Ore and Coke Bin Level Measurement in Steel Plants

Ore, sinter, flux and coke bins expose level instruments to impact, abrasion, heavy dust, vibration and temperature changes. Their surfaces are uneven and their flow can bridge or rat-hole. A continuous radar trend is valuable for operations, but installation and alarm logic must reflect material movement and the mechanical limits of the bin.

Separate materials and duties

Record each material's lump size, fines, moisture, bulk density, temperature, dielectric behaviour and angle of repose. Coke is lighter and more irregular than dense ore; wet fines may adhere and bridge. Do not use one generic solids setting across all bins without evidence.

Define refill control, inventory trend, low-level feeder protection, high-level conveyor stop and blockage detection separately. Assign independent evidence where a wrong decision can damage equipment or interrupt production.

Map the harsh mechanical zone

Show conveyor discharge, deflectors, liners, grizzlies, gates and outlet geometry. Keep the antenna and bracket outside direct falling material and rebound trajectories. A roof position that appears protected when empty may be struck by a high pile.

Check vibration, thermal expansion and structural movement. The mount must remain aligned and allow safe access without placing personnel over an open or unstable burden.

Select beam and signal margin

Plot the full beam against steelwork and expected pile slopes. A narrow beam can improve selectivity between structures but may track a local peak or valley. Confirm antenna aperture and range for the weakest credible material return.

Dust and deposits can reduce margin. Avoid long narrow nozzles, provide required antenna projection and retain raw echo diagnostics. Do not mask broad regions merely to make the display stable.

Account for heat and abrasion

Verify process and ambient temperature separately, including radiant heat, hot fills and shutdown cycles. Use approved thermal extensions or shielding without trapping heat around electronics. Confirm gasket, seal and cable temperature limits.

Non-contact measurement reduces wear, but antenna face, flange and bracket can still receive abrasive dust or impact. Establish inspection criteria for erosion, loose fasteners and damaged protection.

Design realistic alarms

High-level stopping must include sensing delay, damping, PLC response, conveyor stopping distance and material already in chutes. The highest local pile may reach the roof before an average-level calculation indicates full.

A low reading does not prove the outlet is flowing. Combine level with feeder current, belt scale, gate status or chute monitoring where bridging and starvation must be detected.

Commission and preserve evidence

Capture echo curves during filling, settling and discharge for each material. Verify local value, PLC scaling, alarms and diagnostic status. Record conveyor route and material type with each test.

Inspect after early production cycles for alignment, impact and deposits. Retain accepted parameters and photographs so changes in liners, conveyors or product mix trigger a focused reassessment. Record the as-found condition before cleaning; otherwise maintenance history cannot show whether the interval is controlling wear and buildup.

Engineering checklist

Characterize ore, coke and fines separately.
Keep hardware outside impact and rebound zones.
Plot the beam against steelwork and pile slopes.
Check radiant heat, vibration and abrasion.
Include conveyor stopping and material in transit.
Use flow evidence for blockage and starvation.

Frequently asked questions

Can the same setup be copied from an ore bin to a coke bin?

Not without review; density, pile geometry, reflection and dust behaviour differ.

Does non-contact radar eliminate abrasion risk?

It removes a submerged probe but exposed mounting and antenna components can still be damaged.

Why can a high alarm be late?

Filtering, local pile shape, conveyor stopping time and material already in transit all add to the final level.

Need a project-specific review? Send process data, drawings, photographs and acceptance criteria through our contact page.