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.
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.
Workplace fires are more common than you might think. According to the National Fire Protection Association (NFPA), U.S. fire departments respond to a fire somewhere in the nation every 24 seconds. That’s why it’s so important for businesses to understand the risks and do everything possible to prevent fires from occurring.
At Highmark Analytics, we have over 20 years of experience helping companies protect their facilities, assets, and, most importantly, their people. We distribute and service gas analyzers and emissions monitoring equipment to help organizations across industries meet EPA emissions standards and ensure their large machinery and systems run safely and efficiently. By partnering with us, we can help you choose the right equipment to minimize fire hazards right from the start. Here are 10 of the most common fire hazards in work environments and tips on mitigating the risks in your facilities.
Electrical equipment is the leading cause of workplace fires, producing over 24,000 blazes per year. Things like old wiring, overloaded outlets, and faulty appliances can produce sparks or overheat and ignite nearby combustibles. To reduce electrical fire risks, businesses should conduct routine inspections and replace damaged or outdated electrical equipment. Ensure there are sufficient outlets so cords aren’t overloaded, and enforce organizational policies to avoid paper buildup around electronics. It’s also critical that certified electricians handle all electrical work to avoid amateur mistakes.
On average, over 4,500 workplace fires originate from improperly stored flammable materials. These substances, like chemicals, fabrics, solvents, and paper goods, are a key fuel source feeding facility blazes. Organizations should keep only necessary quantities onsite to safely manage them and store these items in dedicated flammable storage cabinets away from potential ignition sources. Always clearly label materials and train staff on proper handling to avoid mishaps. Also, prohibit smoking near any inventory containing flammables.
Kitchen appliances like stoves, microwaves, and toasters lead to around 2,000 annual office fires due to grease buildup and unintended operation. To use these cooking appliances safely:
Cigarettes, cigars, pipes, lighters, and other smoking materials ignite thousands of workplace fires annually due to improper disposal. To prevent such blazes, businesses must prohibit smoking indoors and except in designated outdoor areas with sturdy ashtrays and cigarette butt receptacles. Use sand-filled buckets for safe butt disposal. Also, locate outdoor smoking areas at least 25 feet from building entrances and any external flammable storage.
Hot work like welding and soldering produces sparks that can travel up to 35 feet to ignite materials. Without precautions, this leads to many avoidable blazes — over 2,800 per year, according to NFPA data. To perform hot work safely, businesses should designate specific areas away from combustibles for these activities and cover nearby surfaces with fire-resistant sheets as an added barrier. Also, be sure to shut off any fuel sources, properly ventilate the space before beginning, and fire-watch the area for at least 30 minutes after work is completed.
While convenient on cold days, portable space heaters are responsible for over 1,500 workplace fires per year due to close contact with combustibles. To use portable heaters safely, businesses should only purchase newer, UL-certified models with tip-over protection. Power off and unplug heaters when leaving workspaces unattended. Place such devices on flat surfaces at least 3 feet from anything flammable and never allow storage of objects on top, which can fall onto heating elements.
While less common, materials like oily rags can self-ignite through spontaneous combustion under the right conditions. This occurs when oils undergo an oxidation reaction leading to intense, localized heat buildup. Properly dispose of grease-stained rags in covered metal containers to prevent spontaneous combustion fires. Also, stack lumber or similar material neatly to enable airflow and slow oxidation risks. Keep any piles separated from buildings and flammables, and control dust accumulation on lighting, machinery, and electronics, which can also ignite.
High-powered equipment like industrial ovens and boilers reach extreme temperatures and thus carry explosion dangers from gas leaks. To operate them safely, use qualified personnel to install all such equipment according to manufacturer specifications. Perform routine maintenance and inspections to check for damage or component failures that may lead to gas leaks or other hazards. Also, be sure to properly train staff on all safe equipment use procedures. For an added safety net, integrate automatic emergency shut-off functionality connected to gas leak detectors.
Flammable liquids also introduce extreme hazards, especially if large uncontrolled spills occur. Flammable liquid spills can create substantial quantities of vapors that ignite rapidly into intense flash fires from nearby ignition sources. Always use leak-proof containers clearly labeled with their volatile contents to prevent such catastrophes. Also, store and transport only necessary quantities isolated from potential ignition sources. Have proper spill containment and cleanup supplies on hand for immediate deployment in case of any escaping liquids. Make sure to train staff on proper spill response procedures as well.
Unfortunately, malicious acts also contribute to workplace fires. Installing security alarm systems with video surveillance capabilities goes a long way toward deterrence by increasing the risk of getting caught. Ensure all facility entry points stay locked during off hours. Quickly repair any vandalism and graffiti that could inspire additional such behaviors if left unchecked. Always report suspicious activity on properties promptly to law enforcement.
Now that you know about the top 10 workplace fire hazards, it’s time to evaluate your facility thoroughly. By understanding the unique risks present and taking proactive precautions, companies can feel confident they’ve taken every reasonable measure to prevent fires and protect what matters most. Here at Highmark Analytics, your safety drives our mission. Please reach out if you have any questions or want to discuss options for your facility.
Our team at Highmark Analytics has extensive experience installing emissions monitoring equipment and helping organizations meet critical EPA emissions standards for safe operation. We offer comprehensive site assessments and can make expert recommendations customized for your exact environment. Over 50% of Fortune 500 companies trust us to help them make the right purchase the first time to truly minimize fire risks. We’d love to schedule a consultation to explore ways we can help you operate both profitably and safely. Reach out today to get started!
Operating heavy machinery like boilers, heaters, and furnaces requires diligent monitoring to ensure efficient, safe, and compliant performance. This is where combustion analyzers come in. As an expert integrator of emissions monitoring solutions with over 20 years of experience, Highmark Analytics knows that the right combustion analyzer provides invaluable insight into combustion efficiency and safety. Continue reading to explore what combustion analyzers measure, how the readings should be interpreted, and what actions operators should take based on the data. Whether you’re looking to improve efficiency, meet emissions regulations, or ensure workplace safety, understanding your combustion analyzer is the critical first step.
Modern combustion analyzers are equipped with an array of sensors to measure key parameters. While options exist for more advanced units, most combustion analyzers provide real-time readings on:
These four measurements give operators the essential data to optimize efficiency, identify issues, and ensure safety. Let’s look at how to interpret each reading.
The oxygen reading provides immediate insight into combustion efficiency and safety. Too much oxygen indicates excess air that absorbs heat and reduces efficiency. Dangerously low oxygen risks incomplete combustion and hazardous gas accumulation. Compare your oxygen reading to your burner’s recommended range – usually between 2% to 4% for boilers and 4% to 10% for heaters and furnaces. Work with Highmark Analytics to fine-tune based on fuel type for ideal efficiency.
The total combustibles reading detects the combined accumulation of carbon monoxide (CO) and hydrogen (H2) gases – byproducts when fuel doesn’t fully combust. Even low single or double-digit parts per million (ppm) combustibles indicate incomplete combustion. If combustibles rise continuously, it likely signals insufficient air for the fuel input. However, any gradual increase warrants further investigation into equipment wear or failure. Consult Highmark Analytics early on for professional guidance. Our team can troubleshoot issues like:
Getting to the root cause of rising combustibles quickly is key to restoring safety and efficiency.
The combustion analyzer’s built-in thermocouple tracks inlet air temperature versus exhaust temperatures. Performing a flue gas analysis determines your net system efficiency by revealing how much heat actually transfers into your machinery versus getting lost out of the exhaust. While expecting some loss is reasonable, you likely have room to lower excess air and enhance heat capture. Highmark Analytics can holistically assess your burners, controls, and systems to curb losses. Our team will evaluate:
Then, deliver data-backed recommendations tailored to your equipment.
Getting readings on oxygen, combustibles, and temperature means nothing without properly configuring alarm thresholds and action plans. Highmark Analytics draws from decades of experience to provide consultation services on how to:
We also offer solutions to record data for tracking over time. Highmark Analytics has you covered whether you need local data logging or seamless software integrations for real-time visibility. Our services include:
This creates accountability within your team to respond to alarms while giving leadership data to drive capital and operational decisions.
While some heat loss is unavoidable, analyzers reveal how much more heat you can capture. By comparing inlet air to exhaust temperatures, our engineers perform flue gas analysis to pinpoint savings opportunities. Upgrading old insulation, redirecting airflow, adjusting stack dimensions, and replacing worn burner components have yielded some sites 10% to 25% fuel savings. Finding the source of loss is the critical first step – then we size solutions. These system assessments pay dividends through enhanced safety and reduced expenses.
For facilities needing to meet regulatory emissions limits, upgrading to integrated toxic gas sensing can simplify compliance. We offer analyzers featuring built-in sensors for gases like:
These streamline monitoring, alarms, and reporting for regulated toxins and greenhouse gases using the same user-friendly interfaces as standard analyzers.
If you currently lack a combustion analyzer or have an older unit, upgrading now is likely your most cost-effective option. Simply put, combustion analyzers pay for themselves by unlocking combustion efficiency and safety. New touchscreen interfaces for clear real-time and historical visibility make decision-making easier.
Reach out to Highmark Analytics to explore analyzers like:
With flexible purchase, rental, and service programs available, upgrading needn’t break budgets. Our team draws from extensive first-hand product experience to ensure you get set up with the right analyzer for long-term success the first time.
Understanding what your analyzer tells you transforms meaningless numbers into actionable insights for efficiency, compliance, and safety. As your knowledgeable partner, Highmark Analytics strives to place tailored solutions in your hands through:
Want to improve your combustion monitoring? Contact Highmark Analytics to explore your options with a solutions-focused partner. Our decades of hands-on emissions analysis experience mean in-depth guidance tailored to your operations. Connect with one of Highmark Analytics’ combustion efficiency specialists today for a complimentary site assessment and analyzer selection consultation.
The cement industry plays a pivotal role in the construction sector, providing the fundamental building material for infrastructure development worldwide. Cement production involves complex chemical processes that require precise control and monitoring. One crucial aspect of this control is gas analysis. At Highmark Analytics, we want to help you understand the purpose of gas analysis in the cement industry and its significance in ensuring quality and efficiency.
Before delving into the specifics of gas analysis, it’s essential to understand the basics of cement production. Cement is manufactured through a process that involves several stages, including crushing and grinding raw materials, blending them, and finally heating them to high temperatures in a kiln. This results in the formation of clinker, which is then ground into a fine powder to produce the final cement product.
Gas analysis plays a crucial role in cement production for several reasons:
One of the primary applications of gas analysis in the cement industry is monitoring combustion processes. In the kiln, where raw materials are heated to produce clinker, precise combustion control is essential. Gas analysis allows plant operators to monitor the composition of gases within the kiln, ensuring that the combustion process is efficient and that emissions are within acceptable limits.
Maintaining consistent product quality is paramount in the cement industry. Gas analysis helps in quality control by monitoring the chemical composition of clinker and cement. By analyzing the gases released during the production process, operators can ensure that the desired chemical reactions are occurring, leading to the formation of high-quality clinker.
Energy consumption is a significant cost factor in cement production. Gas analysis aids in optimizing energy efficiency by providing insights into combustion efficiency. By adjusting parameters based on gas analysis data, operators can reduce fuel consumption and greenhouse gas emissions, leading to cost savings and environmental benefits.
Environmental regulations require cement plants to monitor and control emissions of pollutants such as nitrogen oxides (NOx), sulfur dioxide (SO2), and particulate matter. Gas analysis systems are instrumental in continuous emissions monitoring, ensuring that cement plants comply with local and international environmental standards.
Gas analysis data is invaluable for process optimization. By analyzing the composition of gases at different stages of production, plant operators can identify bottlenecks, inefficiencies, or deviations from the ideal process conditions. This information enables them to make informed decisions and implement improvements to enhance overall productivity.
Several gas analysis techniques are commonly used in the cement industry:
FTIR spectroscopy is a powerful technique that allows for the simultaneous measurement of multiple gases. It is particularly useful for monitoring emissions and processing gases in cement plants. FTIR analyzers can detect a wide range of gases, including CO2, SO2, NOx, and VOCs.
Gas chromatography is a versatile technique for separating and quantifying individual gas components. It is often used for analyzing gas samples from various points in the production process to determine the concentration of specific gases.
In-situ gas analyzers are directly installed at specific points in the cement plant, such as the kiln or stack, for real-time monitoring. These analyzers provide continuous data, allowing for immediate adjustments to the process.
Extractive gas analyzers collect samples from various process points and transport them to a central analyzer for measurement. This approach is suitable for applications where in-situ analysis is challenging due to extreme temperatures or hazardous conditions.
The integration of gas analysis into cement production processes offers several key benefits:
By ensuring the proper chemical reactions occur during production, gas analysis contributes to the consistent production of high-quality cement. This quality assurance is crucial for meeting customer expectations and industry standards.
Gas analysis helps cement plants optimize their processes, increasing energy efficiency and reducing operational costs. This is particularly important in an industry with high energy consumption.
With stricter environmental regulations, cement plants must monitor and control emissions effectively. Gas analysis systems provide the data needed to meet regulatory requirements and minimize environmental impact.
Gas analysis provides real-time data that allows plant operators to make informed decisions quickly. This enables proactive troubleshooting and process adjustments, improving overall plant performance.
As the cement industry continues to evolve and face new challenges, reliable gas analysis solutions are essential for ensuring efficiency, compliance, and sustainability. Highmark Analytics is your trusted partner in providing state-of-the-art gas analysis systems tailored to the specific needs of cement plants.
Our expertise in gas analysis technology and a commitment to innovation and customer support make us a leader in the industry. We offer a range of gas analyzers, including FTIR spectroscopy and in-situ systems, designed to meet the unique requirements of cement production.
With Highmark Analytics, you can:
Gas analysis is vital to cement production, serving multiple purposes, from quality control to environmental compliance. By leveraging advanced gas analysis techniques and solutions, cement plants can achieve improved product quality, energy efficiency, and sustainability while meeting the demands of an evolving industry.
As you strive to enhance your cement plant’s performance and sustainability, partner with Highmark Analytics for comprehensive gas analysis solutions tailored to your specific needs. Contact us today to learn more about how our expertise and technology can benefit your operations.
