Ethanol Plant Gets 3D Level Scanner for Reliable Measurement

The plant had been using guided wave radar—a single-point measurement technology—in a very large bin with uneven material surface topography. Using just a single measurement was not providing an adequate level of accuracy, as the level of the material varied significantly in different areas of the bin. Also, the sensing cables on the guided wave radar repeatedly broke, which made measurements impossible and caused operations to shut down until the cable could be recovered from the material contents, then replaced.

Solution: BinMaster`s 3DLevelScanner

The MV model of the 3DLevelScanner was mounted on a 150 ft. tall, 75 ft. diameter concrete silo containing whole corn. The silo offsets fill with multiple discharge sites in a very dusty and noisy application.

The device was optimized to track during a rapid and extremely dusty filling cycles with the advanced parameters of 3D Level Manager software. With multiple discharge sites and empty rates up to 150 tons per hour, the 3DLevelScanner was able to provide far more accurate volume readings than the single-point guided wave radar device.

After the success of the first unit, the customer purchased three additional units for its other large silos.

Benefits of the 3D Solids Scanner for Ethanol Applications

The 3DLevelScanner was able to meet the challenge of the dusty environment and was optimized to track during the filling and emptying processes. The low-frequency acoustic waves were able to penetrate the dust generated during fill.

By using the MV model, which takes multiple measurements within a 70° beam angle, accuracy of inventory was improved significantly. This enabled the plant to optimize filling and emptying schedules, as well as railcar traffic.

The non-contact device eliminated the risk of breaking cables, preventing work stoppages while providing plant personnel inventory measurement current data.

Large Silos Require the 3DLevelScanner for Multi-Point Measurement

Corn Storage

Corn is delivered by trucks or rail to the plant where it is analyzed, unloaded, and pre-cleaned. The product is then conveyed into large storage silos, generally designed to supply the plant for seven to ten days. The large size of the silos makes it problematic for conventional single-point instrumentation to accurately measure the volume of stored material.

Additionally, corn storage silos may have multiple fills or discharge points, which creates uneven surface topography and may deem a single point of measurement unreliable. It`s essential to know what`s within the silo to be able to closely monitor inventory levels, support lean replenishment, and ensure an ongoing production process. 

The BinMaster 3DLevelScanner system overcomes this problem. Accurately measuring the amount of grain in the silos in real-time is important, giving plant managers an understanding of how much grain was used in the manufacturing of ethanol. This allows them to better calculate the cost of goods sold and profitability of the plant.

Dried Distillers Grains (DDGS)

Wet distillers grains are often sent through a drying system to remove moisture and extend shelf life. The resulting dried distillers grain with solubles (DDGS) is commonly used as a high-protein ingredient in cattle, swine, poultry, and fish diets.

DDGS is removed from the production process by conveyor to an adjacent dedicated DDGS storage area. The DDGS is stored in huge silos, warehouses, or open bins. The material—which contains about 10% fat and corn oil—is sticky and can settle irregularly within the storage vessel. This uneven topography presents a problem for end users trying to assess accurate inventory levels. 

BinMaster’s 3DLevelScanner system solves this problem by measuring multiple points, providing a highly accurate volume reading and an optional visual profile of the material in the silo, warehouse, or open bin