Measurement & Control Systems

SmartFill (Coal)

360° impact sound analysis of ball mills

A homogenous degree of fineness is vital to ensure optimum combustion properties for your coal. SmartFill – a fail safe, high precision fill level and temperature measurement system for ball mills – has bee developed to help you achieve this.

For the first time ever you can now ac­cu­rate­ly meas­ure the most im­por­tant grin­ding pa­ram­e­ter: fill lev­el. Since it is not pos­si­ble to meas­ure this key pa­ram­eter di­rect­ly, meas­ure­ments need to be taken on the ba­sis of a­cous­tics or vi­bra­tions. Pre­vi­ous meas­uring meth­ods such as mi­cro­phones have a num­ber of ob­vi­ous dis­ad­van­tages that mean they are whol­ly un­suit­a­ble for a­chiev­ing the ex­act­ing stan­dards re­quired by to­day’s in­dus­trial pro­duc­ers even meas­ur­ing the drive cur­rent does not give ac­cur­ate e­nough re­sults.


How does SmartFill improve your energy efficiency?

Ac­cur­ate meas­ure­ments al­low you to con­trol the mill mean­ing you can main­tain an op­ti­mum fill-lev­el at all times. Con­se­quent­ly the mill’s op­er­a­tion is sta­ble and reg­u­lar re­sul­ting in a much more u­ni­form coal out­put.
What is more, set­ting the op­ti­mum fill-lev­el re­du­ces wear to the balls and mill shell. You can a­void over­fil­ling the mill there­by im­pro­ving the plant’s up­time; this in turn leads to in­creased lev­els of pro­duc­tion. Ir­re­spec­tive of the type of con­trol sys­tem used SmartFill al­lows you to make the right de­ci­sions at the right time. Thanks to SmartFill, you can now act rath­er than re­act when con­trol­ling your mill.


What type of mills is SmartFill suitable for?

SmartFill (Coal) is suit­a­ble for use in a va­ri­e­ty of dif­fe­rent types of ball mills in­clu­ding (air-swept) tube mills, cen­tre dis­charge mills and SAG mills. It can also be used ir­res­pec­tive of the type of lin­ing (steel/rubber), grind­ing media (balls/cylpebs) or grind­ing proc­ess (wet/dry).

SmartFillTM has been on the market for over seven years and is already used by more than 400 companies worldwide in the coal, cement and minerals industry.


High precision fill-level measurement:

  • easy installation
  • zero crosstalk
  • unoccupied frequency band
  • virtually maintenance-free
  • process interface (4—20 mA)
  • up to 3 sensors of your choice
  • self-powered (On Mill Unit)
  • type tested: IP65 / Atex