Pool Condenser Level Measurement Solution: Application of JWrada®-35 Radar Level Meter
1. Industry Background: The Critical Role of Pool Condensers in Urea Plants
In the urea production process, the pool condenser is one of the core pieces of equipment in the synthesis system. Its primary function is to enable the reaction of carbon dioxide (CO₂) with ammonia (NH₃) under high-temperature and high-pressure conditions to form ammonium carbamate. This substance is an important intermediate for the subsequent urea synthesis reaction, and its formation efficiency and stability directly affect the operating performance of the entire plant.
During this process, the interior of the pool condenser is typically subjected to extreme operating conditions: not only high temperature and high pressure, but also highly corrosive and reactive media. Therefore, continuous, precise, and highly reliable monitoring of the liquid level inside the equipment is essential to ensure stable reaction progress and prevent safety risks.
Against this backdrop, achieving stable and reliable level measurement has become a key factor in ensuring safe plant operation and production efficiency.
2. Operating Condition Analysis: Measurement Challenges in a High-Pressure Condensation Environment
1. Basic Process Parameters
Measurement task: Continuous level measurement
Measurement location: Tank
Measuring range: Approximately 4 m max.
Media: Ammonium carbamate, ammonia, carbon dioxide
Process temperature: +170 °C to +180 °C
2. Main On-Site Challenges
The operating environment inside a pool condenser is extremely demanding and presents severe challenges for level measurement:
- Extremely harsh high-pressure environment: The equipment operates under ultra-high pressure for long periods, placing very high demands on instrument sealing performance and structural strength.
- Highly corrosive media: Ammonium carbamate is highly corrosive and can easily damage sensor materials.
- Interference from high-temperature steam and mixed gases: Gas-liquid two-phase flow exists inside the vessel, which can affect measurement stability.
- Liquid level fluctuations and dynamic reaction changes: The reaction process is complex, and level variations are irregular.
- High safety risk: Any measurement error may affect system pressure balance and lead to safety hazards.
Under such conditions, traditional level measurement technologies such as differential pressure instruments or mechanical devices often suffer from insufficient reliability and frequent maintenance, making them difficult to meet the operating requirements of high-end chemical plants.
3. Solution: Application of the JWrada®-35 Radar Level Meter in Pool Condensers
To address the special requirements of pool condensers operating under high temperature, high pressure, and strongly corrosive conditions, the Jiwei JWrada®-35 radar level meter provides a highly reliable solution for continuous level measurement based on 80 GHz millimeter-wave radar technology.
The device adopts a non-contact measurement principle and does not come into direct contact with the medium, fundamentally avoiding corrosion and buildup problems. At the same time, its high-frequency radar signals offer excellent penetration capability and strong resistance to interference, enabling stable measurement in complex vapor-phase environments and meeting the strict safety and continuity requirements of urea plants.
1️⃣ Advanced Measuring Principle: FMCW Technology Enables High-Accuracy Measurement
The JWrada®-35 is based on the Frequency Modulated Continuous Wave (FMCW) radar measuring principle. By transmitting 80 GHz high-frequency electromagnetic waves and receiving the reflected signals from the material surface, it performs precise level calculation.
Its core process includes:
- Transmitting linearly frequency-modulated continuous-wave signals
- Receiving reflected echoes and mixing them with the transmitted signal to generate an intermediate frequency (IF) signal
- Analyzing the frequency spectrum through FFT (Fast Fourier Transform)
- Calculating propagation time (TDR) and converting it into level height
This technology uses frequency difference as the basis for measurement. Compared with traditional methods, it is less susceptible to changes in temperature, pressure, and gas composition, making it particularly suitable for high-pressure gas-liquid mixed environments.
2️⃣ High-Performance Structural Design: Adapted to Extreme Operating Conditions
The JWrada®-35 radar level meter is equipped with a 76 mm high-performance lens antenna featuring excellent signal focusing capability, which effectively reduces interference caused by internal vessel structures and gas disturbances. Meanwhile, its maximum measuring distance reaches 150 m, far exceeding the actual requirement of 4 m, thereby providing higher resolution and greater measurement stability.
The device adopts a corrosion-resistant sealed structural design, enabling it to withstand strongly corrosive media and operate stably at temperatures up to 220 °C, meeting the needs of high-temperature chemical applications.
3️⃣ Intelligent Signal Processing: Handling Complex Reaction Environments
To address the complex gas-liquid two-phase flow and dynamic reaction environment inside the pool condenser, the JWrada®-35 features a built-in self-learning intelligent echo processing algorithm capable of:
- Automatic identification and suppression of false echoes
- Multi-echo separation and processing
- Dynamic liquid surface tracking
This algorithm continuously optimizes the measurement model according to on-site conditions, accurately identifying the true liquid level even under high pressure, high temperature, and gas disturbance, thus ensuring continuity and reliability of the measurement results.
4️⃣ Intelligent Communication and Remote Maintenance
The JWrada®-35 supports multiple communication methods, facilitating system integration and remote management:
- HART communication protocol for integration with DCS/PLC systems
- Built-in Bluetooth 5.0 for wireless commissioning
- Support for the “Jiwei Intelligent Control” WeChat Mini Program
Users can complete parameter configuration, status monitoring, and remote maintenance through mobile terminals, significantly improving operational efficiency and safety.
5️⃣ Advantages of Non-Contact Measurement: Ensuring Long-Term Stable Operation
In highly corrosive and high-pressure environments, contact-type instruments are prone to corrosion or failure. Through its non-contact measuring method, the JWrada®-35 avoids direct contact with the medium, thereby significantly extending service life and reducing maintenance frequency.
Its design without mechanical moving parts further reduces the risk of failure, enabling truly long-term stable operation.
4. Application Advantages: Why the JWrada®-35 Is Suitable for Pool Condensers
1️⃣ High Reliability: Suitable for Strongly Corrosive Media
Under pool condenser operating conditions, ammonium carbamate is highly corrosive, and the simultaneous presence of ammonia and carbon dioxide places extremely high demands on instrument materials and sealing structures. The JWrada®-35 adopts a dedicated corrosion-resistant sealing structure and high-grade material system, effectively resisting long-term attack from corrosive media and preventing measurement deviation or equipment failure caused by material degradation.
At the same time, the non-contact measuring method means that the radar antenna does not need to come into direct contact with the medium, fundamentally reducing the risk of corrosion. Even under long-term high-load operation, the device can maintain stable output, providing continuous and reliable level data support for high-risk chemical plants.
2️⃣ Strong Resistance to High Pressure and High Temperature
Pool condensers typically operate in a high-pressure environment of 130 to 160 bar, combined with process temperatures above 170 °C. This places stringent requirements on the structural strength and stability of instrumentation. Through optimized structural design and a high-strength sealing solution, the JWrada®-35 can operate stably in high-temperature environments up to 220 °C.
Although radar measurement itself is not directly affected by pressure, reliable sealing performance and mechanical strength under high-pressure conditions are equally critical. The overall design of the JWrada®-35 fully considers the requirements of high-pressure applications, ensuring good long-term stability and safety under extreme conditions.
3️⃣ Maintenance-Free Design Reduces Costs
Traditional contact-type level measurement equipment is prone to scaling, corrosion, or mechanical wear in high-pressure corrosive environments, resulting in frequent maintenance or even replacement. In contrast, the JWrada®-35 adopts a non-contact radar measuring principle, and the entire measurement process does not rely on any sensitive elements in direct contact with the medium, fundamentally avoiding contamination, wear, and aging problems.
In addition, the device has no mechanical moving parts, eliminating the risk of structural wear. During operation, it requires no regular calibration or cleaning, significantly reducing maintenance frequency. For continuously operating urea plants, this “maintenance-free” feature not only lowers labor costs, but also effectively reduces downtime losses caused by maintenance.
4️⃣ Comprehensive Safety Certifications for High-Risk Operating Conditions
In environments characterized by high temperature, high pressure, and potentially flammable or corrosive gases, the safety performance of the device is especially critical. The JWrada®-35 has obtained multiple international explosion-proof certifications, including Ex db IIC T6 Gb, Ex ia IIC T6 Ga, and Ex tb IIIC T80°C Db, allowing it to meet the requirements of both gas and dust hazardous-area applications.
These certifications demonstrate that the device complies with stringent standards in electrical safety, structural protection, and operational reliability. It can therefore be widely used in petrochemical, fertilizer, and other high-risk process industry applications, providing strong support for safe plant operation.
5️⃣ Easy Operation and High Level of Intelligence
As industrial automation and digitalization continue to advance, the intelligence level of field instruments has become an important evaluation criterion. The JWrada®-35 integrates a Bluetooth 5.0 communication module and supports the “JW Tools” mobile application, enabling users to complete parameter setting and commissioning without opening the instrument housing.
Through mobile terminals, operators can view the operating status of the device in real time, adjust parameter settings, and perform remote diagnostics and maintenance. At the same time, the device supports the HART communication protocol and can be seamlessly integrated into DCS or PLC systems for centralized data management and remote monitoring. This intelligent design not only improves ease of use, but also significantly enhances maintenance efficiency and on-site safety.
Overall, in the extreme operating conditions of pool condensers characterized by high temperature, high pressure, and strong corrosion, the JWrada®-35 radar level meter achieves stable, safe, and low-maintenance level measurement performance through its highly reliable design, excellent environmental adaptability, and intelligent functional advantages. For urea plants with extremely high requirements for safety and continuity, this product is undoubtedly an ideal choice for achieving efficient operation and risk control.
5. Application Results and Customer Value
In practical applications in pool condensers within urea plants, the JWrada®-35 not only ensures measurement stability, but also brings significant overall value enhancement to enterprises, fully demonstrating Jiwei’s technical strength in the field of high-end level measurement.
1️⃣ Stable and Reliable Measurement
Even under high-temperature, high-pressure, and strongly corrosive conditions, the JWrada®-35 can maintain stable output, avoiding signal drift and false measurement. Even in the presence of gas-liquid two-phase disturbances and steam interference, the device can still accurately identify the true liquid level, providing reliable data support for process control.
2️⃣ Significantly Improved Safety
Stable level measurement can effectively prevent system fluctuations or safety risks caused by level errors. At the same time, the product features comprehensive explosion-proof certifications and a highly reliable design, enabling safe operation under high-risk conditions and providing continuous protection for the plant.
3️⃣ Effective Reduction in Maintenance Costs
Thanks to its non-contact measuring principle and wear-free structural design, the device requires virtually no maintenance during operation, significantly reducing maintenance frequency and downtime, lowering overall maintenance costs, and improving equipment utilization efficiency.
4️⃣ Continuous Optimization of Operating Efficiency
Accurate and stable level data helps operators better control the reaction process, improving the stability and continuity of system operation, thereby optimizing production efficiency and reducing energy waste.
5️⃣ Brand and Technological Strength as Assurance
The stable performance of the JWrada®-35 is rooted in Jiwei’s long-term technological accumulation and engineering experience in the field of level measurement. Through self-developed radar technology and a strict quality control system, Jiwei provides customers with reliable products and mature application solutions, helping enterprises achieve safe and efficient operation.
Overall, the JWrada®-35 not only improves measurement reliability, but also creates continuous value for users in terms of safety, cost control, and production efficiency. It is a trustworthy level measurement solution for high-temperature and high-pressure operating conditions.
6. Conclusion: A Preferred Level Measurement Solution for High-Pressure Corrosive Environments
In the typical application scenario of a pool condenser characterized by high temperature, high pressure, and strong corrosion, the reliability of level measurement is directly related to plant safety and production efficiency.
With its:
- 80 GHz high-frequency radar technology
- Excellent anti-interference capability
- Non-contact, maintenance-free design
- Comprehensive safety certification system
the JWrada®-35 radar level meter provides the chemical industry with a reliable, stable, and efficient level measurement solution, making it an ideal choice to replace traditional measurement methods.