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Innovative Solutions for Kaolin Processing: The Role of NIVELCO's EasyTREK Ultrasonic Transmitter

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Introduction:

Kaolinite, commonly known as kaolin or china clay, is a versatile silicate clay mineral widely used in various industries. From paper production to medical applications, and from ceramics to cosmetics, kaolin plays a crucial role due to its unique properties. One of the leading producers of kaolin in the South-eastern USA faced significant challenges in their processing plant, leading them to seek a more reliable solution for monitoring slurry levels in their filter vats.


Challenges Faced:

The kaolin producer experienced frequent failures of their existing ultrasonic level transmitters. These failures were primarily due to:


Moisture from the warm slurry vapours: The humid environment created by the slurry vapours caused the existing transmitters to malfunction.

Tight dimensions of the filter vats: The confined space within the vats made it difficult for the transmitters to function effectively.

Dusty environment from the kaolin clay: The powdery nature of kaolin clay created a dusty environment that further contributed to the failures of the transmitters.

Solution by NIVELCO:

Seeking a cost-effective and reliable ultrasonic transmitter, the kaolin producer approached NIVELCO USA. NIVELCO recommended the EasyTREK model SPA-38N-4, which boasts a rugged, remote mount, IP68 design, and a highly focused beam angle, making it ideal for challenging environments.


Key Features of EasyTREK:


Rugged and Remote Mount Design: The IP68-rated design ensures durability and reliability in harsh conditions, protecting the transmitter from moisture and dust.

Highly Focused Beam Angle: This feature allows precise level measurement even in tight and confined spaces, addressing the issue of the vats' dimensions.

Ease of Configuration: The EasyTREK transmitter can be easily configured using the UNICOMM SAT-304-0 HART-USB modem and EView2 software. This user-friendly setup enables quick installation and configuration, saving time and reducing operational downtime.

Trial and Results:

The EasyTREK transmitter was installed on a trial basis, and it successfully addressed all the issues:


Performance: The trial unit performed without any problems or issues, demonstrating its reliability and suitability for the application.


Customer Satisfaction: Impressed by the performance, the customer placed orders for additional EasyTREK units to replace all existing transmitters in their plant. They also requested to stock this model for quick delivery for future orders.


Configuration Benefits: The ease of configuration and the ability to save and transfer configuration files to other EasyTREK transmitters streamlined the setup process, making it a popular choice for the customer.


Applications of Kaolin:

Kaolin is utilized in a variety of industries due to its unique properties:


Paper Production: Kaolin is used to produce glossy paper grades.

Medical Applications: It is added to gauze to promote blood clotting.

Ceramics and Porcelain: Used in the manufacture of fine ceramics.

Cosmetics and Skin Creams: Incorporated into products for its soothing properties.

Paint and Insecticide Sprays: Used as a filler and extender.

Water and Wastewater Treatment: Helps in the purification processes.

Cement Additive: Enhances the properties of cement.


Conclusion:

The adoption of NIVELCO's EasyTREK ultrasonic transmitters significantly improved the operational efficiency and reliability of the kaolin processing plant. The customer not only benefited from the robust performance of the EasyTREK transmitters but also appreciated the convenient configuration options provided by NIVELCO’s software and hardware solutions. This case study highlights the importance of selecting the right equipment for specific industrial challenges, ensuring continuous operation and efficiency.


Ajax Solutions Easytrek KAOLIN PROCESSING PLANT

Ajax Solutions process control silos

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