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Foam Control & Measurement


Charis Technology is the market leader in Foam Measurement and Control Systems. The foam sensors are designed for the sole purpose of detecting foam in water-based and non water-based liquids.

Applications

Foam is a major problem in many biotech and other industrial processes. Typical applications are found within production of food and drink, paint and printing ink, water and effluent treatment and biogas, where the sensors are installed in reactors, evaporators, vacuum cooling plants and aerobic as well as anaerobic fermentors.

Benefits of improved foam control

  • Increased throughput by reducing downtime
  • Reduced product loss
  • Addition of antifoam is optimized and costs reduced
  • Reduced waste and pollution due to foam overflow

Basis foam control

Six frame powerpoint presentation demonstrating basic method of foam control using Charis Foam Control System.

Foam control systems – product range

IMA Sensing® technology for Fouling Immunity

Using the patented Multi Action Sensing Technology “IMA Sensing® technology” Charis sensors are able to discriminate between the residual deposits of foam and product that build up on the sensor itself, and the foam being created in the process. Because of this unique technology, the sensors have high accuracy and reliability.

Effectively the Foam Sensor ignores the inevitable fouling while continuing to monitor the foam. No matter how heavily the Sensor is coated, or how dense and sticky the layer, its unique construction enable it to keep measuring foam throughout the process cycle.

The picture shows a Charis sensor coated in a sticky build-up of foam and product. The measuring current which is shown in red continues to flow only through the foam. The blue line represents the leakage current driven by the guard electrode. This enable the sensor to function as the leakage is measured separately and not as part of the foam signal.

Often it is not possible to prevent material build-up, but the “IMA Sensing® technology” enables the sensor to function reliably despite extensive coating or fouling. To see a short video demonstration of “IMASensing® technology” at work please click here

The photographs left show a Braun fermenter which is coated with product. The close-up picture of the sensor (seen arrowed protruding from the headplate) shows it to be completely covered with material but it was still working when the vessel was opened. The user was so astonished that he took a photograph to send to Charis Technology.

The SureSense Range

StyFoam Control Systems – for use in water based foam applications

SureSense sensorer

  • The sensor rods are available in various lengths and with a wide range of fittings for mounting in all sizes and types of vessels and fermentors. The construction is in accordance with the FDA guidelines.
  • Sensors are sanitary, and SIP steam sterilisable
  • Mounting fittings Flange, DN25, BSP, or sanitary Tri-clamp.
  • A wide range of steriale fittings are available for adjustable insertion length
  • Insertion lengths up to 4 meters
  • Laboratory sensors with insertion length 150 mm, 250 mm and 400 mm
  • Max. operating temperature 150 degC (peak temp.170 degC)
  • Max. pressure 10 bar

Foam Controllers for use with SureSense sensors

The control units include adjustment of the sensitivity, and it is possible to adjust both response time and shot time for antifoam agent.

FCW2 Foam Controller

  • Wall mounted, encapsulation IP65
  • Transmit a signal to a process controller or alarm, alternatively to control a pump or valve directly to dose antifoam by means of a ‘Delay and Shot’ algorithm.

FCR2 Foam Controller

  • Rack mounted in a standard 19″ rack
  • Transmit a signal to a process controller or alarm, alternatively to control a pump or valve directly to dose antifoam by means of a ‘Delay and Shot’ algorithm.

FTRAN

  • The FTRAN operates in the same way as the FCW2 but is designed to be surface mounted inside the customers existing control cabinet.b

FCS200 Foam Control System with antifoam pump

  • FCS200 Foam Controller is an advanced design foam controller unit built to rugged industrial standards
  • A diaphragm pump ad antifoam into the process automatically when required.
  • FCS200 can also be connected to external devices such as process controllers, Scada systems and alarms.

FCS2 Laboratory Foam Controller with antifoam pump

  • Bench foam control system with laboratory sensors
  • Control foam in laboratory reactors and process
  • Integral peristaltic pump for automatic addition of antifoam agentn be means of Delay and Shot’ algorithm.
  • One relay activate when foam is detected
  • One relay activate when the pump is operating

FLCW2 Foam and Liquid Controller

  • The FLCW2 can differentiate between liquid and foam.
  • Wall mounted, encapsulation IP65
  • The FLCW2 will detect the rising liquid level, as the foam sensor become submerged in the liquid.
  • The FLCW2 can be used in a “stand alone” system to control a pump or valve directly to dose antifoam by means of a ‘Delay and Shot’ algorithm.
  • This unit is also available as a 19″ rack mounting version the FLCR2

The DiFoam Range

Foam Control Systems – for use with non water-based foam

The DiFoam product range measure and control non-aqueous foams and liquids such as oil, resin and solvents. This foam system differentiate from the SureSense systems by using a technology that is sensitive to the dielectric properties of the media being tested. Applications include resin foam control such as yacht varnish, hydrocarbon foam control, solvent foam control, and level controls in oils and fats such as cocoa butter.

DiFoam Sensors

  • Sensors are hygenic and SIP sterilisable
  • Mounting fittings Flange, DN25, BSP, or sanitary Tri-clamp.
  • A range of steriale fittings are available for adjustable insertion length
  • Insertion lengths from 250 mm to 3 meters
  • Max. operating temperature 200 degC
  • Max. pressure 25 bar

DiFoam Controllers for use with DiFoam sensors

FdiCR DiFoam Controller

  • Rack mounted in a standard 19″ rack
  • Transmit a signal to a process controller or alarm, alternatively to control a pump or valve directly
    to dose antifoam by means of a ‘Delay and Shot’ algorithm

FdiCW DiFoam Controller

  • Wall mounted, encapsulation IP65
  • Transmit a signal to a process controller or alarm, alternatively to control a pump or valve directly
    to dose antifoam by means of a ‘Delay and Shot’ algorithm
  • The optional FCDiW/Z configuration include a Zener barrier for installtion in Ex classified areas.

FTA Foam Tendency Analyser

Foam tendency is a measure of the ability of a process liquid to create foam given adequate conditions of aeration or agitation.

The FTA Foam Tendency Analyser is a pre-emptive approach to foam control. Instead of measuring the foam created our FTA can predict that foam will occur in advance and take the appropriate action before any significant build up occurs.

Applications include bearing coolant on turbines where foaming can cause lack of lubrication and damage, and water features such as fountains where the introduction of foaming agents such as liquid soap can prove both costly and messy.

FTA Foam Tendency Analyser with sampling and antifoam pumps

  • The FTA continually samples the process liquid and creates foam inside a small test chamber
    and the foam is then measured. Based on the results, appropiate actions can be taken before
    there is a significant foaming.
  • One sample every 4 min.
  • Sample volume 200 ml
  • Enclosure IP65
  • If required the antifoam pump can be replaced by an intelligent interface to your own
    process controller.

The MultiSense Range

Multi-Sense is an exciting new concept for foam and level measurement

MultiSense can measure and control liquid and ignore any foam, or measure both liquid and foam giving separate indications of each. It can also be used to just measure foam level precisely over a wide range in processes where foam level is critical. MultiSense will also detect interfaces between phases in the materials, e.g. liquid and foam or different liquids.

Applications have been found in Bioreactor foam control, Water Treatment level control, De-Inking Flotation Processes, Mineral Recovery, Foam Control on varying liquid levels and Liquid level control.

Understanding MultiSense

MultiSense – a new concept.

MultiSense sensors

  • The MultiSense uses an array of mirco-sensors built into one body with each separate micro-sensor
    measuring the material adjacent to it. This allows very high accuracy and enables a number of
    separate parameters to be measured simultaneously.
  • The micro-sensors detect the interfaces between phases in the material, e.g. liquid and foam or
    different liquids
  • The MultiSense sensor array can be supplied in a variety of lengths and fittings, and with varying
    numbers of sensors depending upon the application requirements
  • Immune to fouling
  • Sanitary construction
  • Insertion lengths from 250 mm up to 3 meters
  • Max. operating temperature 180 degC
  • Max. pressure 25 bar

MultiSense Controller

  • The controller energises the sensor and processes the data.
  • The controller can drive up to 8 sensors.
  • The controller calculates the volume of liquid from the height and the internal diamenter of the vessel
  • Wall mounted, encapsulation IP65
  • Output 4-20 mA liquid level
  • Output 4-20 mA foam level
  • Relay contacts for both level and foam control
  • Although the control panel display is part of the MultiSense Control unit, it may be placed in an
    existing control room by using a special cable.
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