

3、 Application scenarios and benefit analysis

High frequency explosion-proof radar level gauges have been widely used in the monitoring of liquid levels in petrochemical storage tanks, hygienic design in the pharmaceutical industry, and liquid level control of high-temperature molten metals in metallurgy. Taking the atmospheric pressure storage tank project of a certain refinery as an example, using80GHzAfter the high-frequency radar level gauge, the measurement accuracy is improved±5mmupgrade to±1mmThe number of shutdowns caused by false alarms of liquid level in the year has decreased80%The direct economic benefits exceed200Ten thousand yuan.

The high-frequency explosion-proof radar level gauge provides a safe and accurate level monitoring solution for high-risk industrial environments through the integration of high-frequency technology, explosion-proof certification, and intelligent algorithms. When selecting, it is necessary to comprehensively consider the explosion-proof level, antenna type, process connection, and maintenance convenience to achieve the best match between equipment performance and scene requirements. With the advancement of industry4.0Advance, the new generation of radar level meter with edge computing capability will further promote the intelligent upgrade of level measurement in dangerous areas.