Country: Sweden | Product: Micropilot FMR57 | Key Configuration: Horn antenna, integrated purge-air connection, HART protocol | Quantity: 1 unit / single point | Delivery: Customized | Application: Wood chip drying silo, heavy dust, condensation, and steam environment, process temperatures up to high range
Market Background
In biomass combined heat and power (CHP) plants, level management in wood chip silos directly impacts boiler feed continuity and power generation efficiency. Excessive levels can cause material blockages, while insufficient levels affect boiler load stability. However, the drying process generates substantial dust, condensate, and steam—challenges that consistently degrade signal quality and create false echoes in level measurement. Conventional ultrasonic level transmitters are nearly inoperable under such conditions, while frequent manual inspection and maintenance incur prohibitive operational costs.
Customer and Application Scenario
Borås Energi och Miljö operates a biomass silo at the Ryaverket CHP plant in Sweden, used for temporary storage of dried wood chips before they are fed into the boiler. The silo environment is extremely harsh: the drying process continuously releases dust, condensate, and steam. The material surface is irregular with an angle of repose, and internal structural components generate interfering reflections.
The customer had previously attempted to replace an old unit with a low-cost ultrasonic level transmitter. After installation, it failed entirely to deliver usable level readings. The operations team was forced to invest substantial man-hours in on-site monitoring and maintenance. What initially appeared to be the "most cost-effective solution" ultimately resulted in exorbitant hidden costs.
Our Solution
For this application, the Micropilot FMR57 free-space radar level transmitter was recommended. Key selection criteria included:
The FMR57's core specifications support its reliability in such applications: measurement accuracy ±3 mm, process temperature range –40 to +400°C, process pressure range –1 to +16 bar. Radar measurement is inherently far less sensitive to dust, condensation, and steam than ultrasonic technology, where sound waves are absorbed or scattered in humid, dusty environments.
Key Technical Specifications
Customer Feedback
Merit Österberg, Sales Engineer at Endress+Hauser, commented: "Radar is not sensitive to dust, condensation, or steam—unlike ultrasonic. We selected our Micropilot FMR57 for this application. The device was sold with startup services. After our service technician performed the commissioning on-site, they haven't needed to touch the instrument—everything has worked perfectly from day one."
Thomas Sandman, Electrical Installation Manager at Dalkia (operating partner for Borås Energi och Miljö), added: "We've had this sensor installed for about a year now and it has performed perfectly throughout. It sends a signal to a PLC and the overall system, giving us full control over the silo level at all times."
Summary
From "completely inoperable" with an ultrasonic unit to "flawless operation" with the FMR57, this case demonstrates the core value of radar technology in challenging bulk solids applications. The FMR57 delivers 70 m range, ±3 mm accuracy, and –40 to +400°C wide process capability as its hardware foundation, complemented by Multi-Echo Tracking interference rejection and an integrated purge-air connection—effectively solving level measurement challenges in heavy dust, condensation, and steam environments.
For high-dust silos in biomass power generation, cement, mining, and similar industries, prioritise non-contact radar solutions with antenna purge capability and multi-echo tracking algorithms. These two configuration choices will have the greatest impact on long-term operational reliability and maintenance costs.
Your message must be between 20-3,000 characters!
