【2026 Level Measurement】80G radar level gauge suitable for two extreme operating conditions (extremely high temperatures, extremely low temperatures)
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This post was last edited by The one on 2026-7-5 14:14. In industrial level measurement, extreme temperature conditions are the main causes of instrument failures; general-purpose instruments struggle to function in such special environments, often experiencing issues such as erratic readings, malfunctions, damage, or cracking due to freezing. The two typical extreme operating conditions in industrial settings can be classified into two categories: one is the ultra-high temperature environment associated with molten iron at temperatures of 1200–1380°C in the metallurgy industry, and the other is the ultra-low temperature environment of outdoor storage tanks at -40°C in industrial facilities located in northern areas. The causes of failures and the equipment compatibility requirements differ significantly between the two operating conditions, making it impossible to use the same equipment in both cases. The customized 80G millimeter-wave radar level gauge can be tailored to address two extreme environments – high-temperature and low-temperature – effectively solving industry-related issues such as damage caused by high temperatures, shutdowns due to low temperatures, signal fluctuations, and frequent maintenance needs.
I. Measurement of molten iron under high-temperature extreme conditions of 1200–1380°C. Applicable scenarios: metallurgical high-temperature equipment such as steelmaking electric furnaces, refining furnaces, molten iron ladles, torpedo tanks, and transfer tanks for molten metal. Hot metal measurement falls under the most extreme high-temperature conditions in industry, with medium temperatures far exceeding the tolerance limits of conventional instruments. The site is characterized not only by heat conduction and thermal radiation at temperatures of over a thousand degrees, but also by complex disturbances such as high-temperature smoke and dust, metal vapor, molten iron splashes, and turbulence within the furnace; as a result, ordinary radars, laser level gauges, and contact-type instruments cannot operate stably over long periods of time.
Summary of key pain points: Extremely high thermal radiation can damage instruments; slag formation on the end faces can cover the sensors; flue gas interference causes data fluctuations; continuous production prevents shutdown for maintenance, thus requiring extremely high reliability from the equipment.
Exclusive customized standard solution (four core components, all of which are essential): (1) High-purity silicon carbide SiC antenna: Instead of using conventional PTFE or ceramic materials, an industrial-grade high-purity silicon carbide lens is employed; it can withstand temperatures up to 1600°C over long periods of use, covering all conditions associated with molten iron at 1380°C. It features high material hardness, oxidation resistance, and thermal shock resistance; it can withstand the impact of molten iron splashes, and does not stick to slag, crack, or deform. Combined with an 80G high-frequency 2° ultra-narrow beam, it precisely focuses on the liquid surface, effectively avoiding false echoes generated by the furnace walls, supports, and furnace structure.
(2) 310S/Inconel extended water-cooled jacket stub: A 250–400mm extended insulation structure designed to handle intense thermal radiation; a double-layer hollow water-cooling jacket through which clean circulating water at 0.2–0.4 MPa is pumped to prevent the upward transmission of heat. This setup allows the temperature on the outer surface of the equipment’s flanges to be kept below 85°C, thereby preventing instruments from being damaged or failing due to high temperatures. It can also be equipped with a low-water and over-temperature alarm function to provide safe interlock protection for the equipment.
(3) Ring-shaped nitrogen purging system: A flange-integrated ring-shaped purging interface is used to continuously supply dry, high-purity nitrogen at a pressure of 0.15–0.25 MPa, thereby creating a stable protective gas barrier at the end face of the antenna. This barrier effectively prevents the adhesion of high-temperature smoke and dust, iron oxide particles, and metal vapors, ensuring that the lens remains clean and transparent. It thus solves the problems of slag formation, coating on the surface, and signal attenuation that occur over time as a result of long-term operation of the instrument. In locations without a nitrogen gas supply, it can be replaced with dry, oil-free, clean instrument air.
(4) Split remote transmission structure + online maintenance valve: It features a design in which the probe is completely separated from the electrical meter head; the high-temperature resistant probe is installed in the high-temperature area of the furnace, while the transmitter head is installed at a distance via 3–15m of shielded cables, thus staying completely away from high-temperature heat radiation. An optional high-temperature cut-off gate valve allows the probe to be removed and replaced online, without shutting down the furnace, stopping production, or reducing temperature, thereby significantly reducing the costs associated with downtime and maintenance for enterprises.
II. Extreme low-temperature conditions – Measurements in -40°C outdoor extreme cold environments. Applicable scenarios: outdoor storage tanks in cold regions of the north, open-air powder silos, chemical storage tanks in field areas, oil field storage equipment, etc. In this operating condition, the medium is usually ordinary materials at normal temperatures, with no high-temperature interference; the core pressure arises from the extremely low ambient temperature. In extremely cold outdoor environments at -40°C, ordinary industrial instruments are prone to problems such as circuit boards failing to start up, LCD screens going black due to frost formation, seals becoming brittle and cracking, and cables hardening and aging. The large temperature differences between day and night can also cause condensation inside the instruments, signal drift, and erratic measurement data, severely affecting the stability of production monitoring.
Summary of key pain points: shutdowns due to low-temperature electrical control, damage to structural seals from freezing, interference caused by frost in outdoor environments, data instability resulting from large temperature differences, and high difficulties in maintaining equipment in field conditions.
Exclusive low-temperature adaptation solution: (1) Custom electric control system for wide temperature ranges down to -40°C: The entire unit uses industrial-grade circuit boards designed for low temperatures, with a standard operating temperature range of -40°C to +70°C. It allows for immediate startup at -40°C without the need for preheating; there is no screen blackout or system shutdown, and the components operate stably. This prevents signal attenuation and data drift at low temperatures, making it suitable for 24/7 operation in harsh, cold environments.
(2) Complete set of low-temperature compatible materials: The equipment is equipped with low-temperature resistant, freeze-proof shielding cables, specialized elastic seals for low temperatures, and freeze-resistant antenna structures, which address common issues such as brittleness, hardening, water condensation, and aging due to low temperatures in ordinary materials, enabling use in extremely cold outdoor environments over extended periods.