Fine powders are generated in large volumes by industrial activities such as mining, metallurgical processing, energy generation and processing of waste. To meet specifications for further use, powder processing such as comminution and size classification are commonly applied. To optimise the design and operation of air-flow based classification processes, continuous online, monitoring of variations in dust particle concentration are an asset. This paper reports on the development of a novel ultrasonic measurement system suitable for robust monitoring of air-borne dust concentration variations during the operation of powder classification installations. The system was tested on a pilot-scale classifier designed for air-borne separation and recovery of ultrafine powders from coal combustion fly ashes. The monitoring method is based on a measurement of ultrasonic wave attenuation by particles suspended in the air-flow of the classifier. (C) 2020 Elsevier B.V. All rights reserved.