Author: Carla

How Testo Helps Mining Customers Accurately Measure Emissions at Low Concentrations

Carla |

As environmental regulations tighten and sustainability goals become more central to mining operations, accurate emissions measurement has never been more important. One of the biggest challenges facing the mining industry today is reliably measuring very low concentrations of gases—levels that may seem minor but can have significant implications for compliance, efficiency, safety, and equipment performance.

Testo provides advanced emission measurement solutions designed specifically to meet these challenges, helping mining operators gain confidence in their data and make informed operational decisions.

The Challenge of Measuring Low-Concentration Emissions

Mining operations generate a wide range of gases, including carbon monoxide (CO), carbon dioxide (CO₂), nitrogen oxides (NOₓ), sulfur dioxide (SO₂), methane (CH₄), and hydrogen sulfide (H₂S). While high concentrations are easier to detect, low-level emissions are often more difficult to measure accurately, especially in harsh and variable mining environments.

Application of Machine Learning for Calibrating Gas Sensors ...Yet these low concentrations matter. Even trace emissions can:

  • Influence environmental compliance and reporting accuracy

  • Indicate inefficiencies in combustion or ventilation systems

  • Signal early signs of equipment or process issues

  • Affect worker safety if not properly monitored

Traditional monitoring methods may lack the sensitivity or stability needed to capture reliable data at these low levels, leading to uncertainty and potential compliance risks.

Testo’s Approach: Precision You Can Trust

Testo addresses this challenge by providing high-sensitivity, portable emissions analyzers that deliver accurate, repeatable measurements—even at very low gas concentrations. Designed for demanding industrial environments, Testo instruments allow mining professionals to measure, document, and analyze emissions directly in the field.

https://static.testo.com/image/upload/c_fill%2Cg_auto%2Ch_600%2Cw_900/f_auto/q_auto/v1/HQ/testo-industrial-flue-gas-analyzers-product-range-v2?_a=BATAXdAA0

Key advantages of Testo solutions for mining applications include:

High Sensitivity at Low Levels

Testo analyzers are engineered to detect trace gas concentrations with a high degree of accuracy, ensuring that even small changes in emissions are captured and recorded.

Portable and Field-Ready

Mining sites are rarely static or predictable. Testo’s portable analyzers enable on-site testing at exhaust points, vents, and combustion sources without the need for permanent installations.

Multi-Gas Measurement

Mining operators often need to monitor several gases simultaneously. Testo instruments support multi-gas analysis, giving teams a more complete picture of process conditions and emissions behavior.

Reliable Data for Documentation

Accurate measurement is only valuable if it can be trusted. Testo systems provide consistent, defensible data that can be used confidently for internal reporting, audits, and regulatory compliance.

Why Accurate Low-Level Data Makes a Difference

With precise emissions data, mining operations can move beyond basic compliance and unlock additional benefits:

  • Improved regulatory confidence: Clear, accurate documentation supports environmental reporting and inspections.

  • Operational optimization: Emissions trends help identify inefficiencies in combustion, ventilation, or control systems.

  • Enhanced safety: Early detection of hazardous gases reduces risk to personnel.

  • Extended equipment life: Identifying subtle changes in emissions can prevent long-term damage and unplanned downtime.

By understanding emissions at all levels—not just the highest ones—mining teams gain deeper insight into how their systems are performing day to day.

Supporting a More Sustainable Mining Industry

As mining companies continue to balance productivity with environmental responsibility, the ability to measure emissions accurately at low concentrations becomes a critical capability. Testo’s emissions measurement solutions empower mining customers to meet regulatory demands, improve efficiency, and support safer, more sustainable operations.

With precision instrumentation, field-ready design, and a focus on data reliability, Testo helps mining professionals turn accurate measurement into actionable insight.

https://miningmagazine.com.au/how-testo-helps-mining-customers-accurately-measure-emissions-at-low-concentrations/

Manufacturing Safety in the Lithium-Ion Era: Why LEL Gas Monitoring Matters

Carla |

The manufacture of lithium-ion (Li-ion) batteries is far more complex than simply assembling cells and packaging them up. It’s a rigorous chain of steps — from electrode preparation and cell assembly, to formation, aging, module and pack assembly, then testing and quality assurance. Each stage contributes to the battery’s performance and safety.

The Invisible Risks: Gases & Exposures

One of the less obvious but critically important aspects of battery manufacturing is gas monitoring. In Li-ion production, manufacturers may encounter gases that pose serious hazards — both for workers and for the facility.

For example:

This is where LEL (Lower Explosive Limit) gas detection comes into play. Monitoring for flammable or combustible gases helps ensure that any build-up of such gases is caught early, before a dangerous concentration is reached.

Why Uncontrolled Gas Emissions Are a Major Concern

When flammable or toxic gases accumulate in a manufacturing environment, the risks are two-fold:

Effective gas-monitoring systems, paired with proper ventilation, protective gear, training, and emergency response plans, form the backbone of a safe Li-ion manufacturing facility.

The Role of Continuous Gas Monitoring

Continuous monitoring is not a nice-to-have — it’s essential. With reliable gas detection in place, manufacturers can:

As demand for Li-ion batteries skyrockets (for EVs, grid storage, portable electronics and more), the need to protect manufacturing environments grows in parallel.

Regulatory Framework & Standards

Safety doesn’t stop at equipment and procedure — it extends into regulation. Manufacturers must stay aligned with industry standards like:

That means gas detection systems not only protect people and property — they’re also part of a framework that supports product quality, operational efficiency, and regulatory compliance. For example, early detection of leaks or irregularities can reduce waste and prevent costly downtime or product failures.

A Practical Toolset for Manufacturers

For Li-ion battery manufacturers, the right monitoring hardware matters. The original article highlights gas-monitoring solutions such as:

When chosen and calibrated correctly, these systems become an integral part of the manufacturing safety setup.

Final Takeaways

By : PureAire Monitoring Systems   Posted on : September 17, 2024   Combustible Gas Monitors, News Room

Understand the Benefits of Fixed Gas Detection Transmitter

Carla |

 

Fixed gas detection

Fixed gas detection transmitters are critical devices designed to identify the presence of toxic gases, oxygen, and other flammable gases in various settings, ranging from industrial facilities to commercial spaces. The transmitter utilizes multiple sensor technologies to meet diverse gas detection challenges in a variety of global industries and has the capability that up three gas sensors can be connected.

 

Honeywell OmniPoint Brochure

Understanding the Difference Between Emissions Analyzers and Combustion Analyzers​

Carla |
Gas turbine electrical power plant with in Twilight power for factory energy concept.

In industries that rely on combustion processes, accurate gas analysis is crucial for both efficiency and compliance. Two primary tools used for gas analysis are emissions analyzers and combustion analyzers. While they may seem similar, these devices serve distinct purposes and have significant differences in their functionality. This post will explore the key differences between emissions analyzers and combustion analyzers, with insights into why high-quality emissions analyzers like the Testo 350 stand out as industry leaders.

What is a Combustion Analyzer?

A combustion analyzer is designed to measure the efficiency of a combustion process by analyzing gases such as oxygen (O2), carbon monoxide (CO), and sometimes nitric oxide (NO). These tools are typically used for tuning burners, boilers, and furnaces to optimize fuel efficiency and reduce pollutant emissions.
However, combustion analyzers lack the precision and durability required for emissions monitoring. They are primarily used for spot-checking combustion conditions rather than providing long-term emissions data.

What is an Emissions Analyzer?

An emissions analyzer, on the other hand, is a more sophisticated instrument engineered to provide accurate and repeatable measurements of pollutants in exhaust gases. These analyzers are essential for regulatory compliance, environmental monitoring, and optimizing pollution control technologies. The Testo 350, one of the most widely used emissions analyzers in the world, is a prime example of a robust and reliable emissions analyzer used across industries, including by OEMs of thermal and pollution treatment systems.

Key Differences Between Emissions and Combustion Analyzers

Emissions analyzers have three key engineering advantages over combustion analyzers:
Advanced Sample Gas Conditioning
An emissions analyzer like the Testo 350 features an internal, purpose-engineered sample gas conditioner that brings the gas to a 4-degree dew point. This system minimizes analyte loss due to solubility and ensures more accurate measurements by reducing wetted areas that can absorb sample gases.
Temperature Correction for Accuracy
Portability in emissions analyzers requires built-in temperature correction curves to maintain accuracy under varying operational conditions. Without this feature, sensors can experience temperature-induced bias drift, leading to inaccurate readings. The Testo 350 compensates for these fluctuations, ensuring consistent results.
Superior Pumping System for Reliable Sampling
A consistent sample flow is crucial for accurate emissions testing. The Testo 350 features a sample pump that is five times more powerful than those found in standard combustion analyzers, with five different voltage levels to adapt to changing flow requirements. This capability ensures that samples are properly delivered to the analyzer regardless of the operational conditions of the thermal system being tested.

Why Choose the Testo 350 for Emissions Monitoring?

The Testo 350 emissions analyzer is widely trusted in industries that require precise emissions monitoring. Unlike combustion analyzers, which often require external sample gas conditioners to produce a dry basis reading (an additional cost factor), the Testo 350 is designed with built-in systems to ensure reliability and accuracy. Almost all turbine manufacturers and their field service organizations, rely on the Testo 350 for field service and guarantee  emissions monitoring needs.
Additionally, the Testo 350 is available in kit configurations for low-concentration sampling, making it ideal for turbine testing. With proper maintenance and servicing, this analyzer can remain in service for up to 15 years, making it an excellent ROI and a long-term investment in emissions compliance and operational efficiency.

Conclusion

While combustion analyzers serve an essential role in optimizing combustion efficiency, they fall short when it comes to precise emissions monitoring. Emissions analyzers like the Testo 350 are engineered with advanced gas conditioning, temperature correction, and superior pump performance to ensure reliable and accurate measurements. Investing in the right analyzer can make a significant difference in meeting regulatory requirements, improving efficiency, and reducing environmental impact.
For those in need of emissions analysis solutions, Highmark Analytics can supply analyzer systems, calibration gases, and training to support quarterly monitoring in compliance with the D6522 requirement. Choosing the right analyzer is critical to ensuring accurate data, regulatory compliance, and long-term cost savings.  Analyzers can be provided as new, refurbished or rental options.

Influencing and measured variables for gas turbines

Carla |

Gas turbines in industrial applications

Testo 350 Turbine V1 2000x1500
Testo 350 Turbine

Thanks to their outstanding performance in the peak load range, gas turbines have proven themselves as crucial and reliable components in numerous industrial applications. Gas turbines are used especially frequently in the electrical and heat generation sector, as well as in the oil and gas industry. In industrial energy production, gas turbines ensure that consumption peaks are covered and produce heat for buildings. Frequent areas of use are gas turbine works, combined heat and power (CHP) plants and cogeneration plants. A particularly high level of energy efficiency can be achieved using a combination of gas and steam turbines. In the oil and gas industry, gas turbines are in use as mechanical drives for pumps, compressors and generators in the transportation and processing of raw materials. Gas turbines are operated with liquid and gaseous fuels such as natural gas, gasoline, diesel, heating oil or petroleum. Optimizing the fuel- and exhaust gas-intensive process to the highest level of efficiency involves a complex interaction between the exhaust gas parameters and the combustion process settings of the gas turbine – the basis for an optimum performance. For a service technician, it is important to understand the function of the combustion process and the influence of the individual measurement parameters on the performance and pollutant emission of gas turbines.

Functional principle of gas turbines

Testo 350 Turbine
Turbine

Gas turbines are combustion engines which consist of three components: a preliminary compressor the central combustion chamber and the actual turbine. The design, performance and size of gas turbines differ depending on the application and area of use. However, their working principle is always the same, and is based on the thermodynamic cycle process according to James Prescott Joule (“Joule process”). Air is compressed via the blading of one or more compressor steps, and then mixes with a gaseous or liquid fuel in the combustion chamber, ignites and combusts.

A hot gas is produced from this mixture of compressed air and combustion gas, which can reach temperatures of +1,000°C, and which escapes to the downstream turbine component, and expands. Thermal energy is converted into mechanical energy. Subsequently, in the expansion turbine, the energy-rich, hot exhaust gas expands almost to ambient pressure, losing its velocity. During the expansion process, the exhaust gas transfers power to the turbine. Approximately 2/3 of this power is needed to drive the compressor (air intake). A directly coupled generator converts the mechanical energy into electrical energy. Roughly ¹/₃ of the power output remains available on the low pressure side for a second drive, for example for driving a generator, rotor, compressor or pump, before the hot gas is diverted to a downstream heat recovery boiler for the purpose of heating buildings.

 

Analyzing exhaust gas concentrations correctly

Location Turbine 2000x1500

The concentration of the released exhaust gases provides important information on the efficiency of the combustion and how it can be increased. CO and NOX values provide information on the current status of the system and the adherence to the emission limit values. The air input between rich and lean and the correlating combustion chamber temperature influence the emission behavior of the gas turbine.

Challenges in commissioning, operation and servicing

In emission measurements in gas turbines, the challenge is measuring not only at very high, but also at very low gas concentrations. At the right operating point, optimally adjusted gas turbines emit only low levels of CO and NOX. However, high gas concentrations can occur, for example when the plant is started up for testing purposes. The reduction of NO2 emissions as well as the avoidance of pressure loss in the combustion chamber are also important factors for the efficient operation of the gas turbine.

 

 

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