Application

Level Measurement and Inventory Control in Chemical Plants

Answer in brief

In a chemical silo the measurement has to survive the filling, the dust and the chemistry.

Ultrasonic measurement fails during pneumatic filling, and a low dielectric powder reflects radar weakly, so the sensor has to match the material.

Match the principle to the dust and the material.
Keep overfill protection independent of the continuous measurement.
Treat inventory as a different question from level.

Reviewed October 21, 2026 · Updated October 21, 2026

The problem

Pneumatic filling fills the headspace with dust, corrosive atmospheres attack sensors, and uneven surfaces make a single-point reading a poor inventory figure.

Desired outcome

A measurement that stays reliable during filling, survives the atmosphere, and an independent protection that prevents overfill.

Process approach

Radar handles dust during filling far better than ultrasonic, with antenna selection adjusted for low dielectric materials.

An independent point level switch provides overfill protection, because a continuous measurement and a safety function should not share a device.

Where inventory accuracy matters commercially, scanning devices map the surface instead of reading one point.

Principle matched to dust conditions and material properties.
Independent high level protection.
Scanning where inventory accuracy is a commercial figure.

Selection factors

Dust density during filling.
Dielectric properties of the powder.
Corrosivity of the silo atmosphere.
Whether the requirement is level or inventory.
Area classification for the sensor.

Common failure modes

Ultrasonic sensor failing during pneumatic filling
Overfill protection taken from the continuous measurement
Low dielectric powder giving a weak radar return
Inventory reported from a single-point reading

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