Radar technology improves lime mixing at British Sugar
As the sole processor of the UK’ s beet sugar crop, British Sugar works closely with 3,500 growers and customers to produce up to 1.4 million tonnes of sugar annually. Alongside this, its innovative manufacturing processes generate co-products such as bioethanol, power, and animal feed, placing British Sugar among the world’ s most efficient sugar producers.
At the heart of this process is the production and mixing of milk of lime – an essential formulation for use in sugar production when purifying the juice from beet or cane. Roughly 125kg of limestone is needed per tonne of sugar produced, making it a key input. After slicing and diffusing the sugar beet to extract juice, lime, derived from calcium limestone, is added to remove impurities. A high quality lime-water mixture is required in the sugar process to ensure an efficient, high quality sugar juice purification stage.
Lime also plays a role in environmental management, used to treat wastewater and creates agriculturally beneficial by-products, such as soil additives and conditioners. Most sugar processing sites operate their own lime kilns, converting good, highpurity limestone into quicklime at
900 ° C, which is then mixed with water to form milk of lime. This exothermic reaction of mixing alkali and water also generates heavy condensation inside the tank. It is during this process that an accurate, reliable level measurement ensures consistent production.
British Sugar previously used a differential pressure transmitter with a modified bubbler system, but it proved costly to run, and prone to inaccuracy from blockages, build-up, and the changing lime density. The process area also demands strict safety – lime is harmful to skin and eyes, and tank overflows are hazardous to manage. Reliable, accurate level control was essential, not just for efficiency but to protect personnel, prompting British Sugar to seek a safer, more dependable solution.
To address these challenges, British Sugar’ s Newark site installed an 80 GHz radar sensor from VEGA – a robust, contactless solution ideal for harsh environments. Despite turbulent surfaces, steam from condensation, and splashing and build-up on the antenna, the radar reliably measures the liquid level. All outer surfaces are either plastic or stainless steel in construction, with a fully encapsulated PTFE antenna, ensuring minimal corrosion and long service life in the highly alkaline conditions.
The unit installed uses 80 GHz frequency, giving its DN80 / 3” flange a narrow 3 ° beam angle that delivers precise readings even near tank walls. Its 120dB sensitivity and advanced signal processing help it cut through condensation and build-up, maintaining reliable and accurate measurement even with a turbulent or agitated process surface – including through valves or long nozzles.
The result? Improved reliability, reduced maintenance, better quality milk of lime, and a safer working environment. VEGA’ s 80 GHz radar proved its value in tough conditions, consistently delivering accurate, contactless level measurement where other methods fell short. A dependable solution that made a lasting difference.
Tel: + 44 1444 870055 E-Mail: info. uk @ vega. com Web: www. vega. com / uk
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