Against the background of accelerating global energy transition, bioenergy, renewable gas, and resource recovery projects are becoming important directions in Europe’s clean energy development. Recently, Shenzhen Jiwei Automations Ltd. successfully won the bid for the France Helios BioEnergy Project, relying on its product strength, engineering experience, and comprehensive technical service capabilities in the field of level and material measurement. Jiwei Automation will provide multiple sets of process measurement instruments, including the PRO series radar level meters and Ring-11 series tuning fork level switches.
In this project, Jiwei Automation products are applied in key process sections such as methanol recovery, absorption and separation, condensate collection, multiphase media separation, and dry-run protection. These instruments provide stable and reliable level monitoring support for continuous production, process control, and safety interlock operation in the clean energy plant.
I. Project Overview: An Integrated Bioenergy Plant for Europe’s Clean Energy Transition
The France Helios BioEnergy Project is located in an industrial area in northern France and is one of the important projects in the local clean energy industry chain. Using biogas as the main feedstock, the project adopts separation, absorption, distillation, condensation, and recovery processes to purify and utilize biomethane and methanol, ultimately supporting green power generation, chemical feedstock recovery, and low-carbon energy production.
According to the project plan, the plant will be capable of processing organic waste on a large scale and continuously producing renewable energy products after completion. It is expected to make a positive contribution to reducing greenhouse gas emissions and improving the resource utilization of organic waste. For this type of integrated clean energy facility, stable level data is not only related to process efficiency, but also directly affects equipment protection, interlock control, and on-site safety.
In absorption towers, distillation columns, condensation separators, methanol traps, and multiphase separation equipment, the liquid level changes frequently and the medium conditions are complex. If level monitoring is inaccurate, it may lead to pump dry running, abnormal tower bottom conditions, medium overflow, or reduced separation efficiency. Therefore, the project owner set high requirements for the accuracy, reliability, explosion-proof performance, corrosion resistance, and system compatibility of the level instruments.
II. Complex Operating Conditions Require Higher Performance from Level Instruments
The main media involved in the Helios project include methanol, water, carbon dioxide, methane, hydrogen, hydrogen sulfide, and sulfur dioxide. The site conditions are characterized not only by multiple components, but also by gas-liquid two-phase flow, liquid-liquid stratification, foam, rapid condensate changes, and the influence of corrosive gases.
In some process sections, the operating temperature can reach approximately 150°C, and the maximum pressure can reach 21 bar. The medium state varies significantly in different equipment:
In absorption towers and distillation columns, gas-liquid exchange is frequent and the liquid surface fluctuates significantly;
In methanol traps and condensation separation systems, gas condenses to form liquid layers, and the level changes rapidly;
In multiphase separation equipment, methanol, water, and organic residues may form stratified layers, placing higher demands on measurement stability;
At pump inlets, tower bottoms, and reflux tanks, reliable high- and low-level alarms and dry-run protection are also required.
Such working conditions are challenging for traditional level instruments. High temperature, high pressure, corrosive media, foam interference, and gas-phase disturbance may cause measurement drift, unstable echoes, or false alarms. Therefore, during the equipment procurement stage, the project owner clearly required the instruments to have explosion-proof capability, safety level certification, pressure adaptability, a high protection rating, and complete test reports and English technical documentation.
III. Jiwei Automation Solution: Coordinated Configuration of Continuous Measurement and Limit Protection
Based on the operating conditions of the Helios project, Jiwei Automation adopted a combined solution of “PRO series radar level meter + Ring-11 tuning fork level switch,” integrating continuous level measurement with safety protection at key points.
The PRO series radar level meter is responsible for continuous level monitoring in key vessels and towers, providing real-time process data to the DCS system. The Ring-11 tuning fork level switch is used for high- and low-level alarms, overflow prevention, dry-run protection, and safety interlock applications, improving operational safety redundancy.
This combined configuration not only meets the process demand for continuous measurement data, but also strengthens protection capability under abnormal conditions. It is suitable for level control applications in bioenergy, chemical recovery, environmental treatment, and complex separation systems.
IV. PRO Series Radar Level Meter: Non-Contact Level Monitoring for Complex Processes
In this project, Jiwei’s PRO series radar level meters are installed on key equipment such as absorption towers, distillation columns, methanol traps, and multiphase separators to achieve continuous, non-contact, high-precision level measurement.
This series adopts 80 GHz FMCW radar technology, featuring a focused beam, strong anti-interference capability, and stable echo recognition. Since radar measurement does not require contact with the medium, it effectively reduces the impact of corrosion, buildup, crystallization, and medium adhesion on the instrument. It is especially suitable for complex scenarios such as methanol recovery, gas-liquid separation, and condensate monitoring.
In terms of system integration, the PRO series radar level meter supports 4–20 mA + HART signal output and can be connected to mainstream DCS systems. According to project selection requirements, the product can be equipped with corrosion-resistant antenna structures and process connections suitable for the operating environment, meeting the site’s requirements for long-term stable operation and convenient maintenance.
During commissioning, Jiwei’s engineering team conducted echo curve analysis, parameter optimization, and site condition matching, enabling the instrument to maintain stable output under foam, vapor, and slight liquid surface disturbance conditions. This provided reliable level data support for the project’s core process sections.
V. Ring-11 Tuning Fork Level Switch: Reliable Limit Protection for Safety Interlocks
In addition to continuous level measurement, the Helios project also set clear requirements for high- and low-level alarms at key positions. Jiwei’s Ring-11 tuning fork level switches are applied in condensation separators, reflux tanks, tower bottoms, pump inlets, and overflow alarm points to identify level status and trigger corresponding protection actions.
The Ring-11 series drives the fork body to vibrate through piezoelectric elements. When the fork contacts liquid, its vibration frequency changes, allowing the instrument to determine whether the liquid level has reached the set position. This measuring method features a simple structure and fast response, without relying on complex mechanical moving parts. It is suitable for methanol, condensate, gas-containing liquids, and some corrosive liquid applications.
According to project requirements, the Ring-11 can be configured with intrinsically safe explosion-proof design and supports NAMUR signal output, making it convenient to connect with common European safety instrumented systems and process control systems. In pump protection, overflow alarm, and tower bottom level interlock applications, this product can serve as an independent limit protection unit, effectively reducing equipment damage and safety risks caused by abnormal liquid levels.
VI. From Selection to Delivery: Full-Process Quality Management Ensures Project Execution
The Helios project set high requirements for equipment delivery documents, testing procedures, and quality traceability. After winning the bid, Jiwei Automation established a dedicated project team to manage the entire process, including technical selection, working condition confirmation, drawing review, manufacturing, factory testing, and documentation delivery.
During production, Jiwei Automation conducted factory calibration, sealing tests, pressure adaptability checks, and functional verification for the instruments in accordance with quality management system requirements. To meet the needs of overseas project delivery, the company also prepared a complete English technical documentation package covering datasheets, model selection sheets, wiring diagrams, process connection drawings, FAT reports, safety instructions, installation and commissioning manuals, and relevant certificates.
During FAT acceptance, Jiwei assisted the customer’s technical team in completing product verification through remote video and synchronized test documentation. This approach not only improved the efficiency of cross-border project communication, but also helped the customer fully understand instrument performance, wiring methods, and commissioning precautions before shipment.
VII. On-Site Application Results: More Stable Level Data and Significantly Reduced Manual Intervention
After the equipment was put into operation, the Helios project operation team gave positive feedback on the level instruments provided by Jiwei Automation. Field application results show that the PRO series radar level meter maintained stable echoes under high humidity, high temperature, foam, and vapor interference conditions. The level curve remained continuous and smooth, meeting the process control requirements for real-time data.
In some working conditions involving condensation on tower inner walls, medium density fluctuations, and obvious gas-liquid mixing, the radar level meter still identified level changes reliably, reducing manual verification and on-site intervention caused by measurement abnormalities.
The Ring-11 tuning fork level switch showed clear switching performance in multiphase media and gas-containing liquids. During start-stop tests, the alarm response remained consistent with actual level changes, providing reliable support for pump protection, overflow control, and safety interlocks.
With the stable operation of the level monitoring system, the frequency of manual inspection on site decreased. Operators can now obtain the level status of key equipment more promptly through the control system, improving overall operation and maintenance efficiency.
VIII. Project Value: Application Breakthrough of Chinese Instruments in European Clean Energy Projects
The successful implementation of the France Helios BioEnergy Project demonstrates Jiwei Automation’s engineering adaptability in demanding level measurement and control applications. Facing complex conditions involving high temperature, high pressure, corrosive media, multiphase flow, and safety interlock requirements, Jiwei provided a solution combining continuous radar measurement with tuning fork limit protection, offering customers a path that balances accuracy, safety, and maintainability.
This project also further proves that Chinese process instruments are upgrading from single-product supply to engineering-oriented, systematic, and international service capabilities. For clean energy, environmental treatment, chemical recovery, and resource utilization projects, a stable level measurement and control system is not only a basic instrumentation configuration, but also an important component for ensuring production continuity and operational safety.
IX. About Jiwei Automation
Shenzhen Jiwei Automations Ltd. focuses on the research, development, and manufacturing of level, material level, and process measurement instruments. Its product portfolio includes radar level meters, tuning fork level switches, rotary paddle level switches, vibrating rod level switches, and other series. These products are widely used in chemical, energy, environmental protection, water treatment, food, pharmaceutical, and metallurgical industries.
The company adheres to reliability as its core principle, continuously improving its R&D, manufacturing, testing, and quality traceability systems while meeting multiple domestic and international certification and testing requirements. With independent R&D capability, engineering application experience, and a global technical service system, Jiwei Automation is providing safe, stable, and intelligent process measurement solutions for more customers in China and overseas.
X. Conclusion
From methanol recovery in bioenergy plants to level monitoring in multiphase separation systems and dry-run protection for key equipment, Jiwei Automation’s application in the France Helios BioEnergy Project demonstrates the adaptability and engineering value of Chinese level instruments in international clean energy projects.
In the future, Jiwei Automation will continue to focus on technology upgrades in radar measurement, tuning fork detection, and safety interlock applications, while further improving its international certification system and project delivery capabilities. The company is committed to providing global industrial customers with more reliable, intelligent, and safer level and material measurement solutions.
