Foam Detection Systems

HYC-FD
JR11/13

FOAM DETECTION
AND
CONTROL SYSTEMS

LEVEL DETECTION FOR FOAM

 LIQUID AND FOAM LEVEL MEASUREMENT
Hycontrol have the most extensive range of aqueous and non-aqueous
foam detection systems in the world. These sensors and systems are
purposely designed and manufactured to detect, analyse and process
virtually any foam. They provide key benefits to industry including;- huge
reductions in anti-foam products, increased batch sizes, reduced
environmental pollution and significantly improved production efficiency.
Hycontrol’s foam detection range uses patented ‘Intelligent Multi-Action’
(IMA) sensor technology to detect the foam. This technology originated
from Shell Oil’s research and development team purely for the purpose
of foam detection within their own business. This technology has now
been integrated into Hycontrol to expand and develop further into a
global, market leading foam detection range.
This range of products will detect a very light foam, even with heavy
deposits coating the measuring probe. This unique ability differentiates the Hycontrol range from all other competitive
foam detection systems.

FEATURES, ADVANTAGES AND BENEFITS

• REDUCE ANTI-FOAM COSTS UP TO 40% • IMPROVE PLANT EFFICIENCY

• REDUCE PROCESS DOWN TIME • AVOID ENVIRONMENTAL POLLUTION

• REDUCE WASTE AND PRODUCT LOSS • INCREASE PRODUCTION CAPACITY

• INCREASE BATCH SIZE CAPACITY • HYGIENIC FDA APPROVED

• MEASURE FOAM + LIQUID SIMULTANEOUSLY • IMMUNE TO PROBE FOULING

FOAM PROBLEMS
SUITABLE OCCUR
FOR ALL IN MANY INDUSTRIES
INDUSTRIES

FOOD FUELS & OILS PHARMACEUTICAL CHEMICAL WATER & WASTE

TYPICAL APPLICATIONS

· Food Processing · Tanker washing plants · Animal feed

· Pharmaceutical · Alcohol distilleries · Paper mills
· Water and waste · Pressure cookers · Sugar factories
· Chemicals · Varnish production · Brewing and yeast
· Beverages · Antibiotic production · Oilseed processing
· Coolants · Bio-fuels · Gas scrubbing
· Resin production · Bitumen production · Oil lubrication
 SURESENSE - DETECTION, MEASUREMENT & CONTROL

The SureSense range allows for the accurate control of aqueous foam by sensing
when the foam reaches the end of the probe. This range has excellent resistance to
fouling and build up on the measuring probe and still continues to operate reliably
with large deposits on the sensing element. The SureSense range can have single
or dual set points, and is used extensively for reducing the amount of chemical anti-
foam agents used. This range is designed to be used with a controller which can
provide output signals to indicate foam density and foam level, utilising a 4-20mA
output. This range can be mounted horizontally or vertically in the tank.

• 316 Stainless Steel probe • Probe length up to 6m

• FDA approved materials • Steam sterilizable

• SGS system certificate • Pressure up to 10 bar

• PEEK (chemical resistant) • ATEX system certificate

• Unique IMA® sensing technology • Resolution +/- 1mm

MULTISENSE - DETECTION OF FOAM AND LIQUID

The MultiSense can measure aqueous foam and liquid levels at the same time, and
can provide an output of both levels simultaneously if required. This range is
available in three versions, one for foam, one for liquid level only and one for both
foam and liquid. The device uses an array of small sensors built into one probe body
and is mounted vertically into the tank. Each sensor acts as a separate micro-
sensor, which is used to measure the material adjacent to it. This enables precise
level control of both foam and liquid levels simultaneously. The MultiSense uses
patented IMA sensing technology which provides reliable continuous level
measurement but with the ability to ignore any product fouling on the sensor probe.

• Unique IMA® sensing technology • Hygienic construction

• Pressure up to 40 bar - (options) • 316 Stainless Steel probe

• Foam and Liquid measurement • 4-20mA Output

• Temperature up to 180°C • Resolution +/- 1mm

• Wide range of process connections • Steam sterilizable

DIFOAM - NON-WATER BASED FOAM

The DiFoam range of sensors and controllers are designed for the measurement
and control of non-water based foams, these are very similar to the SureSense and
MultiSense but have very different electronic detection circuits, due to the large
difference in dielectric of the materials measured. They provide an efficient, reliable
and cost effective solution to foam control in a diverse range of industries, where the
production and control of foam causes a problem. Typical applications include
oilseed processing, oil and gas separation, resin production, solvents and gas
scrubbers.

• 316 Stainless Steel probe • Resolution +/- 1mm

• Detects non-water based foam • Temperature up to 200°C

• Wide range of process connections • Pressure up to 40 bar

• Unique IMA® sensing technology • PEEK (chemical resistant)

 FOAM TENDENCY ANALYSER - FOR FOAM PREDICTION
Foam can occur in many processes in different applications but can
also manifest itself to show later downstream of the process. For
example, vehicle washing stations or outlets, treatment works into
river courses or coastlines. Here the foam may not develop until it is
agitated by the flow downstream or by the constant churning of the
surf. This means it may look ok before it leaves a works, but when
into the environment it can produce an unsightly pollution incident.

The FTA100 is a unique foam control system that provides a pre-

emptive (rather than reactive) approach to foam control. Operating
fully automatically, it measures the tendency of a liquid to create
foam and can take action before foaming occurs. This is achieved by
taking a sample from the process and analysing the foam tendency
in a small test cell.

The FTA includes a series of pumps for sample handling. A fill pump (A) is used to draw a sample from a process into
the test cell (B). The sample in the test cell is analysed by sparging air through it to create foam. The foam is then
measured using a foam sensor. Once the measurement is complete the sample is removed by means of the drain
pump (C), and returned to the process or discarded.
EARLY WARNING
As an option, the system can be (optional)
On Foam Dose Error
set to act as an early warning to Anti-
detect foam before it occurs foam
pump
elsewhere down stream of the
Process line monitored

FTA100 Controller
process. Alternatively, it can be
used to simulate a process to Foam
Anti-foam
indicate that foam is being tank Sensor
generated. Air
pump
Air out
ERROR DETECTION
A built in error detection system
prevents the pumps running if the Drain
pump
sample is not flowing correctly. A
For example; if the test cell does
not fill then the system will Fill C
pump
generate an error alarm.
Sample Discharge
MINIMAL MAINTENANCE point from process line B to waste
The FTA100 has been designed
for minimal maintenance Test cell
intervention and will operate for
long periods without any attention. The test cell can be easily removed to rinse out any debris that builds up, when
necessary. The FTA100 has an option to be supplied without an integral dosing pump in applications where the
customer wishes to provide their own dosing pump. This is the FTA101.

TYPICAL APPLICATIONS

Outflows from effluent Public fountains and Outflows from effluent Sewers and drains which
plants, industrial car wash water feature plants into rivers, streams are inaccessible for foam
systems pollution and coastlines detection
 UNIQUE FOULING IMMUNITY WITH IMA SENSING

Product fouling and deposits on a measuring probe are often associated with many
foaming applications. The high sensitivity required to detect light foam products is essential
but equally important is the ability to differentiate between product coating and product
rising in a tank. This is where Hycontrol IMA (Intelligent Multi Action) sensing leaps ahead
of all other ‘foam’ detecting technologies, as it will operate efficiently and repeatably even
when the probe becomes fouled with residual product.
Hycontrol foam control systems utilise IMA sensing technology incorporating a special
guard electrode shown on the diagram opposite (in blue). This guard electrode disrupts the
signal produced from the accumulated fouling on the probe which has a desensitising
effect on the switch. This then enables the main foam sensor (in red) to ignore this product
build up no matter how thick it is and to only monitor the foam within the process. Therefore
even with dense or sticky fouling on the sensor may become, the Hycontrol foam probe
continues to function giving accurate and reliable foam control.

A small batch
reactor still
operating
efficiently with the
probe covered
and totally hidden!
Sensing
Probe covered
IMA principal
displaying the
guard probe and
the measuring
probe

TYPICAL FOAM PROCESS CONTROL SYSTEM

Many foam applications require not only a switch or level measurement device to detect the foam, but also a system
to control the process. A typical example of automatic foam control would be in a fermentor in a pharmaceutical
process, whereby it is known that during the process foam will occur. It may be that the process requires a minimum
amount of foam to chemically react or no foam at all but this will vary from application to application. Historical control
has been automated to dose at a nominal amount on a timed basis, wether there is foam or not.

However, what typically will happen is that overdosing occurs which can have several detrimental side effects. This
includes a vast overdose effect using far more anti-foam chemical agent than is actually required or more importantly
it may have an effect on the biological process such
as reducing the efficiency of the process and thus Foam Controller
Sensing Probe
reducing yield from the batch. Both scenarios are
undesirable and both can be rectified easily.

Hycontrol provide a complete automatic dosing

control system similar to the one shown in the Control
relay O/P
schematic adjacent. This system operates by taking
for dosing
a measurement, looking for foam, then if foam is pump
detected releasing a small amount of anti-foam Dosing
Pump
agent which is controlled by the Hycontrol
controller. If the foam disappears then it will stop
dosing. However, if the foam persists it will
automatically continue the dosing rate and dose Foam
again until the foam has reduced to an acceptable Anti-Foam
level. This system provides a closed loop control to Tank Liquid
control foam and reduce anti-foam agent, at a
minimal cost but with maximum efficiency.
 FOAM DETECTION SPECIFICATIONS
SPECIFICATION SURESENSE MULTISENSE DIAFOAM FOAM TENDENCY ANALYSER

AQUEUOS Yes Yes No Yes

NON-AQUEOUS No No Yes No

LEVEL SWITCH Yes Yes Yes Yes

CONTINUOUS LEVEL No Yes No No

MAX. PROBE LENGTH 4m Max. * 4m Max * 1m n/a

VERTICAL MOUNTING Yes Yes Yes n/a

HORIZONTAL MOUNTING Yes No Yes n/a

RELAY OUTPUT 1 or 2 SPDT 3A/230V 3x SPDT 3A/230V 2x SPDT 3A/230V 1x SPDT 3A/230V

VOLTAGE 110/230V AC or 24V DC 90/300V AC or 24V DC 110/230V AC or 24V DC 110/230V AC

4-20mA OUTPUT Yes Yes (x2) Yes No

FOAM DENSITY OUTPUT Yes n/a Yes No

FDA APPROVED Yes Yes Yes n/a

HYGEINIC OPTION Yes Yes Yes n/a

ATEX Yes No Pending n/a

DUAL SENSING Yes n/a No No

IMA SENSING Yes Yes No Yes

FOAM PREDICTION No No No Yes

* Probes can be manufactured longer if required but will be priced on an individual basis. Contact Hycontrol for more information.
When considering a foam application it is important to identify all the key parameters required to make the correct selection. Please
consult Hycontrol for a pre-application questionnaire providing a check list to ensure the correct probe is chosen and to enable Hycontrol
to issue a performance warranty.

Honda Client
Automotive Industry
Paint production Application
A paint production process included a vacuum stage during which solvent was extracted. However, foam was
generated when the vacuum was created, causing considerable disruption to the process. A Charis Foam Control
System was installed to close to the vacuum valve and inject controlled amounts of nitrogen into the process,
restoring reliable control throughout the whole process.

Lilly Client
Veterinary products Industry
Research vessels Application
Having installed a new suite of research vessels, Lilly ( manufacturer of animal drugs), discovered that one process
was rendered inoperable by foaming. The whole suite of vessels was effectively out of action. Once Charis Foam
Sensors and controls were installed the problem was completely solved. They regained effective and reliable control
at every stage of the process.
 TYPICAL APPLICATIONS & USERS
Sasol Client
Oil & Gas Industry
Gas scrubbing Application
Sasol used a gas scrubbing process as part of its production. Foam occurred in the column which reduced the
available flow rates. The company evaluated many systems before commissioning Charis to develop a special multi-
functional sensor which could be used to analyse the foaming conditions in the column.

Genzyme Client
Pharmaceutical Industry
Fermentation Application
A well known U.S. Diagnostic pharmaceutical manufacturer installed a new Charis Foam System on a production
fermenter. The next week the anti-foam use fell by 40% and the product yeild rose by 15%. The company
investigated and found that the old system had been adding too much antifoam, and unknown to them this had
significatly reduced the efficiency of the process. The payback period of the new system was immediate.

GlaxoSmithKline Client
Antibiotic production Industry
Fermentation Application
GSK, A well-known British pharmaceutical company installed Charis Foam Controls in its antibiotic production
fermenters. The improved foam controls gave a reduction in the headspace volume and a resulting increase in
production volume. The payback time for this application was a matter of days.

Giusti Briggs Client

Food Industry
Vacuum cooling Application
Within the food industry a vacuum cooling process is often employed which results in rapid foaming.
Briggs Giusti is a major cooking vessel manufactuer whom have incorporated the Charis Foam System as a
standard part of their equipment to prevent product loss and damage to vacuum pumps.

Scott Bader Client

Resin manufacture Industry
Gas stripping Application
The production of resin generated foam as part of the gas stripping process. The foam was particularly difficult to
measure and a new high-sensitivity sensor was developed for this application.

ICI Client
Chemical Industry
Effluent treatment Application
Was having problems with detergent leaking into the effluent stream that found its way into the nearby river. This
resulted in large amounts of foam at the outflow. Charis designed a system which gave an early warning before any
foam appeared in the river, followed by intervention, thus eliminating pollution into the environment.
HYCONTROL LEVEL TECHNOLOGIES

(1) (2)
(3) (4)
Product Range For Solids :- (5)
(1) TDR Radar For Solids
(2) Ultrasonic, ‘Through Air’
(2) 2 Wire Ultrasonic Transmitter
(6)
(3) FMCW 2 Wire Radar
(4) Continuous ‘Servo’ Level Indicator (7)

(5) FMCW 2 Wire Radar (8)

(6) Capacitance Level Switch
(9) (9)
(7) Vibrating Probe Level Switch
(8) Rotating Paddle Level switch
(9) Microwave Level Switch
(10) Doppler Flow Switch (10)

Product Range For Liquids :- (4)

(5)
(1) By-Pass Level Indicator With Radar (3) (6)
(2)
(2) TDR Radar For Liquids (7)
(1)
(3) 2 Wire Ultrasonic Transmitter
(4) FMCW ‘Horn’ Radar 2 Wire
(5) Magnetic Float Switches (8)
(6) FMCW 2 Wire Radar
(9) (10)
(7) Foam Level Switch
(11)
(8) Capacitance Level Switch
(9) RF Admittance Level Switch
(10) Side Mounting 316 SS Float Switch (11)

(11) Tuning Fork Level Switch

(11) Tuning Fork Level Switch (13)
(12) Ultrasonics ‘Through Wall’ (12)
(13) Mini Magnetic Float Level Switch

Hycontrol Ltd, Larchwood House, Orchard Street, Redditch, Worcestershire, England, B98 7DP
Tel : 01527 406800, Fax : 01527 406810, [email protected], www.hycontrol.com