Say goodbye to manual silo inventory checks and single-point material estimation! The 3D radar level scanner enables precise, three-dimensional inventory counting across the entire coal silo.

Raw coal silos, clean coal silos, and buffer silos at thermal power plants, coal mines, coal washing plants, and coal chemical plants face three major management challenges year-round, which have long hindered production and safety control:

1. Traditional single-point measurements result in significant errors, leaving inventory levels perpetually “unpredictable.”

Conventional single-point radar and heavy-weight level sensors can only measure the height at a single vertical point. Coal naturally accumulates in silos to form piles with extreme height variations, often resulting in uneven distribution, bridging, “mouse holes,” and coal buildup on the side walls. Data from a single point cannot accurately represent the total inventory in the silo; measurement errors can easily reach hundreds of metric tons, leading to coal procurement and production scheduling that rely entirely on empirical

2. Manual inventory counting poses high safety risks and is extremely inefficient.

To verify the actual amount of coal, on-site personnel must climb dozens of meters to the top of the silo and manually measure the volume using a tape measure in a highly dusty, enclosed, and flammable and explosive environment. Risks such as high temperatures, dust, and coal collapses and falls are ever-present; a single full-silo inventory takes 1–2 hours, and during peak periods, frequent remeasurements are required. Labor costs remain high, and this process is highly prone to causing safety incidents.

3. In high-dust environments, conventional monitoring equipment frequently malfunctions.

The continuous feeding and discharge of coal from the silo generates large amounts of suspended coal dust, which easily obscures optical laser equipment, leading to signal loss and data drift; conventional radar lacks sufficient penetration capability, and the mist and moisture inside the silo further exacerbate measurement failures, making it impossible to achieve continuous, stable 24-hour monitoring.

The kaidi3D Radar Level Scanner: A Core Solution Setting a New Standard for Digital Coal Bin Measurement

The KD-LF-3D7300 3D Radar Level Scanner was specifically developed for high-dust, explosion-proof, and enclosed environments in coal silos. Leveraging continuous-wave millimeter-wave 3D scanning technology, it upgrades traditional “single-point height measurement” to 360° full-area scanning, performing real-time 3D CT scans of coal silos to completely resolve the industry’s measurement challenges. 1. Full-bin 3D Modeling with Automatic, Precise Calculation of Volume and Tonnage Equipped with a multi-angle rotating scan module capable of 360° horizontal and 90° vertical rotation, the device captures 16,200 high-precision point cloud data points, fully capturing all details such as the unevenness of the material pile, voids, and material displacement. Complemented by intelligent algorithms for automatic mesh modeling, the system outputs the following in real time: maximum material level, average material level, total material volume, and raw coal weight. The comprehensive measurement error is controlled within 0.5–2% FS, putting an end to rough, estimate-based management. The system’s backend generates a color-coded 3D heatmap model, visualizing the material distribution within the silo on a single screen, allowing managers to intuitively grasp the full picture of the silo’s contents without having to climb inside. 2. Millimeter-wave radar penetrates dust effectively and operates stably around the clock Unlike laser-based optical devices, millimeter-wave radar signals are not affected by high concentrations of coal dust, mist, or water vapor. It maintains stable distance measurement even during peak dust generation periods and does not suffer from lens obstruction or failure due to dust accumulation. The entire unit features an IP67 protection rating and comes with coal safety and explosion-proof certification, making it perfectly suited for flammable and explosive enclosed silos such as raw coal silos and pulverized coal silos. It withstands extreme temperatures and corrosion, enabling 24/7 uninterrupted online monitoring. 3. Unmanned, Fully Automatic Scanning for Zero-Manual-Intervention Inventory Counting Supports customizable scheduled scanning: every 30 minutes / every hour / daily automated full-bin inventory at fixed times—no downtime or on-site personnel required. Historical data is automatically stored and archived, generating material level change curves and monthly inventory reports. Data can be seamlessly integrated with power plant fuel management systems, coal mine ERP systems, and DCS control platforms, eliminating production data silos and providing precise data support for coal procurement and unit load scheduling. 4. Lightweight and easy to install, with zero major construction required for retrofitting existing silos. The device is hoisted through the existing instrument access opening on the silo roof; the installation opening is only 200 mm in diameter, eliminating the need for large-scale silo modifications. A single person can complete the commissioning. A single unit covers small to medium-sized silos, while large and extra-large coal silos support networked scanning using multiple devices. The algorithm automatically fuses point cloud data from multiple units to achieve full, blind-spot-free coverage of extra-large silos.

Practical application scenarios covering the entire coal industry chain

▲ Thermal Power Plant Raw Coal Silos and Pulverized Coal Silos: Real-time monitoring of fuel inventory, precise control of coal consumption, reduction of power generation costs, and assurance of a stable coal supply to power generation units;

▲ Coal Mine Coal Preparation Plants: Separate metering for raw coal, clean coal, and gangue silos to accurately distinguish between different types of coal inventory;

▲ Coal Chemical and Coking Plants: Explosion-proof monitoring of sealed pulverized coal silos to provide early warnings of risks such as bridging, blockages, and voids;

▲Port coal storage silos: Unified digital management of multi-silo clusters, with automatic inventory counting of transshipped coal volumes.

Amid the wave of digital transformation sweeping the coal industry, safe, accurate, and efficient material measurement is a key strategy for companies to reduce costs, improve efficiency, and strengthen their safety defenses. The kaidi3D Radar Level Scanner overcomes the limitations of traditional coal silo measurement technologies. With its four core capabilities—3D visualization, high-dust adaptability, explosion-proof safety, and fully automated, unmanned inventory management—it replaces outdated manual and single-point measurement methods, delivering standardized smart coal silo measurement solutions for power plants, coal mines, and coal chemical enterprises.

To obtain on-site survey plans for coal silos, product specification white papers, and case studies from the industry, please send a private message to our support team with the keyword [Coal Silo Inventory]. Our technical engineers will provide free, one-on-one solutions tailored to your specific operating conditions!