This document provides information on various flow measurement devices from SWR engineering Messtechnik GmbH. It describes their SolidFlow, MaxxFlow, DensFlow, PicoFlow, SpeedFlow, FlowJam, FlowJam Plus, FlowJam A, SlideControl and Paddy devices. For each device it provides details on measuring capabilities, installation, applications and industries where they can be used such as incineration, food/pharma, cement, steel, carbon black and grain. It emphasizes that the devices can measure solids flow in various transport applications including pneumatic, free fall, and dilute and dense phase.

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How to measure solids flow?
How to measure bulk solids mass flow?
How to measure flow of bulk solids?

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SolidFlow
Measurement of solids in diluted phase in free fall and
pneumatic transported applications

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 Applicable to quantities approx. up to 20 t/h
 In pneumatic or in free fall transport
 4...20mA-Signal
 Accuracy +/-2...5%
 All materials measurable
 Easy installation / easy retrofit
SolidFlow - Features

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SolidFlow - Installation

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Installation in a pneumatic transport Free fall installation
SolidFlow - Applications

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 Material: Spice
 Freefall after screw feeder
 Quantity: approx. 14 kg/h
 Diameter: DN50
SolidFlow - Applications

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 Material: Cement
 Freefall after screw feeder
 Quantity: approx. 12 t/h
 Diameter: DN200
SolidFlow - Applications

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 Material: Limestone
 Quantity: ca. 1,8 t/h
 Vertical pneumatic pipe
(waste incinerator plant)
SolidFlow - Applications

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 Quantity: approx. 5 t/h
 Pneumatic transport from silo to mill
 Material: coal dust
SolidFlow - Applications

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MaxxFlow
Continuous mass flow measurement independent of pipe installation

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 Measuring range: 10…300 t/h
 Arbitrary mounting position (inclined / free fall)
 No intrusive parts into the cross-section
 Independent from the material velocity
 Headroom: max. 330 mm
 Accuracy: +/-3 %
 Temperature up to 120°C
 No danger because of abrasions
 Works with 3% to 50% of filling in the pipe
 High mechanical stability Throughput (kg/s or t/h) calculated by:
Density (kg/m³) x Velocity (m/s) x Cross-Sectional Area (m²)
MaxxFlow - Features

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After bucket elevatorAfter screw feeder After slides
MaxxFlow - Installation

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 Quantity: approx. 150 t/h
 Material: potash salt
 Impact weigher replacement
MaxxFlow - Applications

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MaxxFlow - The substitute for impact-plate-systems
What is the drawback of
impact-plate-systems?
 Accuracy is mostly not sufficient
 Mechanical parts in process
 Big headroom necessary
 Not dust proof
 Difficult calibration

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MaxxFlow - Calibration
 Reference per drop test ?
NOT ANYMORE !
Only 10 litters of material needed for
calibration.
Conditions:
Knife gate below the sensor
Material inlet above the sensor

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 Quantity: 80…200 t/h
 Material: Cement
 Mill optimization 3 Systems in total
 Impact weigher replacement
MaxxFlow - Applications

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 Quantity: 50…100 t/h
 Material: cement
 Mill optimization
MaxxFlow - Applications

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MaxxFlow - Applications
 Range: 70 up to 130 t/h
 Raw meal
 DN 200
 after air conveyor
 Impact weigher replacement

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Defining MaxxFlow
3%
To ensure greater process safety we only recommend the MaxxFlow
for maximum concentration amounts of 50% pipe section
The sensor shall operate with the maximum recommendable
concentration of material inside the tube
Information to define MaxxFlow
50%
Concentration
Not possible to change
Possible to change

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DensFlow
Continuous solids mass flow measurement for dense-phase

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Pneumatic Dens phase Conveying
DensFlow - Applications

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DensFlow - Applications
 99% in blast furnace
 applications (coal measurement)

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the
PicoFlow
Mass flow detection in thin stream applications

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PicoFlow - Installation

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PicoFlow - Applications

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SpeedFlow
Speed measurement for solids

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Animal food
 Flow: 300 ... 400 kg / h
 Range: 10 a 12 m/s
 Product: ingredients
 Control speed of the
material to guarantee right
particle size
SpeedFlow - Applications

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FlowJam
A device which is telling you if there is material in motion or not
Principle = Microwave
Utilization of the Doppler Effect

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 Detection through every non-conductive
material (build up)
 Easy installation with 1 ½“- fitting
 Only a relay-switch
 Easy isolation to high temperature and high
pressure with adapter
 High sensitivity version available
max. pressure: 20 bar
max. temperature: 200°C (optional 700°)
FlowJam - Features

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 Smaller sensor (only 8 cm)
 Sensor and electronic are separated
 Applicable in Ex-zones (only with adapter)
FlowJam ATEX
FlowJam S - Features

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FlowJam - Installation
e.g. monitoring of mixing processes e.g. detection in pneumatic pipes

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Monitoring of cyclone-outlets
in a sugar plant
Detection of wood chips after a rotary valve
FlowJam - Applications

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Detection of coal in every single lance in
a steel plant in Austria
Coal detection in every single lance in a
steel plant
FlowJam - Applications

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FlowJam - Applications
Flow detection of cement
after air chutes
Flow detection of material over conveyor belts

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Detection in a cyclone (600 °C)
(Cement plant)
FlowJam - Application

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The new FlowJam Plus supplies 2 relay signals:
 Flow / no flow (like all the rest of the providers)
 Full / empty - while the no flow-signal
(non of the other providers can offer this)
Link to
the
FlowJam Plus - Features

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FlowJam A
Material flow monitoring for hose lines

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FlowJam A - Features
FlowJam A detects streams of solids of all types flowing at
a minimum speed of 0.1 m/s through the detection area.
The detection is independent of the direction of flow
through the Doppler effect evaluation system.
The flow of material through non-metallic pipelines is
displayed by two switching states on the output relay.
The sensor differentiates between the two switching
states:
• Material flow
• Material blockage or standstill.

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SlideControl
Trend monitoring in air slides

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SlideControl detects the variation of the
distance between moving material
surface and sensor.
System
SlideControl - Installation

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SlideControl - Applications

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Paddy
Screen Break Detection

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Screen in normal conditions After screen break, some
particles start passing through
Paddy - Function

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 Maximum flow: 20 t/h
 Oversize flow must be 10% of total flow (mass %)
System FFT spectral
analysis
Results
Paddy – How it works?

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Vibration
screen
Detection of which
screen is broken
Paddy - Applications

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....generally all branches where we find solid materials
Industries
Incineration Food and Pharma Cement
Steel Carbon Black Grain

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Incineration
1. Point level detection in charging chute
2. Mass flow measurement of absorbent
3. Flow/NoFlow detection at cyclone outlet
4. Ash level detection at filter outlets
5. Flow detection at ash transportation system
6. Continuous level measurement in storage silos
7. Individual chamber baghouse performance
monitoring
8. Predictive bag filter row monitoring
9. Process gas monitoring
10. Mainstack compliance gas, dust and flow
measurement
11. Potential hazards measurements

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Food and Pharma
1. Mass flow measurement out of spray dryer
2. Continuous moisture measurement in
fluidized-bed dryer
3. Mass flow measurement for inline blending
4. Flow/NoFlow detection in return powder lines
5. Primary filter performance monitoring
6. Compliance dust measurement stroke trending
7. Ambient dust monitoring
8. Potential hazards measurement

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Cement
1. Continuous mass flow measurement of mill
reject
2. Flow trending in air slide
3. Flow/NoFlow detection on cyclones
4. Process gas monitoring
5. Mass flow and velocity measurement of coal
into kiln
6. Continuous moisture measurement of
secondary fuel
7. Individual chamber baghouse performance
monitoring
8. Predictive bag filter row monitoring
9. Silo baghouse performance monitoring
10. Continuous level measurement in storage silos
11. Mainstack emissions compliance gas, dust and
flow measurement
12. Potential hazards measurement

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Steel
1. Mass flow measurement of pulverized coal into
blast furnace
2. Flow/No Flow detection in single coal lance
3. Continuous moisture measurement of coal
4. Continuous flow measurement of sinter dust
5. Level detection in storage silos
6. Silo baghouse performance monitoring
7. Individual chamber baghouse performance
8. Monitoring electro-flter efficiency
9. Process gas monitoring
10. Mainstack emissions compliance gas, dust and
flow measurement
11. Potential hazards measurements

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Carbon black
1. Flow/No Flow detection at filter outlets
2. Flow measurement after pelletizer
3. Continuous moisture measurement after dryer
4. Process gas monitoring
5. Predictive monitoring of bag row failure
6. Final stack emissions for compliance and
performance monitoring
7. Emissions compliance monitoring
8. Potential hazards detection

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Grain
1. Flow measurement after intake and cleaning
2. Flow/No Flow detection of flow into roller mills
3. Continuous moisture measurement after
conditioning
4. Screen break detection
5. Continuous level measurement in storage silos
6. Silo baghouse performance monitoring
7. Stroke filter performance
8. Ambient dust monitoring
9. Compliance dust emission measurement

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SWR engineering
Messtechnik GmbH
Gutedelstraße 31
79418 Schliengen
+49 (0) 7635 827248-10
info.swr@envea.global
Contact

54. PART OF THEENVEAGROUPOur company Products Industries Contact

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