| |  Flue, Stack and General Emissions Monitoring
Flue gas is gas that exits to the atmosphere via a flue, which is a pipe or channel for conveying exhaust gases from a fireplace, oven, furnace, boiler or steam generator. Quite often, it refers to the combustion exhaust gas produced at power plants. Its composition depends on what is being burned, but it will usually consist of mostly nitrogen (typically more than two-thirds) derived from the combustion air, carbon dioxide (CO2) and water vapor as well as excess oxygen (also derived from the combustion air). It further contains a small percentage of pollutants such as particulate matter, carbon monoxide, nitrogen oxides and sulfur oxides.
Why is combustion analysis important? Combustion Efficiency = Fuel Savings1% increase in efficiency nets 1% fuel savings Combustion SafetyCO toxic to humans Preventive MaintenanceIdentify repairs and reduce downtime Environmental MeasurementsCO & NOx hazardous to the environment
CO2 is a “Greenhouse Gas” 
Testo 350 flue gas analyser
testo 350 XL analyser box, equipped with O2, CO (with switch-off and rinse function), NO, NO2, differential pressure measurement, 2 temperature probe sockets, gas preparation, Testo data bus adapter, automatic fresh air rinse with valve including measurement range extension with dilution factor 5 for all sensors), built-in rechargeable battery, data memory, can be upgraded to max. 6 measurement modules (with H2S, HC, SO2, CO2 NDIR)
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Testo 335 flue gas analyser testo 335 is the new generation flue gas analyser, specially tailored to industrial applications' requirements. The typical kit comprises of a testo 335 flue gas analyser, rechargeable battery and calibration protocol included, equipped with O2 sensor, upto 2 optional sensors, a industrial or vehicle probe, case and infrared printer. | 4 respect. 6 gas sensors | yes, optional | yes | yes | 5 steps up to factor 40 for CO (optional) | yes, up to 1000m | optional for testo 350 M, standard for XL (as well suitable for overpressure) | CU: climate parameters -via BUS: t454 + additional analysis boxes | several days (tube pump) | yes, built-in | integrated |
| sensor equipment | H2S, CO2, HC | Δp- / m/s-measurement | gas processing | Dilution (measuring range extension) | control unit + analysis box separated | fresh air valve | additional parameters via probes | long-duration measurements | printer | power mains |
| max. 3 sensors | no | yes, optional | no | 2 dilutions: - factor 5 for CO/SO2/NO2 - factor 2 over all (optional) | no _ portable instrument | no | temperature | max. 2 h (monitored condensation trap) | optional table printer | separate |
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Carbon Monoxide (CO) CO is a colorless, odorless, poisonous gas and is the product of incomplete combustion. It has about the same density as air, therefore mixes easily. CO prevents the blood from absorbing oxygen. The Threshold Limit Value (TLV) is 50 ppm.
CO Health Effects 50 ppm200 ppm400 ppm800 ppm1600 ppm3200 ppm6400 ppm12800 ppm | OSHA Permissible Exposure Limit – 8 hours
Slight headache with 2-3 hours
Headache within 1-2 hours
Sickness & twitching of limbs within 1- 2 hours; unconsciousness in 2 hours
Headache within 20 minutes; death within 2 hours
Death in 30 minutes
Death in 10-15 minutes
Death in 1-3 minutes |
Nitrogen Oxides (NOx) At higher combustion temperatures, the N2 in the fuel and ambient air combines with the O2 in the air to form nitrogen monoxide (NO). This colorless gas then oxidizes with O2 to form nitrogen dioxide (NO2).
NO2 is a respiratory poison and combines with UV radiation (sunlight) to form ground-level ozone (smog).
Sulfur Dioxide (SO2) SO2 is a colorless, toxic gas with a pungent smell. It is formed by sulfur present in the fuel (eg. fuel oil, coal, mixed fuels), combining with O2.
The Threshold Limit Value (TLV) is 5 ppm.
SO2 combines with water or condensate to form sulfurous acid (H2SO3) or in the atmosphere as acid rain. Unburned hydrocarbons Unburned hydrocarbons (CxHy) are formed under incomplete combustion conditions. This group includes methane (CH4), butane (C4H10), and benzene (C6H6).
CxHy contribute to the greenhouse effect and global warming.
Goals The following goals apply when measuring industrial flue gases:
Emissions monitoring
– Adherence to legally specified limits (e.g. TA Luft)
– Meeting ISO 14000 requirements
– Important parameters: NOx (NO + NO2), SO2, CO, H2S, O2 and in some cases CO2 Adjustment and optimisation of systemsThis refers to adherence to emission limits. Otherwise the aim is to reduce operation costs by saving energy.
Important parameters: O2, CO, CO2, excess air and efficiency. Process monitoring in the manufacturing industries
Monitoring combustion processes for quality assurance purposes, ISO 9000
requirements, reduction of non-spec products, reduction of costs by saving
energy and minimising down periods. Important parameters: O2, CO, CO2, SO2. |
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