Solid Flow Meter SolidFlow 2.0

Description

SolidFlow 2.0 is a microwave-based sensor for continuous, online measurement of mass flow rates of bulk solids (dust, powders, granules from 1 µm to 10 mm) in metallic pipelines, with a maximum capacity of up to 20 t/h. It is specifically designed for dilute-phase pneumatic conveying or free-fall applications after mechanical feeders (screw conveyors, belt weighers). The sensor is installed through a welded stub without intruding into the material flow and is compatible with pipe diameters up to 800 mm. It is ATEX-certified for explosive atmospheres (DustEx Zone 20 inside, GasEx Zone 1), handles pressures up to 1 bar (optional 10 bar) and temperatures up to +200 °C (optional +900 °C), with accuracy ±2–5 % in the calibrated range. Outputs: 4–20 mA, Modbus RTU, pulse, relay; compact design (sensor Ø 60 mm, length 271 mm, weight 1.3 kg).

Operating Principle

The sensor generates a low-power microwave field in the K-band (24.125 GHz ±100 MHz, 5 mW) inside the metallic pipe. Moving particles reflect the signal, and the system analyses both the frequency and amplitude of the reflected waves, effectively acting as a particle counter (number of particles per unit time). Signals from deposits are actively filtered out – only moving particles are evaluated. Active compensation for roping (stream formation) and stratification (layering) ensures reliable measurement even in inhomogeneous flows. Calibration is performed in-process by comparing raw values with a reference flow; the signal is converted into a frequency spectrum to detect flow patterns.

Main Application Areas

• Pneumatic conveying: monitoring fuel dust (coal, biomass) injection into combustion chambers for precise and uniform distribution, preventing imbalances.

• Free-fall: measuring actual flow of dosed additives (e.g., iron(II) sulphate) after belt weighers to ensure consistent product quality.

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

Advantages of SolidFlow 2.0

• Reliability in challenging conditions: active roping and stratification compensation for accurate results in non-homogeneous flows; immune to wear, deposits and abrasion; full ATEX certification for hazardous areas.

• Installation flexibility: simple retrofit via welded stub with no flow interruption; works with any pipe diameter up to 800 mm; minimal drop height of 300 mm; multiple sensors possible for large pipes (>200 mm).

• Accuracy & versatility: ±2–5 % accuracy, independent of material type (dust/powder/granules); true online measurement up to 20 t/h; easy menu-guided calibration (German/English/French).

• Technical benefits: completely contact-free, no moving parts; IP65 (sensor), IP40 (DIN-rail transmitter); real-time interfaces (4–20 mA, Modbus, pulse); low power consumption (20 W); service life >10 years; minimal installation and maintenance costs.

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.