Ceramic Slurry and Glaze Tank Level Measurement

Ceramic body slip and glaze tanks contain abrasive solids, pigments and binders that can coat probes and nearby surfaces. Agitation keeps solids suspended but creates vortices, splashing and foam. Non-contact radar can reduce wetted contamination and wear, provided the antenna has a clear view and the installation remains cleanable.

Define the product range

Record solids concentration, density, viscosity, conductivity, dielectric behaviour, particle size, temperature and additives. Include different glaze colours, body recipes, recycled material, water flushes and cleaning chemicals. The easiest water condition is not a valid substitute for the highest-solids recipe.

Specify whether the duty is mixer protection, pump control, batch volume, high alarm or low usable inventory. Each requires different response and reference evidence.

Choose a representative surface

Map mixer shaft, blades, baffles, returns, powder addition and transfer inlets. Avoid the vortex centre, direct splash and falling material. A wall position can suffer heavy deposits or surface climbing, so confirm the location during real mixing.

If the process is measured only after settling, document the delay and control consequences. If live control is required, verify the radar at every normal agitator speed.

Prevent nozzle and antenna buildup

A narrow recessed nozzle can fill with dried slurry or glaze and create a dominant near-field echo. Follow antenna projection and beam-clearance requirements. Provide a cleanable connection with safe access and no unapproved shield inside the beam.

Review condensation and spray. Any air purge or rinse must be compatible with product quality, pressure, hazardous requirements and cleaning validation.

Control contamination and materials

Confirm process-facing antenna, flange and gasket materials against pigments, binders and cleaning media. Non-contact does not mean no exposure: splash and vapour reach the connection. Avoid materials or lubricants that could contaminate a batch.

Record inspection and cleaning as part of recipe changeover where required. A previously used probe or poorly drained nozzle can carry colour or composition into the next product.

Handle foam and invalid signals

Define whether foam top or liquid-slurry surface is required. Foam changes with surfactants, agitation and air entrainment. Save echo curves under representative recipes and configure lost-target quality indication.

Set damping to control normal turbulence without hiding a rapid rise or delayed pump response. Verify that the PLC identifies held or failed values instead of treating them as current measurements.

Commission and maintain

Compare level with an appropriate independent reference at low, normal and high points. Verify output, PLC scaling, HMI, alarms and batch calculations. Record recipe, density and mixer speed for each test.

Inspect after early production and cleaning cycles for dried coating and bracket movement. Use detailed as-found evidence and signal trends to define cleaning intervals. Recheck after the most adhesive glaze and after the full cleaning sequence, because a clean-water test cannot prove that dried pigment or binder will not create a persistent false target. Document any recipe for which the signal is restricted or requires a settling delay. Retain the cleaning evidence.

Engineering checklist

• Test the full solids and recipe range.
• Map mixer, vortex, inlets and baffles.
• Keep the antenna projected and cleanable.
• Verify contamination and material compatibility.
• Define foam target and invalid-signal status.
• Commission at required mixer speeds.

Frequently asked questions

Can clean water be used for final acceptance?

It can verify part of the signal chain, but representative slurry or glaze is needed to prove process performance.

Why avoid the vortex centre?

Its depressed and unstable surface may not represent vessel inventory.

Does non-contact radar need cleaning?

It may; splash, condensation and dried deposits can still coat the antenna or nozzle.

Related measurement solutions

80 GHz radar level meters · 26 GHz radar level meters