IoT-Based Liquid Level Monitoring and Control System for Industrial Applications

Storage vessels play a crucial role in the chemical industry by accommodating a wide range of solvents, including those that are toxic, volatile, or hazardous. It is essential for process engineers to maintain optimal liquid levels for various unit operations, making continuous fluid level monitoring a necessity. Failure to monitor the liquid level in a tank appropriately can lead to spills and potentially dangerous accidents. Inadequate liquid levels can also result in vessel damage and operational disruptions. In this study, we have developed a real-time liquid level monitoring system that calculates and transmits data to a remote server via a wireless network. This IoT-based monitoring system is constructed using components such as the ESP32 microcontroller, HC-SR04 ultrasonic sensor module, LCD display, and motor driver unit. This system sends real-time data to a central server, allowing multiple users to access the current level and quantity of chemicals or solvents. Furthermore, our system offers remote valve control capabilities through IoT technology, enabling users to open or close inlet and outlet valves remotely, and even automate these actions. This work provides significant benefits to process engineers, as it offers live updates on liquid levels, which can be conveniently accessed from their workstations or mobile devices, enhancing safety and efficiency in chemical industry operations.