Silo Level Measurement

April 28, 2025

About Silo Level Measurement

Silo level measurement is to measure the height or position of materials in the silo. The level meter can record the entry, exit and storage of materials in real time, providing managers with detailed data support. In addition, the level meter can also help companies predict material demand trends, prepare in advance, and avoid production delays caused by material shortages. At the same time, the level meter can timely detect and deal with potential hidden dangers by monitoring the storage of materials in real time.

In today’s context of rapid industrial development, silos are important facilities for material storage. They are widely used in many fields such as food, chemical industry, mining, energy, etc. Real-time monitoring of the material level status in the silo can improve storage efficiency and predict accidents. Silo material level measurement is of great significance to related companies.

How to Measure Silo Level?

The level monitoring system is a comprehensive system that integrates level monitoring, control and information management. It is widely used in various fields of industrial production. Such as cosmetics factories, flour mills, salt factories, mixing stations, commercial concrete stations, cement plants, building materials factories, etc.

The system uses high-precision detector technology to monitor the storage status and changes of materials in warehouses or silos in real time, providing key data support for the production management and optimization of enterprises. Sino-Inst’s intelligent paperless recorder is suitable for a variety of industrial sites and integrates many new functions. It is widely used in many fields such as electricity, petrochemicals, metallurgy, light industry, pharmaceuticals, aviation, etc.

For example, our most commonly used radar level meter and ultrasonic level meter. The level meter is installed on the silo. The ultrasonic Level sensor and radar level sensor convert the level change into an electrical signal. After data collection and processing, it is displayed to the manager in a visual way (PCL, DCL and paperless recorder).

Difficulties and Solutions in Measuring Silo Level

Material characteristics

Uneven materials: Granular materials such as coal and ore may have uneven particle size and inconsistent bulk density in the silo.

Solution:

The method of taking the average value of multiple points can be adopted.
Select measurement technology that is highly adaptable to changes in material density. Such as radar level meter.

Poor material fluidity: Some materials are prone to agglomeration, bridging or adhesion to the silo wall.

Solution:

Install auxiliary equipment such as vibration devices or air cannons.
Vibrate or blow the silo regularly to keep the material fluid.
For materials that are easy to adhere, an anti-stick coating can be applied to the inner wall of the silo.

Environmental factors

Dust interference: Powdered materials will generate a lot of dust during loading and unloading. Powdered materials interfere with the signal transmission of optical, ultrasonic and other sensors.

Solution:

Use sensors with dustproof function. Such as radar level meter, capacitive level meter, etc.
Install protective devices on the sensor, such as dust cover, filter, etc. The sensor can be cleaned and maintained regularly.

Temperature change: Extreme temperature change will cause measurement errors.

Solution:

For sensors that are greatly affected by temperature, such as ultrasonic sensors, a temperature compensation device can be installed.
Select sensors with strong adaptability to temperature changes, such as a radar level meter.

Silo structure

Silo shape and size: Silos of different shapes and sizes have requirements for the installation and measurement range of sensors. Circular silos may produce signal reflections, and large silos may cause signal attenuation.

Solution:

Select appropriate sensors and installation locations according to the shape and size of the silo.
For circular silos, special signal processing technology or reflective plates can be used to reduce signal reflections. 3. For large silos, high-power, high-sensitivity sensors can be selected or signal relay devices can be added.

Internal obstacles: Obstacles such as the supporting structure, feed port, and discharge port inside the silo may block the sensor signal or be mistakenly identified as the material surface.

Solution:

When installing the sensor, avoid the influence range of obstacles.
Use sensor technology that can identify and eliminate obstacle interference, such as the false echo recognition function of the radar level meter.
Optimize the internal structure of the silo to reduce the impact of obstacles.

Measurement technology

Signal attenuation: In large silos or when the material dielectric constant is high, the sensor signal may be attenuated.

Solution:

Use high-power, high-sensitivity sensors, add signal amplifiers, repeaters and other equipment,
Optimize the installation position and angle of the sensor to reduce signal attenuation.

Multi-signal interference: When multiple sensors work at the same time or there are other electronic devices around, electromagnetic interference may be generated.

Solution:

The sensor is electromagnetically shielded.
Use sensors and communication protocols with strong anti-interference capabilities.
The installation position and wiring method of the sensor can be reasonably planned to reduce electromagnetic interference.

Maintenance and calibration

Sensor maintenance is difficult: Some sensors are installed on the top or inside the silo, which is inconvenient to maintain and replace.

Solution:

Select sensors that are easy to maintain and replace, and reserve maintenance channels and space.
Use remote monitoring and diagnostic technology to detect sensor failures in time and handle them.

Inaccurate calibration: Due to the characteristics of the materials in the silo and the influence of environmental factors, the calibration of the sensor may be inaccurate.

Solution:

Calibrate the sensor regularly and adjust the calibration parameters in time according to the material characteristics and environmental changes.
Use automatic calibration technology to improve the accuracy and efficiency of calibration.

Applications of Silo Level Measurement

Energy and power industry

Coal industry: used to measure the coal level in coal bunkers, such as raw coal bunkers in coal mines, clean coal bunkers in coal preparation plants, etc., to reasonably arrange production and transportation.

Power industry: In coal-fired power plants, it is used to monitor the material level of coal powder bunkers, lime bunkers, etc., to ensure the stable supply of equipment such as coal feeders, and to ensure the continuity of power generation.

Building materials industry

Cement industry: The raw material silo, cement silo, coal powder silo and slag storage silo of cement plants all need to measure the material level. It can realize the automatic control and optimized management of the production process.

Gypsum board production industry: Monitor the material level of gypsum powder silo, etc. It really improves production efficiency and product quality.

Grain and oil food industry

Grain and oil processing industry: Used to measure the material level of grain silos such as soybeans, corn, and wheat. It realizes inventory warning and automatic control.

Food and beverage industry: The raw material silos and finished product silos of milk powder factories, flour mills and other enterprises all need to measure the material level. It can ensure the continuity of production and product quality.

Chemical industry

Basic chemical industry: In raw material and intermediate silos, reaction tanks, solid silos and separators. It can measure the material level of various chemical raw materials and products, such as plastic particles, fertilizers, soda ash, etc.

Fine chemical industry: The material level of some special chemical raw materials and intermediates, such as catalysts, additives, etc. is measured. It can ensure the precise control of the production process.

Metallurgical industry

Steel industry: used for level measurement of ore silos, ore crushers, raw material silos, auxiliary material silos, blast furnaces, alumina powder silos, etc. It provides accurate data for production scheduling and batching.

Nonferrous metal industry: Level measurement in various ore and raw material warehouses, grinding towers, etc. It ensures smooth production processes and stable product quality.

Paper-making industry

Pulping link: Level monitoring of wood chip yards, chemical material storage silos, etc. It provides accurate raw material supply information for pulping production.

Paper-making link: In raw material silos, storage towers, etc. in paper mills. It measures the level of paper, pulp, etc. to ensure production continuity and quality stability.

Port terminal industry

Bulk cargo terminal: Level measurement of silos for dry bulk cargo such as coal, ore, and grain. It improves storage utilization, reduces material loss, and optimizes cargo loading and unloading and transit processes.

Container terminal: The cargo storage warehouses of some container terminals may also adopt silo structures. It requires material level measurement to optimize inventory management and logistics scheduling.

Our Sino-Inst products can support customization in any industry. If you need, you can contact us at any time. We will provide you with a perfect solution. The following is our customized split radar level meter cases.