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Thermal Mass Flow Meters. Market and applications. Geographic Sales. 12%. 23%. 34%. 10%. 6%. 3%. 10%. 3%. Competition. Competition. Industry. Applications. Pipe Size. TYPE. Location. Technology. Sage Metering Sales Representative Sales. Applications. Green House Gases
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Thermal Mass Flow Meters Market and applications
Geographic Sales 12% 23% 34% 10% 6% 3% 10% 3%
TYPE Location Technology
Applications Green House Gases Natural Gas Combustion Air Compressed Air Flare Digester gas/Bio gas/Landfill gas
Green House Gases • 40 CFR 98 • Mandatory reporting of Green House Gas Emissions • CO2, CH4, N2O • Subpart C – Stationary Combustion sources • Other subparts are Industry specific • Natural Gas Industry • Landfill operations • Chemical Plants • Refineries • More • Carbon Credits
Natural Gas Flows • Boilers/Combustion Process • Reporting GHG (EPA requirements) • Reporting Emissions (Local requirements) • Combustion efficiency • Typical Conditions • 2 – 3 inch pipe • Temperatures 60 – 80F • Pressures max 5 psig • Flow rates: • 2” = 10,000 SCFH • 3” = 20,000 SCFH (6,000 SFPM) • Burner Size • 20 MM BTU/hr
Natural Gas Flow • Sub-metering • Internal cost allocation within a facility • Typical Conditions: • Pipe Size 6” • Pressure – 20 psi • Flow rate = 250,000 SCFH (20,000 SFPM)
Natural Gas Flow • “Check” meter • Gas Company distribution center • Repeatable, relative flow measurements • Check relative time of day flow in different distribution sections • Typical operating Conditions • 18” pipe • 80 – 100 psig • Flow Rate 65,000 SCFM (40,000 SFPM)
Natural Gas Flow • Avoid • Transmission Lines • Pressure too high = 500 to 2,000 psi • Custody Transfer • Not AGA approved • Provide entire meter run
ISO 50001 Energy Management Systems • Reduce Energy Usage • Continually review and monitor energy usage • Goal of improve energy performance • Program supported by US Department of Energy (DOE) Opportunities for Sage: • Improvement in combustion efficiency • Natural gas • Compressed air measurement to reduce leakage
Stoichiometric Combustion Theoretical combustion of all the fuel when mixed with the correct amount of air Fuel + air = Heat + CO2 + H2O + CO + Unburned Fuel + Waste Heat up stack Does not occur in reality – some excess air is needed Control Air Fuel Ratios • Ratio based on the mass of fuel compared to the mass of air Increases as Combustion Air Decreases Increases as Combustion Air Decreases
Stoichiometric Combustion • Optimum ratio of combustion air to fuel flow • Does not exist • Some excess air is required • Want to minimize excess air • Amount of excess air dependent on boiler load • Proper Air to fuel control requires mass flow measurement of air and fuel flow rates.
Combustion Air • DP flow measurement typically used • Flow element: • Averaging pitot tube • Pressure drop around an obstruction in the duct • Venturi
DP - Combustion Air Flow • Limitations: • Require pressure and temperature compensation to get mass flow • Loss of signal at low flow rates • Typical velocity in duct gives 1” w.g. pressure drop. • Square root relationship between flow and signal • Limits turndown • Advantages: • “Sample” multiple points or “entire” flow
Thermal – Combustion Air Flow • Advantages: • Measures mass flow without pressure or temperature compensation • Desired for combustion air to fuel ratio • Excellent low flow sensitivity • High turndown capabilities • Disadvantages: • Single point measurement • How representative is flow measurement • Multi point averaging arrays • Accuracy limitations due to straight run/flow profile • However, repeatability is required
Combustion Air - Conclusion Suitable for “small” ducts Not suitable for “large” ducts
Compressed Air • DOE estimates 30% compressed air produced is lost due to leakage • ¼” leak at 100 psi = 100 CFM • $8,000 - $20,000 per year • Cost Allocation • Compressor efficiency
Flare/Vent Varying gas composition • Natural Gas • Tank venting (Gas Production) • Process Operations (CPI/HPI) • Refineries • 40 CFR part 60, subpart Ja (modified August 2012) • Emissions on non-emergency flares
Sage Selling Points • Compact enclosure • Prime - Smaller enclosure than other suppliers • Insitu calibration verification • Calibration on actual gas • Ability to provide adjustment factors for varying gas composition • Competitive calibration prices • Good delivery • Flow conditioner • Great organization – good people to work with