Effluent Treatment Upgraded with pH Monitoring and Flow Proportional Control at Tenmat

Tenmat, a leading manufacturer of fire protection materials, partnered with Pi through TC Engineering Services to implement a dependable online monitoring and control system for its effluent treatment process at the company’s Irlam facility in the UK. The project required a solution that could maintain accurate pH control, optimize chemical dosing, and perform consistently in a demanding industrial environment.

Tenmat needed accurate pH adjustment and correction, along with precise flow proportional flocculant and polymer dosing control. Due to the harsh conditions inside the effluent treatment system, the company also required equipment that would reduce manual maintenance while supporting long-term process stability and regulatory compliance.

To meet these requirements, Pi supplied two pH sensors equipped with automatic sensor cleaning technology for direct insertion into the serpentine DAF inlet line. One pH sensor controlled alkali dosing to maintain strict pH limits, while the second provided continuous monitoring of system performance. Pi’s AutoClean feature keeps the sensors operational even in heavy fouling environments, which reduces routine maintenance and ensures reliable measurement accuracy.

The CRIUS®4.0 instrument controller received a flow signal directly from the plant’s effluent line flow meter and used advanced flow proportional control to automatically adjust flocculant dosing rates in real time. This capability helped Tenmat maintain compliance, improve consistency in effluent treatment, and optimize chemical usage, which contributed to cost reductions.

All key process data, including pH readings, flow values, and control activity, was logged to an integral micro-SD card in the CRIUS®4.0. This provided a complete audit trail along with full visibility of treatment conditions. The system is also fully online, allowing Tenmat engineers to remotely monitor trends, adjust parameters, and receive direct support from Pi’s engineering team. This remote access capability improved responsiveness, reduced downtime, and ensured that plant performance remained consistent and reliable.

By combining automatic cleaning pH sensors with the versatile CRIUS®4.0 controller, Pi delivered a reliable, low-maintenance, and cost-effective effluent treatment monitoring and control solution for Tenmat. Real-time data logging, intelligent dosing control, and remote engineering support have improved confidence in system performance and long-term operational efficiency.

A short video is available that showcases Pi’s sensor cleaning options. Facilities experiencing similar challenges can contact Pi to learn how solutions such as pHSense can enhance wastewater monitoring accuracy, reduce manual maintenance, and improve process reliability.