I. Application Scenarios

This plan is applicable to various storage silos in the ground and washing and sorting sections of the mining industry, covering silos, hoppers, large storage silos, and other types of storage facilities such as concentrate silos, mineral powder silos, aggregate silos, gangue silos, and finished product silos in the processing sections of metal and non-metal mining. It also meets the storage monitoring requirements for operation environments such as sand and gravel plants and mineral powder processing workshops. The stored materials include various types of metal powder, non-metal powder, sand and gravel, gangue, and other granular and powdery mining raw materials, meeting the monitoring needs for multiple types and various working conditions.

II. Key Challenges 

The monitoring conditions of the material storage bins in the surface and washing and sorting sections of the mining industry are harsh and the environment is complex. The core challenges faced are as follows: 

Extremely high dust interference: During the loading, transportation, and crushing of raw materials in the mine, high concentrations of dust are generated. The dust will severely absorb and scatter the measurement signals, resulting in distorted data and a significant decline in measurement accuracy for ordinary sensors. 

2. Strong impact and vibration: Continuous strong vibrations are generated during the operation of mining equipment and conveying devices. The resonance of the silo body and its internal structure can cause the sensors to shift or be damaged, thereby affecting the stability of the measurement and the lifespan of the equipment. 

3. Impact of complex environments: The open-air storage silos are exposed to extreme environmental changes such as intense heat exposure, rain exposure, and freezing and thawing. The washing and selection workshop also has issues related to high humidity and moisture. Therefore, strict requirements are imposed on equipment protection and temperature resistance performance. 

4. The internal conditions of the silo are complex: The internal structures of the silo, such as ladders, supports, and discharge devices, are prone to generating false echoes, which interfere with the measurement signals; after the mineral materials are fed into the silo, they tend to form a "peak-like" uneven material surface, and traditional equipment is unable to accurately measure the actual volume of the materials. 

5. Variability of material properties: The dielectric constant and density of mining materials vary significantly. Some materials contain moisture and are prone to adhering to the wall and forming lumps, while others have strong fluidity and are likely to cause material surface collapse. This poses high requirements for the adaptability of measurement equipment. 

6. Strict safety management: Manual inspection poses safety risks such as falls from heights, collapse of silos, and inhalation of dust. Industry regulations require the implementation of unmanned and remote control of silos to eliminate the risks associated with frequent manual on-site inspections. 

III. Scheme Architecture 

This scheme is centered on an 80G high-frequency radar level gauge. It is complemented by an industrial-grade PLC control system, a specialized mine-level software, multi-dimensional alarm devices, and an environmental monitoring module. This forms an integrated intelligent monitoring system for unmanned operation of mine silos, covering "sensing - transmission - processing - display - warning", which is fully compatible with the strict requirements of anti-dust, anti-vibration, and resistance to complex environments in the mine's surface and washing and selection processes. 

1. System core components

(1) 80G high-frequency radar level gauge (model HCDAR-81)

Designed specifically for harsh industrial conditions, the core parameters are fully compatible with the monitoring requirements of material storage bins in the mining surface and the washing and selection processes: 

Measurement range: 0 - 120 meters, suitable for large-scale high-capacity silos in mines; 

Accuracy and resolution: ±2mm, resolution 1mm. It can precisely capture the actual height of uneven material surfaces and restore the true volume of the materials. 

Working environment: Temperature range -40℃ to 200℃. Resistant to high and low temperatures in the open air as well as local high temperatures in the workshop. 

Protection level: IP68. Dust-proof, water-proof, and resistant to immersion. Suitable for high humidity conditions in the sorting workshop and outdoor rain exposure scenarios. 

Explosion-proof rating: Ex db ia IIC T6 Gb; Ex tb IIC T80℃ Db, meeting the requirements for the flammable and explosive dust environment in the coal washing workshop. 

Anti-interference capability: Beam angle 3°. The lens-type antenna combined with a dedicated filtering algorithm can penetrate high-concentration mine dust and effectively suppress false echoes from the internal structure of the container. 

Signal output: Supports (4-20) mA HART/RS485 MODBUS-RTU, compatible with industrial standard signal transmission; 

Anti-vibration performance: The high-strength housing design can withstand the continuous vibration generated by mining equipment operations, preventing sensor displacement and damage.

(2) Industrial-grade PLC control system

It adopts the Siemens series PLC, which is suitable for the industrial environment of the mine surface and the washing and selection workshop, and realizes the following three core functions: 

Data logical operations: Merge the data from the radar level gauge and environmental sensors, and combine with the parameters of the silo to accurately calculate the volume and weight of the material. 

Threshold intelligent judgment: The upper and lower limit thresholds for the material level can be customized (e.g., upper limit 85%, lower limit 15%), accurately identifying abnormal material level conditions. 

Control command output: It is linked with the mining feeder, discharge valve, belt conveyor and other conveying equipment to achieve automatic feeding, shutdown, and form a closed-loop control system. 

(3) Specialized Mine Host Computer Software

Custom-developed host computer system that meets the production management requirements of the mine's surface and processing stages. It supports industrial network connection. Core functions: 

Real-time data shows: The large screen provides a visual display of data such as the material levels, temperatures, and humidities in each storage bin. It supports simultaneous monitoring of multiple bins, and the data refresh is without delay. 

Historical data management: Stores material levels, alarms, and equipment operation records. The storage period is ≥ 3 years. It supports historical curve queries and data export, meeting the requirements for mine production ledger management. 

Remote access: Supports remote monitoring of silo status from the dispatch center and mobile devices, enabling off-site control and achieving unmanned operation. 

Production scheduling assistance: Based on real-time material level data, it automatically generates suggestions for replenishment and discharging, assisting mines in optimizing production scheduling and improving production efficiency.

(4) Multi-dimensional Alarm Device

Adapted to the multi-scenario alarm requirements of mines, it enables hierarchical warning and rapid response, with the alarm response time being ≤ 10 seconds: 

On-site alarm: Industrial-grade sound and light alarm system, installed near the silo and in the control room. It provides dual warning through sound and light, suitable for various lighting environments such as workshops and open areas. 

Remote alarm: SMS / Platform alarm module. When the material level exceeds the normal range, it will automatically send alarm information to the managers and dispatchers, ensuring that they are informed immediately. 

Interlinked alarm: When the material level exceeds the upper limit or lower limit, the conveying equipment will automatically stop / start. At the same time, the on-site ventilation and dust removal equipment will be activated to avoid problems such as spillage and dust dispersion. 

(5) Environmental Monitoring Module (Optional)

Cooperating with the radar level gauge, it enables comprehensive monitoring of the entire operating conditions of the silo, including: 

Humidity and temperature sensor: Monitors the temperature inside the silo and its surrounding area, as well as the moisture content of the materials, to prevent material caking and moisture re-entrainment; 

Vibration sensor: Monitors the vibration conditions of the storage container and the conveying equipment, providing early warnings for equipment malfunctions and container deformation. 

Dust concentration sensor: Monitors the dust concentration around the silo. When the concentration exceeds the limit, it will activate the dust removal equipment to improve the working environment.

2. System Work Flow

Based on the production management norms for the surface area and the washing and selection processes of the mine, a standardized and intelligent unmanned operation workflow has been designed to completely avoid the risks associated with manual on-site operations throughout the process: 

Multi-source data acquisition: The 80G radar level gauge continuously collects the material level data in the silo. The environmental monitoring module simultaneously collects data such as temperature, humidity, vibration, and dust concentration, and transmits it via 4-20mA/RS485 signals to the PLC control system. 

（1）Data intelligent processing: The PLC performs precise calculations on the collected data to determine the actual volume/weight of the materials, and also checks whether the material level and environmental parameters exceed the preset thresholds. If any of these exceed the thresholds, an immediate alarm will be triggered and equipment control instructions will be generated. 

（2）Automatic equipment linkage: When the material level is low, the feeding machine and belt conveyor will automatically start to replenish the material. When the material level is high, the equipment will automatically stop. This approach prevents problems such as overfilling or shortage of materials at the source, ensuring the continuity of production. 

（3）Data Display and Storage: The upper-level computer software receives the data transmitted by the PLC, which is then displayed in real time on the large screen at the mine dispatch center. At the same time, historical data is stored according to the production management requirements, supporting the generation of ledgers and data traceability. 

（4） Remote synchronization and control: Data is transmitted from the industrial network to the cloud platform. Managers can remotely monitor the real-time status of the silos using computers or mobile devices, and issue operation instructions remotely, achieving unmanned operation. 

（5） Exceptional Alarm and Handling: Once the alarm is triggered, the on-site sound and light alarm system immediately activates. The alarm information is simultaneously pushed remotely. The system automatically records the alarm time, cause, and handling result, forming a closed-loop management process to ensure that exceptional situations can be handled promptly. 

3. System topology diagram

IV. Core Technical Advantages

In response to the demanding conditions in the mine's surface and processing stages, this solution leverages the core equipment technology advantages to address the measurement challenges in the industry and achieve precise, stable, and long-lasting material level monitoring: 

1. High dust penetration technology: Utilizing the core technology of frequency-modulated continuous wave (FMCW), combined with a 3° narrow beam angle lens antenna, the measurement error is ≤ 0.5%. It can penetrate high-concentration mine dust and accurately capture the true height of uneven material surfaces, eliminating data distortion. 

2. Strong anti-interference and anti-false echoes: With a built-in dedicated filtering algorithm, it can effectively suppress false echoes caused by structures such as ladders and supports inside the container, ensuring the accuracy and validity of the measurement data. 

3. Ultra-high standard protection: IP68 protection grade + Ex db ia IIC T6 Gb explosion-proof grade. It can prevent dust, water, and flammable/explosive dust. It is suitable for high humidity environments, open-air complex conditions, and dust explosion-proof requirements in washing and selection workshops. 

4. Mine operation condition adaptation logic: Deeply integrate the production processes of the mine's surface and washing and selection sections. Pre-set the material level linkage control logic, which can seamlessly connect with existing conveying, dust removal, and ventilation equipment, and does not require large-scale renovation of the existing production system. 

5. Non-contact measurement design: No vulnerable components. The sensor probe is less likely to get clogged or worn out. It is suitable for mining environments with high dust levels and where materials tend to adhere to the walls. This significantly reduces the probability of equipment failure. 

V. Enterprise Service Advantages

1.Relying on Huachuang Measurement & Control's technical accumulation and industry experience in the field of industrial measurement and control, we provide customized, full-process, and highly adaptable service systems for the surface of mines and the washing and selection processes, ensuring the stable implementation and long-term operation of the system: 

Strong R&D and technical breakthrough capabilities have enabled the establishment of provincial-level radar level measurement and control R&D centers and enterprise technology centers. Collaborations have been carried out with multiple universities such as Shenyang Aerospace University and North China University of Science and Technology on multiple key technologies including signal amplification, filtering processing, and dust penetration. We possess a number of independently developed patents and can customize exclusive measurement solutions based on the type of mine silos, material characteristics, and production processes, addressing the specific pain points of individual industrial conditions. 

2. With rich experience in mining-related cooperation, our products have established deep partnerships with major domestic metallurgical and mining enterprises such as Hebei Iron and Steel Group, Panzhihua Iron and Steel Group, and Baotou Iron and Steel Group. Hundreds of mining-related material storage projects, including powder silos, aggregate silos, and finished product silos, have been successfully implemented. We are familiar with the production management norms, on-site construction requirements, and operational characteristics of the mining surface and washing and selection processes. 

3. The exclusive full-process service system for mines 

Pre-sales: Professional technical engineers will visit the site to conduct an on-site inspection. Based on the specifications of the silo, the properties of the materials, and the current production system conditions, they will provide customized solutions and issue reports on equipment selection and system deployment. 

During the sales process: The equipment installation and commissioning are carried out strictly in accordance with industrial construction standards. Quality is strictly controlled. Complete sets of materials such as equipment certificates and explosion-proof certificates are provided. The delivery period can be flexibly adjusted to fit the production plan of the mining site. 

After-sales service: Offer 7×24-hour emergency services, support remote fault diagnosis and online technical guidance, and enable on-site rapid repair for ground equipment; According to the maintenance requirements of mining equipment, provide regular inspections and calibration services to ensure the long-term stable operation of the system. 

4. Nationalized sales and service network 

The products are available in 31 provinces and autonomous regions across the country. Exclusive service outlets have been established in major mining areas such as metal mines, non-metal mines, and sand, stone, and aggregate quarries. We can respond to on-site issues within 24 hours, and for remote mining areas, we can be on-site within 48 hours to quickly solve equipment and system operation problems.

VI. Core Value for Mining Enterprises

This plan creates value for the mining surface and processing and selection processes from four dimensions: safety, cost, efficiency, and management. It not only meets the safety and management requirements of the industry but also achieves cost reduction and efficiency improvement, as well as lean production. The core value is as follows: 

1. Eliminate safety risks at the source and prevent production safety accidents

Replace manual pit inspection and on-site measurements with automated systems, completely avoiding risks such as falls from heights, material silo collapses, and inhalation of dust, which are associated with manual operations. This meets the industry requirements for unmanned operations in the mining sector. 

When the material level exceeds the upper limit, an automatic shutdown command is triggered to prevent the spillage of the mineral materials, which could lead to on-site accumulation and dust dispersion. When the level drops below the lower limit, automatic replenishment is carried out to avoid equipment dry grinding and production interruption caused by empty storage bins, thereby reducing potential safety hazards at the source. 

Real-time monitoring of environmental parameters such as dust concentration, temperature and humidity. When the parameters exceed the standard, the dust removal and ventilation equipment will be activated to improve the on-site working environment and reduce the probability of occupational diseases. 

2. Reduce material loss and lower raw material and environmental costs

Accurately measure the material level (error ≤ 0.5%), completely eliminate the problems of "false storage" and "top storage", and avoid hidden losses caused by overloading of mineral materials and incomplete discharge; an application example of a certain mineral powder processing enterprise shows that it can prevent 2-3 cases of spillage waste per month, and save over 50,000 yuan in material costs per storage unit per year. 

Effectively prevent dust pollution caused by the spillage of raw materials, avoid environmental protection penalties, and at the same time reduce the operating costs of dust control equipment, which is in line with the requirements of environmental protection in mining production. 

3. Replace manual inspections, significantly reducing labor costs

Realize 24-hour automated and unmanned monitoring of the silos, which can replace 90% of manual inspection tasks. For large mines (with more than 20 silos), it can reduce the number of inspection personnel by 3-5. Assuming the monthly salary of a ground inspection staff in the mine is 6,000 yuan, the direct annual savings in labor costs can reach 216,000 - 360,000 yuan. 

The equipment can complete a precise inventory of a single warehouse within 5 minutes. The inventory efficiency is over 10 times higher than that of manual methods. This significantly shortens the inventory period and reduces production delays caused by warehouse sealing during the inventory process, thereby enhancing production continuity. 

4. Ensure continuous production and enhance mine capacity and overall efficiency

The failure rate of radar level gauges is much lower than that of traditional contact-type equipment (rotating drum type, weight hammer type, capacitive type). They can operate stably for a long time under the harsh conditions of high dust and strong vibration in the mine, avoiding production halts caused by measurement equipment failures. 

Linked with the closed-loop system of the mine transportation, it realizes automatic feeding and unloading, eliminating the interruption of the washing and processing stages due to material shortage. After being applied in a certain mine powder washing and selection plant, the downtime due to material shortage has been reduced from an average of 50 hours per year to 0 hours. The washing and selection capacity has increased by 12% - 18%, and significant economic benefits have been indirectly generated. 

5. Reduce equipment operation and maintenance costs and extend asset lifespan

The non-contact design has no vulnerable components. The sensor probe is less likely to get clogged or worn out. The maintenance period can be extended to 1-2 years. Only regular checks on the probe's cleanliness are required, and the annual maintenance cost is reduced by more than 75% compared to traditional mining material level equipment. 

By using level warning systems, we can prevent "overloading of full bins" and "dry grinding of empty bins" in the storage silos, reduce abnormal conditions such as bin deformation, blockage of discharge valves, and wear of conveyor belts, thereby extending the service life of mining equipment such as silos, discharge valves, fans, and conveyor belts. After being applied in a certain aggregate plant, the frequency of discharge valve blockages decreased from 8 times per year to 1 time, the replacement cycle of the fan was extended from 2 years to 4 years, and the annual cost for equipment maintenance and replacement was saved by over 20,000 yuan. 

6. Optimize inventory and production management to reduce capital occupation costs

Real-time and accurate material level data can assist mines in formulating scientific procurement and production plans, controlling raw material inventory within a reasonable range and avoiding excessive procurement that leads to capital accumulation and waste of storage space. Taking the mine powder storage as an example, after installation, the inventory can be reduced from 50 tons to 20 tons. Assuming the price of mine powder is 800 yuan per ton and the annual loan interest rate is 4%, the annual savings in capital occupation costs would be 9,600 yuan. 

Historical material level data can assist mining operations in analyzing the consumption patterns of raw materials, optimizing production scheduling and raw material circulation processes, and further reducing storage and logistics costs. 

The system data can be seamlessly integrated with the mine's ERP and MES systems, enabling digital management of the silos and visualizing production data. This will enhance the overall production management level and decision-making efficiency of the mine.

VII. Summary of Scheme Benefits

This scheme is specifically designed for the surface and processing stages of mines, fully compatible with the harsh working conditions of mines with high dust, strong vibration, and complex environments. It also meets the requirements for safe production and unmanned management in the industry. Small and medium-sized mining enterprises can achieve an annual comprehensive cost savings of 150,000 to 300,000 yuan, while large mining enterprises (including processing, processing, and aggregate production stages) can achieve annual cost savings of 500,000 to 1,000,000 yuan. The initial equipment and system investment can be recovered within 1 to 2 years. 

The system not only enables unmanned and intelligent control of the mine silos, addressing the problems of low measurement accuracy, high failure rate and high labor costs in traditional measurement methods, but also can prevent safety accidents at the source, optimize production processes and achieve digital management. It helps mine enterprises build a safe, efficient, low-cost and lean silo management system, and contributes to the digital and intelligent upgrading of the mining industry.

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