The Role of Certified Flowmeters in Emissions Reduction

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Stricter environmental regulations and stakeholder expectations are reshaping how industry measures and manages emissions. At the heart of credible reporting and real reductions is something often overlooked: accurate, repeatable stack and flue gas flow measurement. If the
flow value is wrong, every downstream calculation including concentrations, mass emissions and abatements drifts with it. That’s why certified flowmeters, engineered for real-world stack
conditions, are essential.

Why accurate flow measurement matters in flue and stack gases
● Compliance depends on it: Permits and schemes (e.g., EU ETS, local air quality regulations) require defensible mass-emission data. Flow uncertainty directly affects reported totals.
● Process optimisation: Reliable flow (and temperature) enables tighter combustion control, better reagent dosing, and fewer unplanned interventions.
● Audit-ready data: Robust, traceable measurements reduce challenge risk and help you pass third-party verification without surprises.

Why certifications (MCERTS, TÜV) are non-negotiable
MCERTS (UK) and TÜV (Germany) certifications demonstrate that an instrument and its measuring method are fit for purpose in stack conditions. This includes:
● Verified measurement uncertainty within defined limits
● Proven performance across temperature, velocity, particulate loading, and moisture ranges
● Standards compliance, including EN 14181 (QA of automated measuring systems) and EN 15267-3 (product certification)

Bottom line: certifications de-risk compliance programmes and strengthens the integrity of your emissions inventory.

Engineering and operational benefits of an integrated system (McMenon Emission FlowGenie)
The McMenon Emission FlowGenie is a purpose-built, certified flow metering system for stacks and flues. It’s engineered to deliver reliable data and make life easier for operations:

● Certified confidence: MCERTS and TÜV approvals, demonstrating compliance with EN14181 & EN 15267-3.
● Configured to your duty: Sized and customised using McMenon’s intuitive Solve software; shipped pre-configured to site parameters.
● Easy to install and maintain: Typically one or two penetrations only; options for manual or automatic purging to manage dust loading; zero/span checks built in.
● Complete measurement picture: Choice of different systems with multivariable transmitter, with a selection of Modbus / HART / 4–20 mA outputs and integral temperature compensation for mass flow calculation and reporting.
● Built for the environment: Rugged probe construction with optional enclosure heater and flexible communication outputs for DCS/DAS/SCADA integration.

Result: fewer interventions, cleaner data, and a system that supports both compliance and continuous improvement.

Case studies across power, steel, and chemicals

Steel: UAE furnace exhaust (case study)
Application: Continuous monitoring of furnace exhaust gas flow and temperature at a major steel facility in the UAE.
Solution: FlowGenie FPD583 with a 60 mm OD flanged probe (2.8 m insertion), multivariable transmitter with HART, and an integral thermocouple. A manual purging option supports reliable operation in dusty, high-temperature conditions.
Outcome: Accurate, stable flow and temperature measurement that simplifies emissions reporting and supports process optimization in a challenging environment.

Chemicals: SRU tail-gas incinerator (extreme temperature duty)
Application: Stack flow measurement downstream of a Sulphur Recovery Unit (SRU) tail-gas incinerator, where gas temperatures commonly reach 850–950 °C and probes are prone to failure.
Solution: A specialised high-temperature averaging pitot probe (engineered in Inconel 625) designed for a large-diameter stack, delivering resilient, repeatable flow data under extreme conditions.
Outcome: Improved reliability in emissions monitoring where thermal and chemical stresses are severe, supporting safer operation and credible reporting.

Power: CCGT/CHP stack retrofits (typical scenario)
Application: Upgrading legacy stack flow measurement on combined-cycle (CCGT/CHP) units to meet modern verification and reporting standards with minimal outage windows.
Solution: FlowGenie configured to existing duct geometry; single/two-hole installation, integral temperature measurement, and certified performance to support QA/QC regimes.
Outcome: Reduced installation time and lower uncertainty, helping operators meet compliance obligations while improving combustion control and auxiliary equipment efficiency.

How to select the right certified stack flowmeter

  1. Define the duty: Temperature, velocity range, particulates, moisture, and corrosives.
  2. Require certification: MCERTS and/or TÜV compliance aligned to EN standards for your jurisdiction.
  3. Plan for the environment: Consider purge strategy, access, and maintainability.
  4. Integrate cleanly: Ensure outputs (HART/4–20 mA/digital) align with
    DCS/DAS/SCADA and reporting workflows.
  5. Validate and trend: Pair certified instrumentation with routine checks (zero/span) and a data regime suitable for audits.

Emissions reduction starts with measurement you can trust. Certified stack flowmeters, engineered for real-world conditions and integrated for operational ease, are the foundation of credible reporting, effective process control, and long-term environmental performance. With FlowGenie, operators gain certified accuracy, simpler installations, and robust data that stands up to scrutiny.

Talk to us
Exploring an upgrade to your stack or flue measurement? Our engineers can size, configure, and create FlowGenie systems pre-set to your application.
sales@mcmenon.com
+44 (0)1900 604 903