Flue gas measuring technology for the trades

Ideal operating range of furnaces The aim of flue gas measuring technology is to ensure the environmentally friendly and economic operation of furnaces. The given formulae and tables can be used to understand flue gas measuring technology. They are also stored in the Testo flue gas analysers. All of the calculations are carried out automatically. Flue gas components Combustion diagram: Ideal operating range of heating installations

Flue gas measuring technology for the trades

Efficiency Maximum efficiency is achieved if there is slight air excess and the flue gas efficiency is as high as possible. For further technical details contact your Testo sales office.
For maximum efficiency CO2 should be as high as possible CO should be within safe limits (very low)

Why you should choose Testo flue gas analysers

Optimum setting of heating installtions Chemical absorption kit 16 years ago chemical kits, the bimetallic thermometer and the smoke tester were the only aids available to adjust the optimum operative range in furnaces. The chemical kits always had one major disadvantage: a continuous measurement during adjustment work is not possible. The effect of a correction to a burner setting was not immediately indicated. It is only with the following measurement that a result was shown. Then reset shake again adjust shake etc. This time-consuming and therefore very expensive method of flue gas measurement helped the electronic flue gas analysers to become an immediate success.

Lack of air

Excess air

s los s a eg Flu

Ca rbo nm on oxi de (C O)

Ideal operating range of furnaces

Fuel/ air mixture

Carbon dioxide (CO

2)

) en (O 2 Oxyg
NOX measurement NOX consists of NO and NO2. NO2 levels in smaller heating installations which are less than 3 % of the total NOX level can be ignored. The measurement of NOX is more important for the correct adjustment of modern NOX reduced burners. This is required by the manufacturer to adjust and approve the system since low NOx is becoming more and more important as a sales argument.

Electronic flue gas analysers from Testo The flue gas analysers from Testo have been proving themselves for 16 years now. They are ready to operate after one minute and can continuously measure values. In this way the rapid measurement and adjustment of furnaces is guaranteed. The life of the inserted measuring cells is between 2 and 3 years.

=1

Excess air

Efficiency ( ) Combustion efficiency is calculated by subtracting the combusting losses from 100% or maximum efficiency. Taking into account the condensation heat, values of more than 100% are possible in furnaces which operate in the so-called gross calorific value mode. This impossible value shown in the display indicates that the furnace is in the correct operating mode.

Gross and net efficiency Efficiency values are calculated to give two values, gross and net. Gross values are calculated including losses due to the water content of fuels. Net values exclude these losses, this results in the net value being higher than the gross efficiency. The most important factor in calculating the efficiency level is the difference between the flue temperature and the ambient temperature. Testo analysers can simultaneously measure both ambient and flue gas temperatures.

FT = Flue gas temperature AT = Ambient temperature K1, K2 = Specific fuel factors for net and gross K = Specific fuel factors for net and gross CO = Measures CO values in % CO2 = Measures CO2 values in % Q = Specific fuel factors for net and gross X = (MH20 = 9 x H) Moisture and hydrogen content fuel specific

Calculation of flue gas efficiency EFF = K x FT-AT CO2

Gas measuring cells The chemical measuring cells in Testo flue gas analysers are used throughout the world and are of the highest technical standard. Many hours of work are required in Research and Development to create a suitable environment for the gas cells which includes the optimisation of the gas paths, correct calculation of crosssensitivities and the uncomplicated method of changing the gas measuring cells by the user. 16 years experience in the development of flue gas analysers as well as many years of cooperation with independent institutes measuring different measuring cell types have given Testo a headstart in this field. This headstart is passed on to the customer in the form of compact, robust, high precision instruments and easy to change measuring cells.

X x 210* - 42 x AT + 2.1 x FT Q K* 2 x CO CO2 + CO

*Net Values

Table of fuel specific factors

Fuel V K K K K gr net CO2 1 2 0.350 0.390 11.9 40 44.3 0.480 0.510 15.4 53 56.4 0.510 0.540 15.8 54 57.2 0.620 0.650 18.4 63 66.0 0.670 0.690 19.1 65 66.5 0.750 0.760 20.6 70 71.1 0.420 0.450 13.8 48 51.8 0.430 0.460 14.1 48 51.6

Excess air calculation In order to achieve full combustion it is necessary to supply the combustion with more air than is theoretically necessary. The ratio of this air to the theoretical air requirement is known as excess air.

Natural Gas Fuel Oil, Class D Fuel Oil Classes E,F & G Coal Anthracite Coke LPG propane LGP butane

International approvals and tests Testo flue gas analysers are used worldwide and therefore have different approvals. Take testo 350 for example:

Efficiency of a small furnace = 100 % - qA qA = Flue gas loss (%)

- TV approval (D) - EAM approval (CH)

- ETV certification (CDN, USA) - GOS standard (CIS countries)

- SCAQMD test (USA, CA) - Fulfills CTM-030 (EPA) (USA)

Calculating CO2 CO x (21 - O2) CO2 = 2max 21

Excess air value =

21 % O2 21 % O2 - % O2

- 1 x 100

Flue gas analysis for industry

Goals The following goals apply when measuring industrial flue gases: Portable flue gas analysers from Testo For over 16 years Testo has been manufacturing portable flue gas analysers for special industrial applications. These instruments fulfill the high requirements of industry e.g.: - High accuracy (comparable with infrared or chemiluminescence technology from stationary applications) - Long-term measurements (practically stationary) lasting from several hours to several weeks - Flexible range of sampling probes for the different sampling points - High to extreme measuring ranges for use in crude gas or special oven atmospheres - Service by the user to save on costs and reduce down times - Not affected by dusty or moist flue gas or tough ambient conditions (high temperature, vibrations...) The measurement principles Testo uses electrochemical measuring cells for the O2, CO, NO, NO2 and SO2 parameters. These sensors have major advantages for portable applications: - Not affected by vibrations and changes in temperature - Small dimensions and low weight - Easy to change without test gas - Wide measuring ranges and low zero point drift for low concentrations - Extreme linearity over the whole measuring range An NDIR sensor is used for CO2.

Flue gas analysis for industry

Typical applications Application testo 325-I testo 300 M-I testo 300 XL-I + + o o o + + + + + + testo 350 M testo 350 XL + + + + + o + + + + + o + testo 360 + = recommended o = recommended in some cases - = not recommended

Oil/gas burner Coal furnace Wood combustion Block-type thermal power station Steel and nonferrous Cement production

CO: + CO: +; SO2: + CO: + NO: o CO: + CO: +; SO2: + o o o + -

+ + + + + + + + + o + + +

Emissions monitoring Adherence to legally specified limit values (e.g. TA Luft); meeting ISO 14000 requirements. Important parameters: NOx (NO + NO2), SO2, CO, O2 and in some cases CO2.

CO2 infrared sensor

Gas Gas

Glass industry Terotechnology Universities/Technical colleges

Adjustment and optimisation of systems This often goes together with adherence to emission limit values. Otherwise the aim here is to reduce operation costs by saving energy. Important parameters: O2, CO, CO2, excess air value and efficiency.

Infrared projector (lamp)

CO2 Infrared detector CO2

Burner/Boiler manufacturers Chemical industry Garbage incineration

Interference filter I= 4.27 m Absorption CO2

Therm. post-combustion

O2 measuring cell
Gas permeable membrane Cathode
OH
-

Process monitoring in thermal manufacturing procedures What is important here is atmosphere monitoring and documentation for quality assurance purposes (ISO 9000 ff), reduction of reject numbers and costs by saving energy and cutting down on stop periods. Important parameters: O2, CO, CO2, SO2.

Overview and operation (example: testo 360)

Why gas preparation? - Condensate collection to protect the instrument - Accurate NO2, SO2 measurement - Unsupervised long-term measurement

OH OH
-

OH OH
-

Flue gas probe

-

Temperature sensor
OH
-

OH

Anode

Operation Programming Analysis Saving

Notebook

Printout Files Analog recorder

Aqueous electrolyte Outer electric circuit

p/Velocity measurement Temperature measurement Heated hose Flue gas moisture meas. Gas dehumidification Alarm output Additional probe inputs CO2 CxHy Alarm Probes

Operation Two physical principles: a) Peltier cooling unit b) Permeation dryer Testo uses the Peltier cooling unit with the following advantages: - Not affected by dirt and dust - No service costs - Lowest absorption of NO2 and SO2 level for exact measurements

Measuring cell e.g. for toxic gases

Flue gas (e.g. CO) Gas permeable membrane Operational electrode Reference electrode
Cal gas

O2

CO

NO

NO2

SO2

Gas outlet

Instrument control power unit etc.

Power

Cal gas inlet

Instrument heating

H+

Backplate electrode

Condensate outlet

Aqueous electrolyte

Fresh air

Gas permeable membrane