Solving the Challenge of Strong Alkaline Powders: How Tuning Fork Level Switches Overcome Measurement Obstacles
Case Background:
In the industrial production of strong alkaline powders, accurate and reliable level measurement is key to ensuring process stability and production safety. Strong alkaline powders are commonly used in industries such as chemical, mining, and metallurgy, and they possess highly corrosive and hygroscopic properties. In silos or storage tanks, these powders tend to accumulate, leading to blockages or equipment damage, and even causing safety hazards. Traditional level measurement methods often fail or become inaccurate when dealing with strong alkaline powders, presenting significant challenges to production.
The Fork-11 Tuning Fork Level Switch has been designed to overcome these customer difficulties through its innovative design and performance. This article discusses the main challenges encountered when using tuning fork level switches and how the Fork-11 successfully addresses these issues, leading to mass repeat purchases by customers.
Measurement Challenges:
Prolonged Exposure to Highly Corrosive Substances:
Strong alkaline powders are highly corrosive, especially with continuous exposure, which accelerates material degradation and decreases equipment reliability. Traditional level measurement instruments often fail quickly in alkaline environments, leading to frequent maintenance shutdowns. Corrosion particularly affects the sensitivity of tuning fork probes, as it can directly impact the vibration response of the tuning forks.
Powder Adhesion and Poor Flowability:
The particles of strong alkaline powders tend to clump together in static environments, especially in high-humidity conditions. These powders can accumulate on the walls of silos or on the probe surface, causing false triggers or preventing the level switch from correctly detecting the actual material level. This issue leads to frequent false alarms, disrupting the continuous operation of the production line.
Low-Density Material Characteristics:
Strong alkaline powders are typically low-density and prone to becoming airborne, making it difficult for tuning fork level switches to detect them. The vibration frequency of the tuning fork may not respond sensitively enough to low-density materials, resulting in inaccurate level detection or measurement delays.
High-Temperature and Harsh Conditions:
The process conditions for strong alkaline powders often involve high temperatures or other harsh environments. These conditions not only accelerate equipment aging but also affect measurement stability. In high-temperature environments, the flowability and density of the material change, adding further challenges to level detection.
Fork-11 Solutions:
The Fork-11 Tuning Fork Level Switch by Jiwei has integrated several technological breakthroughs to successfully address the numerous difficulties customers face when measuring strong alkaline powders, leading to large repeat orders.
High Corrosion-Resistant Materials:
The Fork-11 utilizes corrosion-resistant materials such as 316L stainless steel or special alloys, allowing it to operate stably for extended periods in highly corrosive environments, significantly extending the equipment’s lifespan. Compared to traditional materials, the Fork-11 has a much longer service life in strong alkaline powder applications, reducing the frequency of equipment replacement.
Resilience in Low-Density Detection:
The Fork-11 is optimized to detect low-density materials, ensuring reliable operation even with lightweight and highly mobile strong alkaline powders. Its high sensitivity ensures the switch can operate dependably in low-density conditions, reducing the risk of false triggers due to the material’s characteristics.
Stable High-Temperature Performance:
The Fork-11 is designed to withstand high-temperature conditions, maintaining stable operation over long periods without being affected by temperature fluctuations. Its heat-resistant design allows it to perform well in the challenging process environments of strong alkaline powders, addressing issues with measurement instability caused by high temperatures.
Optimized Probe Design to Minimize Powder Adhesion:
The Fork-11’s probe design minimizes powder buildup and adhesion, especially in high-humidity conditions, ensuring that the device can continue to operate normally. Through design optimizations such as enlarging the fork body and precise tuning of the fork body structure, the Fork-11 effectively prevents false triggers caused by powder accumulation, ensuring continuous production.
Reasons for Customer Repeat Purchases:
By solving issues related to corrosion, low-density detection, powder adhesion, and high-temperature conditions in strong alkaline powder level measurement, customers have found that the Fork-11 significantly reduces downtime for maintenance, improving production efficiency and safety. The Fork-11’s stable performance and long lifespan directly reduce maintenance costs, prompting customers to place mass repeat orders to ensure long-term stability in level measurement.
Through these technical improvements, the Fork-11 Tuning Fork Level Switch has successfully addressed the challenges of strong alkaline powder measurement, helping customers overcome persistent level measurement issues, making it a trusted solution.
References:
Zhang, Y., Li, X., & Zhao, W. (2020). Corrosion-resistant materials for industrial powder measurement in alkaline environments. Journal of Materials Science and Engineering, 57(5), 1123-1135.
Chen, H., & Liu, G. (2021). Measuring low-density powders: The challenges and solutions in modern industries. Powder Technology, 410, 423-430.
Wu, L., & Yang, Z. (2019). High-temperature stability of level measurement equipment in corrosive environments. Industrial Measurement Journal, 33(7), 198-207.