UWT Sensor Technology Ensures Process Reliability in Zinc Processing

Robust level measurement ensures stable operation with abrasive and explosion-prone materials

In industrial production, zinc remains one of the most important non-ferrous metals. It plays a vital role in corrosion protection, alloy manufacturing, battery production and pharmaceutical applications. Approximately half of global zinc output is used to protect steel and other metals against corrosion, underlining its importance across a wide range of UK and international industries.

During processing, zinc is often handled in powdered or granular form. These materials are highly abrasive, extremely dusty and present significant challenges for level measurement technology. Continuous material movement combined with fine particle sizes places intense mechanical stress on sensors, seals and moving components.

In addition to mechanical wear, fine zinc dust can form potentially explosive atmospheres. This makes reliable level measurement not only a matter of operational efficiency but also of safety and regulatory compliance. Measurement solutions must therefore deliver long-term stability while meeting stringent ATEX and functional safety requirements for use in hazardous environments.

The Challenge: Excessive Wear Caused by Fine Zinc Powder

A zinc processing company operating a continuous production system was experiencing repeated failures of its existing level sensors. The fine and abrasive zinc powder led to accelerated wear on seals and mechanical components, causing sensors to fail prematurely.

As a result, the plant faced frequent maintenance interventions, unplanned shutdowns and increasing operating costs. These disruptions affected overall process reliability and placed additional strain on maintenance teams in an already demanding 24/7 production environment.

To overcome these challenges, the company required a low-maintenance and robust level measurement solution capable of withstanding abrasive materials while operating reliably in dusty and potentially explosive conditions. The objective was to improve plant availability, reduce lifecycle costs and ensure safe operation over the long term.

The Solution: UWT Level Limit Sensors for Abrasive Applications

Following a detailed assessment and close collaboration with the local UWT technical team, the plant operator selected two proven sensor solutions for limit level detection: the Vibranivo® VN 4020 and the Rotonivo® RN 6001.

Both sensors were installed at key points throughout the system to ensure reliable monitoring of material levels and prevent overfilling.

The Vibranivo® VN 4020 is a compact vibration level switch featuring a short stainless steel probe extension. Its robust construction and absence of moving parts make it particularly resistant to mechanical stress. This design is well suited to fine and abrasive bulk solids such as zinc powder, where durability and measurement stability are essential.

The Rotonivo® RN 6001 operates as a rotary paddle switch and delivers reliable performance across almost all types of bulk materials. With pressure-resistant versions, optional explosion protection and SIL2 certification, it is designed for safety-critical processes. Its proven mechanical design ensures dependable operation even under high material loads and in challenging process conditions.

Both sensors were installed vertically at the top of silos and used as full detectors. This positioning protects them from direct material impact while allowing straightforward integration into existing process connections, reducing installation complexity and downtime.

Operational Results: Improved Stability, Safety and Reduced Maintenance

The transition to UWT sensor technology delivered measurable improvements in plant performance and reliability.

Reliability: Sensor failures caused by abrasive zinc powder were eliminated. Both devices continue to operate accurately and consistently even in high dust concentrations.

Robustness: Stainless steel construction and proven mechanical designs provide long-term resistance to wear and high material stress.

Safety: The sensors comply with requirements for use in explosive atmospheres, supporting safe zinc processing and improved overall plant safety.

Low Maintenance: The absence of sensor-related downtime has reduced maintenance effort, minimised service interventions and lowered total operating costs.

Result: Higher Process Safety and Lower Operating Costs

The combined use of vibration and rotary paddle level measurement has proven highly effective in this zinc processing application. Overfilling is reliably prevented while precise signal output ensures stable and controlled material flow throughout the process.

The operator’s conclusion is clear and reflects the operational benefits achieved:

“Since installing the UWT sensors, the system has been running without any disruptions. Maintenance requirements have dropped significantly – a real relief for our operations.”

This application highlights how robust level measurement solutions from UWT can make a decisive contribution to process safety and operational efficiency. Even in environments characterised by abrasive materials, high dust levels and strict safety requirements, reliable sensor technology plays a crucial role in maintaining continuous and cost-effective production.

UWT GmbH
Westendstr.5
87488 Betzigau, Germany
info@uwtgroup.com
www.uwtgroup.com