Continuous Flue Gas Analysers for Emissions Compliance
Key Specifications
Overview- Parameters measured
- CO, CO₂, SO₂, NOₓ and HCl
- Measurement principle
- [SPEC NEEDED: e.g. NDIR, electrochemical, chemiluminescence]
- Sample handling
- [SPEC NEEDED: extractive or in-situ]
- Measurement mode
- Continuous, real-time
- Reference conditions
- 11% O₂, dry gas, 273.15 K, 101.3 kPa
- Output signal
- [SPEC NEEDED: analogue/digital interface]
- Data logging
- Automatic, auditable emissions record
- Power supply
- [SPEC NEEDED]
Sensor technology, sample handling, measurement range and output interface are confirmed against the analyser's datasheet for each project. Contact our engineers to specify your installation.
Reading the Gas That Defines Compliance
Each pollutant in the flue gas tells engineers something different. CO is the single most useful indicator of overall combustion quality: consistently achieving below 50 mg/Nm³ gives strong confidence that other products of incomplete combustion, including organic micro-pollutants, are also being minimised. NOₓ, SO₂ and HCl are acid gas and thermal by-products that confirm whether air pollution control downstream of the chamber is doing its job.
Continuous flue gas instruments typically use non-dispersive infrared (NDIR) sensing for CO and CO₂, and electrochemical or chemiluminescence sensing for NOₓ and SO₂, either sampled by drawing a gas stream out to an analyser cabinet (extractive) or measured directly in the duct (in-situ). [VERIFY: confirm which sensing technology and sample method Macrotec's own system uses before launch.]
Readings are reported against standard reference conditions, normalised to 11% O₂, dry gas, 273.15 K and 101.3 kPa, so a result from one stack can be compared fairly against a limit or against another site regardless of local operating conditions. The EU Industrial Emissions Directive (Annex VI) sets the daily average limits below for a controlled-air incinerator.
| Pollutant | EU IED daily limit |
|---|---|
| CO | 50 mg/Nm³ (daily), 100 mg/Nm³ (half-hourly, 95%) |
| SO₂ | 50 mg/Nm³ (daily) |
| NOₓ | 200 mg/Nm³ existing plant, 150 mg/Nm³ new plant (BAT-AEL) |
| HCl | 10 mg/Nm³ (daily) |
The same reading also feeds combustion optimisation work: engineers use trending CO and NOₓ data to tune burner settings and air supply, rather than adjusting a chamber and waiting for the next scheduled stack test to find out if it helped.
- CO as the continuous proxy for combustion quality
- Reported to standard reference conditions
- Auditable, automatically logged record
Emissions Reporting Across Heavy Industry
Regulatory stack emissions reporting and real-time combustion feedback for incinerators, cremators, furnaces and boilers, wherever gas composition must be measured, reported and used to keep combustion on target.
Incinerator & cremator stacks
Power generation
Cement, lime & minerals
Mining & metallurgy
Chemical & petrochemical
Waste-to-energy & municipal
One Record, Every Pollutant That Matters
CO, CO₂, SO₂, NOₓ and HCl
One analyser package covers the pollutants that emission limits are written around, rather than fitting a separate instrument for every gas.
Continuous, real-time measurement
Gas composition is reported as it happens, not reconstructed from a periodic stack test that already ended by the time the report is written.
Auditable emissions record
Every reading is logged automatically, giving a defensible history that stands up to a regulator's or auditor's request without a hand-kept logbook.
Automated regulatory reporting
Raw gas data is turned into the reports regulators ask for, removing the manual step of compiling a stack test summary by hand.
Supports combustion tuning
CO is the single most useful indicator of combustion quality; consistently low CO readings give engineers confidence that a chamber is running as designed.
Integrates with the full system
Data flows into the same dashboard as the dust and oxygen analysers, so one system, not three, gives the complete emissions picture.
Built for the Reports Regulators Ask For
Continuous flue gas readings support the compliance monitoring obligations of the EU Industrial Emissions Directive (2010/75/EU) and South African NEM:AQA, with the applicable limits confirmed for each project. The analyser itself is not independently certified to a specific EN measurement standard; our quality, environmental and occupational health and safety management systems are independently certified to ISO 9001, ISO 14001 and ISO 45001.
Standalone or Factory-Integrated
Flue gas analysers are supplied either as a standalone retrofit or built into a new incinerator at the factory, and are commonly specified alongside a dust analyser and oxygen analyser as one CEMS package.
Standalone / Retrofit
Fitted to an existing stack or duct with its own power and data connection, suited to sites monitoring a legacy incinerator, furnace or boiler that predates continuous monitoring.
Factory-Integrated
Supplied and wired into a new Macrotec incinerator's control panel at build, sharing the same PLC, HMI and monitoring dashboard as the rest of the plant.
Support, Maintenance & Spares
Control systems and instrumentation are designed and built in-house at Macrotec, so calibration, servicing and spares support come directly from the people who built the analyser. Readings also feed our Remote Monitoring dashboard, and our Maintenance & Repairs service covers on-site calibration and support wherever the unit is installed.
Specify Your Flue Gas Analyser
Tell us about your stack and reporting requirements and our engineers will help you specify the right flue gas analyser, standalone or fully integrated.