Ambient Dust Monitoring in Sugar Silos and Conveying Areas
Early warning of abnormal dust events in ATEX-classified process areas
6 monitoring points
under continuous plant supervision
200,000+ tonnes per year
granulated sugar produced at the plant
4–20 mA → DCS
interfaced with the fire alarm system
Continuous ambient dust monitoring helps sugar producers detect dust releases around silos and conveying systems, respond faster to process failures, reduce product loss and support safer operation in areas where combustible dust may be present.
The challenge
A European sugar plant producing more than 200,000 tonnes of granulated sugar per year wanted better visibility into dust events around its silos and conveying system. Sugar handling can generate airborne dust, making early detection important for housekeeping, product-loss control and plant safety.
Two potential release points were identified around each silo: the unloading point, where blockages could cause sugar to spill and create a large dust cloud, and secondary extraction points around the silo base, where a major leak could release dust locally. The conveyor tunnel between production and the silos was another critical area, because a blockage or failure could quickly lead to material accumulation and airborne dust.
The solution
The plant installed six Sintrol Dumo ambient dust monitors at the identified risk points, including silo areas and the conveyor tunnel. The monitors were used in an ATEX-classified environment to provide continuous indication of changes in ambient dust levels.
The 4–20 mA signals were connected to the plant DCS, which was interfaced with the fire alarm system. This gave operators a direct alarm path for abnormal dust events and supported faster response to blockages, spills or local leaks.
Results
The monitoring arrangement gave the plant continuous visibility into dust conditions at locations where process failures could lead to product loss and sudden dust releases.
- Earlier indication of abnormal dust releases around silos and conveyors
- Faster response to unloading blockages, spills and local leaks
- Integration of dust alarms into the plant DCS and fire alarm system
- Better support for systematic housekeeping and combustible-dust risk management
Sintrol
DumoPro Dust Monitor
DumoPro ambient air dust monitor detects dust in industrial environments 24/7. ATEX approved, low maintenance, fast response, and easy Auto Setup for reliable results.
Sintrol
DustCloud
Monitor dust measurements, device status and alerts across multiple locations with DustCloud, Sintrol’s cloud-based industrial dust monitoring service.
Key monitoring points
| Silo unloading points |
|---|
| Monitoring helps identify abnormal dust releases if sugar flow is interrupted and material spills from the unloading area. |
| Silo base and extraction points |
|---|
| Local ambient monitoring provides early warning if a leak or extraction-system failure releases dust around the silo. |
| Conveyor tunnel |
|---|
| Continuous monitoring helps detect dust events from blockages, material accumulation or conveying failures. |
John Korpi
Area Sales Director
Dust Monitoring Solutions
How it works
DumoPro uses Sintrol’s Inductive Electrification technology to monitor total suspended particles (TSP) in ambient air. Signal processing and filtration convert the sensor response into a continuous dust trend for real-time monitoring, alarms and follow-up of changing conditions around silos and conveying systems.