Solid Material Flow Detector FlowJam

General Description FlowJam is a non-contact microwave sensor for continuous monitoring of bulk solids flow (dust, powders, granules) in pipelines and containers, detecting material flow / no-flow conditions and blockages. It uses the Doppler effect to detect moving particles without physical contact and can “see” through non-conductive walls (up to 1200 mm line diameter). The system is extremely compact – sensor and evaluation electronics are integrated in a single housing – with relay output for alarm signalling. Variants include standard housing and short versions with adapters for high temperature/pressure. Key specifications: 24.125 GHz frequency, 5 mW radiated power, IP65, 24 V AC/DC supply, process temperature up to +1000 °C (with ceramic adapter).

Operating Principle

The sensor transmits a low-power microwave signal (24.125 GHz ±100 MHz, 5 mW). When moving particles reflect the signal, the Doppler shift is evaluated to detect motion. The device reliably distinguishes between material flow, blockage, standstill and empty pipe. Sensitivity and response delay (250 ms to 15 s) are adjusted directly on the unit. A relay provides switching signals. The sensor is insensitive to material build-up on the antenna window, works through any non-conductive material and has no separate evaluation electronics or moving parts.

Main Application Areas

• Cement plants: monitoring raw meal cyclones to prevent blockages (up to 50 t/h, temperatures up to 600 °C).

• Gypsum plants: discharge monitoring of screw conveyors for continuous flow assurance.

• Steel mills: blockage detection in pulverised coal injection lines for blast furnaces with automatic stop and cleaning (nitrogen purge).

• Industries: steel, food & feed, biomass, cement, chemicals, coal-fired power plants, coating, waste incineration, minerals, wood processing, lime, power generation, gypsum, foundries.

• Typical uses: pneumatic and screw conveying, gravity lines for dust/powder/granules.

Advantages of FlowJam

• True non-contact & highly robust: operates through the wall, unaffected by deposits, abrasion or aggressive conditions; detects through any non-conductive material (up to 1200 mm).

• Unlimited flexibility: no limitation on line diameter or flow rate; adjustable sensitivity levels and delay times; ultra-compact design (216 mm length, 1 kg) with integrated electronics.

• Extreme process conditions: up to +1000 °C (ceramic adapter), up to 40 bar (pressure adapters); IP65 protection; relay contacts up to 250 VA.

• Easy installation & zero maintenance: mounting via G 1½" thread, DN40 flange or clamp; adapters available (POM for pressure, Tecapeek for temperature, ceramic for extreme conditions); no periodic maintenance required, simple on-site parameterisation.

About ENVEA

ENVEA is a global leader in environmental monitoring with more than 45 years of history, founded in France. The company focuses on precise solutions for emissions measurement, pollution reduction and process optimisation, with a mission to create a sustainable future through innovation and expert consulting. It employs 1,200 people across more than 10 countries (USA, Germany, UK, China, India, etc.) and generated revenue >€100 million (2021). Certified ISO 9001/14001. Its activities cover ambient air quality monitoring, stack emissions (gases, dust, dioxins, mercury), bulk solids process optimisation, laser analysis and microsensors; serving industries such as power generation, metallurgy, chemicals, and oil & gas to ensure regulatory compliance and environmental efficiency.