Process monitoring solid-liquid separation, measuring tasks in hazardous areas

e.g. in separators, centrifuges, decanters, etc. - Precise, maintenance and wear-free!

In mechanical separation process engineering – in separators, centrifuges, and decanters – processes run that are simultaneously highly dynamic and difficult to access. At the same time, many of these installations generate explosive gas or dust atmospheres from the media being processed, requiring certified sensor technology to ATEX and IECEx standards. Tippkemper-Matrix addresses both challenges with a coordinated portfolio of explosion-protected color camera technology and laser distance sensors of the LDH product family – precise, maintenance-free, and wear-free in continuous operatio

Tippkemper-Matrix offers tried and tested solutions for process monitoring and for various measuring tasks (solids discharge, solids level, etc.) in separators, centrifuges and decanters.

We observe the ongoing process through sight glasses or directly within Ex Zone 1, 21 using high-resolution colour camera technology, supported by our powerful lighting technology. For measuring tasks, e.g. in pusher centrifuges, we use the laser distance sensors of the LDH-... product family.

Here we measure the current fill level inside the bowl, or at critical points, whether deposits are forming that could critically influence the process.

Technical data:

Ex Zone 1, 2 / 21, 22 , these units may also be used in Zone 0 due to the OP approval.
Power supply: 24 VDC
Design: M 42, protection class IP 67
Ex type of protection: Ex d (flameproof enclosure)

Typical Measurement Tasks and Monitoring Scenarios

Fill Level Measurement in Pusher Centrifuges

In pusher centrifuges, a hydraulically driven piston discharges the solids cake from the drum in regular pushes. The LDH sensor measures the fill level of the solids cake inside the drum non-contactually and delivers continuous measured values – as the basis for controlling push frequency, optimizing residence time, and preventing overfilling.

Deposit Detection at Critical Locations

If deposits of solids, crystallites, or encrustations form within the drum system, they can increase rotor imbalance, reduce separation efficiency, and in extreme cases cause mechanical damage. The LDH sensor detects these deposits at an early stage through continuous distance measurement at defined control points – without opening the plant, without manual intervention.

Process Monitoring in Separators and Decanters Through Sight Glasses

In separators and scroll decanters, the explosion-protected camera enables visual assessment of the separation process through sight glasses – without entering the closed process space. Plant operators can evaluate solids discharge, phase separation, and any operational anomalies in real time and document them for process optimization or maintenance planning.

Direct Observation in Ex Zone 1 and Zone 21

Where sight glasses are absent or installation conditions require direct sensor positioning, the camera systems from Tippkemper-Matrix operate directly within the hazardous zone – fully certified, without safety compromise.

Why Tippkemper-Matrix for Process Monitoring and Measurement Technology in Ex Zones?

The combination of explosion-protected imaging and non-contact laser measurement technology is rarely available as an integrated solution portfolio in separation process engineering. Tippkemper-Matrix offers both from a single source – with decades of experience in explosion protection applications, products certified to ATEX and IECEx, and practice-oriented consultation for plant-specific configurations. The company is certified to ISO 9001:2015.

Product flyers for laser distance measurement, lighting technology, and color camera systems are available for download. The Tippkemper-Matrix team is available for application-specific configuration and integration consulting on request.