Top 5 Industrial Applications for Ultrasonic Liquid Level Sensors in Tanks & Silos

Industrial Precision Management: Top 5 Applications of Ultrasonic Liquid Level Sensors in Tanks & Silos 

I. The Gold Standard for Non-Contact Measurement: The Industrial Value of Ultrasonic Level Technology 

In the Industry 4.0 era, enterprises' requirements for level data in storage tanks and materials are rapidly shifting from "manual readings" to "intelligent monitoring."  

Ultrasonic level sensors, with their non-contact, maintenance-free, and high cost-performance characteristics, have become one of the most widely adopted technologies in global level automation management.

Why Choose Ultrasonic Technology?  

✅ Non-Contact Measurement — No need to contact liquids or powders, avoiding corrosion, contamination, and wear issues.  

⚙️ Simple Structure — Top-mounted installation for immediate use, nearly zero maintenance.  

High Cost-Effectiveness — More suitable for medium-precision, budget-sensitive applications compared to radar level meters.  

Intelligent Compensation — Built-in temperature compensation and digital filtering algorithms ensure accuracy even in outdoor or complex environments. 

 II. Core Working Principle of Ultrasonic Level Sensors 

D = Sound Speed × Δt / 2  

The sensor emits sound waves → Sound waves are reflected by the liquid surface → Measure the round-trip time difference to calculate the level height.  

Through microprocessor algorithms, stable, linear, and high-precision data output can be obtained (analog / RS485 / Modbus).

 III. Five Major Industrial Application Scenarios and Value Analysis 

1️⃣ Urban and Industrial Water Treatment Systems  

Application Scenarios: Clear water tanks, sedimentation tanks, reagent tanks, pump stations.  

Pain Points: Harsh sewage environments where contact sensors are easily affected by fouling.  

Solutions:  

Ultrasonic level sensors enable non-contact measurement without immersion in liquids;  

Can integrate with PLC / IoT platforms for automatic pump start/stop control;  

Prevent overflow pollution and dry-run damage, enabling unmanned operation.  

Results: Achieve continuous online monitoring and automatic replenishment control, reducing equipment maintenance rates by 70%.

2️⃣ Chemical Industry Corrosive Liquid Storage Tanks  

Application Scenarios: Acid, alkali, salt solution, and industrial waste liquid storage tanks.  

Challenges: Strong corrosive chemical vapors shorten the lifespan of contact probes.  

NiuBoL Solution:  

PTFE or PVDF housing for resistance to strong acids and alkalis;  

Built-in temperature compensation algorithm for precision even in 60°C high-temperature environments;  

Supports explosion-proof grade customization for hazardous conditions.  

Value: Maintenance cycles extended from 3 months to over 2 years. 

3️⃣ Food and Pharmaceutical Sanitary Storage Tanks  

Application Scenarios: Pure water, milk, juice, and brewing raw material storage tanks.  

Requirements: Compliant with sanitary standards, suitable for in-place cleaning (CIP / SIP).  

Features:  

Non-contact design avoids secondary contamination;  

Seamless integration into sanitary tanks without additional openings;  

Compatible with RS485 and 4–20mA outputs, suitable for HACCP / GMP factory automation systems.  

Value: Ensures food safety while reducing manual inspection costs.

4️⃣ Solid Material Silos  

Application Scenarios: Grain, feed, plastic pellets, and small fertilizer silos.  

Challenges: Weak reflection signals from dust and particles.  

Solutions:  

Enhanced echo signal processing algorithms (Echo Filtering);  

Optional installation of guide tubes or acoustic reflectors for stable echoes;  

Enables inventory monitoring and anti-clogging alarms.  

Value: Far lower cost than radar systems, ideal for small to medium-sized storage scenarios. 

5️⃣ Oilfield and Energy Storage Tank Monitoring  

Application Scenarios: Cooling oil tanks, waste liquid pools, lubricant storage tanks.  

Advantages: Low cost, simple maintenance, excellent corrosion resistance.  

Notes: Sensitive to oil vapors; avoid sealed high-temperature environments.  

Highly cost-effective for non-critical tanks (auxiliary level alarms, wastewater tanks).

 IV. Actual Case: Complete Resolution of Corrosion Issues in Chemical Waste Liquid Tanks 

Customer Background: A chemical plant's transfer tank holding high-concentration acidic waste liquid (60°C).  

Traditional Problems: Hydrostatic sensors corroded and failed within 3 months, leading to frequent downtime maintenance. 

NiuBoL Solution:  

Adopted a fully encapsulated PTFE ultrasonic level sensor with top-mounted installation, with only minimal housing exposure to corrosive vapors. The system ran continuously for 2 years with zero maintenance, maintaining level accuracy at ±3 mm.  

Results: Overall maintenance costs reduced by 85%, system uptime increased by 20%.

 V. NiuBoL: The Reliable Choice for Industrial Non-Contact Measurement 

Product Features:  

- High protection rating (IP68)  

- Algorithms resistant to steam and dust interference  

- Industrial bus outputs (RS485 / Modbus)  

- Automatic temperature compensation  

- Customizable explosion-proof types and remote IoT data acquisition modules  

Application Integration: Can directly connect to the NiuBoL IoT cloud platform for:  

- Remote level visualization  

- High/low level alarms  

- Storage tank group management and report exports 

Contact NiuBoL immediately: Build your industrial non-contact level monitoring solution.

 Frequently Asked Questions (FAQ) 

Q1: Can Ultrasonic Level Sensors Be Used in Agitated Tanks?  

A: Yes. The sensor's built-in averaging algorithm smooths fluctuation data. However, for excessive foam or severe vortices, guided wave radar is recommended. 

Q2: How to Handle Blind Zone Issues?  

A: Select models with the smallest blind zones, or position the probe so the highest level is > blind zone distance away. NiuBoL sensors have blind zones as low as 20 mm. 

Q3: Can They Be Used in High-Temperature and High-Pressure Conditions?  

A: Built-in temperature compensation suits high-temperature environments; for high-pressure tanks, select pressure-resistant housings and enhanced sealing flanges.