Volatile organic compound emissions control.

A leading coatings manufacturer in Wales has installed an advanced online gas analysis system to monitor emissions of Volatile Organic Compounds (VOCs), enabling the company to leverage real-time data for measurable environmental, operational and compliance benefits.

ProAmpac Advanced Coatings, which has operated in Wrexham for more than 50 years, invested in a new Regenerative Thermal Oxidiser (RTO) in 2025. The RTO destroys VOCs, air pollutants and odours through high‑temperature oxidation and is continuously monitored using a Signal Group VOC analyser to optimise performance, provide early warnings and support regulatory compliance.

Dan Hitchcock, Project Manager at ProAmpac says “We see the analyser as essential. Real‑time data supports effective process control and allows us to verify that emissions are being correctly abated. That gives us confidence that we will meet emissions limits when regulatory testing is carried out.”

Long‑standing commitment to emissions control.
ProAmpac Advanced Coatings (PAC) is a global supplier of precision coating materials, including coated papers, films and specialist substrates for applications such as digital imaging, electronics, medical and optical technologies. Its manufacturing processes involve the use of solvents, making robust emissions control essential.

As a Part A2 installation, the Wrexham site has long operated an on‑site thermal oxidiser to protect the environment and meet the requirements of an environmental permit issued by the local council. Historically, the permit has included emission limit values (ELVs) for pollutants such as Total Organic Carbon (VOCs), carbon monoxide and nitrogen oxides. These emissions are checked during annual visits by an MCERTS‑accredited contractor. In addition to periodic compliance testing, PAC has continuously monitored post‑combustion VOC emissions for over 20 years using a Signal Group analyser employing a flame ionisation detector (FID), the reference method for VOC measurement. The original analyser remained in operation for approximately two decades.  

Investing ahead of regulatory change.
Installed in 1995, the original RTO was approaching the end of its service life after 30 years of continuous operation, with ageing ceramic beds requiring increasing maintenance. At the same time, emissions regulations affecting solvent‑based coating processes were becoming more stringent. Updates to the Best Available Technique (BAT) Reference Document for Surface Treatment using Organic Solvents (STS BREF) introduced lower emission limits for applicable installations, prompting the local council to begin drafting a revised permit for the site.

“In that context, relying solely on periodic testing would not give us the level of operational visibility we need,” Dan Hitchcock (pictured right) explains. “Continuous monitoring allows us to manage performance proactively rather than retrospectively.” With an ageing RTO, and with the prospect of tighter regulations, PAC chose to install a new, more efficient RTO with a capacity of up to 150,000 Nm³/hour, commissioned in 2025.

Real‑time data, real‑world benefits.
PAC continues to operate continuous VOC monitoring alongside statutory compliance testing. Dan Hitchcock, who has worked at the Wrexham site since 1992, says real‑time data is critical to effective control of both coating processes and the RTO. “The analyser helps us optimise oxidiser performance, manage emissions from the coating lines, and control fuel input.” he says. “Any issue with the RTO could have serious consequences, so early detection is vital.”

An integrated monitoring and alarm system provides management staff with real‑time displays, historical data and automated alerts. The system also confirms correct operation and calibration of both the analyser and the heated sample line.

Seán O’Brien, Health, Safety and Environment Manager at the site, adds: “Continuous VOC monitoring allows us to identify potential problems early and address them before they escalate. It gives us confidence that compliance monitoring will demonstrate performance that meets permit requirements, while providing additional reassurance to the regulator.”  

Proven performance from Signal Group.
Following more than 20 years of reliable service from its first Signal Group analyser, PAC selected Signal once again when upgrading its monitoring system for the new RTO. The original instrument has been replaced with an MCERTS‑approved SOLAR CEMNEX continuous FID analyser, installed at the base of the RTO exhaust stack. Signal Group also supplied the heated sample line. As an MCERTS‑certified system, the analyser’s data are accepted by regulators including local councils, Natural Resources Wales, SEPA and the Environment Agency.

The system is supported by daily automatic zero checks, periodic span checks using calibration gas, and comprehensive on‑site servicing every six months under a long‑term maintenance agreement with Signal Group.

Summary.
Regenerative thermal oxidisers are designed for continuous operation, and any interruption to their operation would also increase the cost of recreating sufficiently high temperatures within the RTO. Also, thermal cycling can cause mechanical stress, increase energy consumption and damage ceramic media affecting the performance of the RTO. At the Wrexham site, where production schedules vary daily, continuous monitoring is critical for providing assurance that the RTO is performing well and for

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Gas analysers not for Christmas.

James Clements, MD at Signal Group, explains how businesses can extract maximum value from an investment in gas analysis. Using total organic carbon (TOC) measurements at thermal processes as an example, he will argue that the same analysers can also be utilised for process control and for checking the performance of abatement equipment.

James Clements, Signal Group

Just as a puppy is not just for Christmas, a gas analyser is not just for regulatory compliance. Process managers generally install a continuous emissions monitoring system (CEMS) because they have to, by law.

Background.
By the time a CEMS measures a process stream for compliance, the process work is done, and the analysers are simply providing proof that the process is complying with its permit. However, the efficiency with which that compliance is achieved can be substantially improved by monitoring at earlier stages in the process stream. This principle applies to almost all regulated processes with emissions to air, and for a variety of measurement parameters. For the purposes of this article we will take a closer look at thermal oxidation processes such as VOC abatement and incineration.

Incineration is a widely adopted method for dealing with materials such as municipal waste, sewage sludge, clinical and hazardous waste, and animal by-products. The advantages of incineration over other waste disposal methods include significant volume reduction, hazardous material neutralization and energy recovery. However, the process of incineration converts much of the solid waste into gases, so tight regulatory limits apply to air emissions.

Under the Industrial Emissions Directive (IED) incinerators are normally required to continuously monitor emissions of carbon monoxide (CO), hydrogen chloride (HCl), hydrogen fluoride (HF,) nitrogen oxides (NOx), sulphur dioxide (SO2), total organic carbon (TOC) and total particulate matter. Under certain circumstances, continuous monitoring of HCl, HF and SO₂ may not be required, and periodic monitoring may be applicable. The specific requirements for continuous or periodic monitoring are detailed in a site’s EPR (Environmental Permitting Regulations) permit. The permit also specifies periodic monitoring frequencies for dioxins and furans, dioxin-like PCBs (polychlorinated biphenyls), heavy metals and poly aromatic hydrocarbons (PAHs).

Following the withdrawal of the Britain from the EU (BREXIT), the requirements of the IED have been maintained in British law through the Environmental Permitting Regulations.

Seeking to minimise the impact of pollution on people’s health and the environment by reducing harmful industrial and intensive livestock emissions across the EU, the revised Industrial and Livestock Rearing Emissions Directive (Directive 2010/75/EU or ‘IED 2.0’) entered into force on 4 August 2024. A key feature of IED 2.0 is the mandate for national authorities to set Emissions Limit Values (ELVs) at the "strictest achievable" level within the BAT-AEL range for a specific installation, unless the operator demonstrates that this is disproportionately costly. As a consequence, ELVs will become tighter.

Thermal oxidation.
Incinerators employ high temperatures to break down complex organic chemicals into simpler forms - ideally water and carbon dioxide. The measurement of TOC emissions is necessary, not just to demonstrate compliance with the site’s permit, but also to help to identify incomplete combustion, which reduces efficiency and increases the risk of non-compliance. The incomplete combustion of some materials, such as plastics, can also result in the production of toxic gases, which emphasises the need for monitoring and feedback control.

Nitrogen oxides (NOx) are worthy of mention in this context because nitrogen and oxygen are abundant in air but do not react in ambient conditions. At higher temperatures, the gases react to form nitrogen oxide (NO) and nitrogen dioxide (NO2), which have serious health and environmental effects, and are therefore tightly regulated. There is a direct connection between combustion process temperature and NOx emissions, so Signal supplies NOx analysers to inform process control. Offering higher levels of accuracy, Chemiluminescence is the preferred measurement method for development engineers at manufacturer laboratories working on new technologies to reduce NOx emissions in the combustion of fossil fuels. For regulatory compliance monitoring, NDIR (Non-Dispersive Infrared) is less costly and more commonly employed.

Process managers seek to avoid incomplete combustion by optimising temperature, residence time and the air/fuel mixture. This process is informed by the continuous measurement of parameters such as oxygen, carbon monoxide and VOCs.

VOC abatement
Thermal oxidation is generally more effective at higher temperatures and with longer residency times, but both of these involve a higher energy requirement, increasing costs and reducing sustainability in the face of rising climate concerns.

In a catalytic combustion system, VOCs are decomposed by thermal oxidization at lower combustion temperatures, which reduces the amount of auxiliary fuel required and can reduce NOx generation. However, there is a risk that the efficacy of the catalyst may be lost due to catalytic poisoning.

VOC monitoring before and after abatement is essential for the optimization of abatement efficiency, and for the rapid detection of potential problems.

Multiplexed gas analysers.
Signal’s extractive gas analysers can be multiplexed, which means that they can be connected to a multipoint sampling system so that one gas analyser can sequentially take measurements from multiple points – before and after abatement for example. To achieve this, Signal has developed a range of ancillary equipment to facilitate sampling from multiple points. For example, Signal's Model 362 splits a single heated sample line into two filtered streams, allowing for parallel analysis of two different sample points. It includes a heated pump, gas distribution manifold, and multiple outputs, including one for a cooler/dryer. This facility to use one analyser for multiple sample points dramatically lowers the cost per measurement location.

Signal MCERTS approved 363SM heated pre-filter
with heated line

Monitoring technology.
Process managers are of course free to select the most appropriate gas analysis technique for process control, but where data are required for compliance purposes, it is likely that a certified standard reference method gas analyser is deployed. For example, the standard reference method for the measurement of TOC is flame ionisation detection (FID).

Signal’s latest FID, the SOLAR CEMNEX, recently passed a rigorous program of tests at TÜV in Germany. As a consequence, this monitor has MCERTS approval verifying compliance with the performance and uncertainty requirements specified in the UK’s Environment Agency Guidance: MCERTS for stack emissions monitoring equipment at industrial installations - Continuous emissions monitoring systems (CEMS) Updated 28 August 2024, EN 15267-1:2023, EN15267-2:2023, EN 15267-3:2007 and QAL 1 as defined in EN 14181: 2014.

Summary.
Process managers know and understand the measurement parameters that can help them to optimise their processes, but they may not be fully aware of the most effective and cost-efficient ways to implement a monitoring system. With over 40 years of experience in designing gas analysis systems, Signal’s in-house experts are able to provide help and advice in the key issues. These include:

• Measurement technique
• Sampling points and sample conditioning
• Multiplexing
• Calibration
• Communication, including Wi-Fi & web-enabled

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Defeating the ‘whack-a-mole’* that is sustainable packaging!

Gas analysers are performing a vital role for packaging manufacturers looking to check the environmental performance of their latest products as they seek new ways to develop sustainable packaging.

Signal Group has seen a particular increase in demand for its continuous VOC measurement instruments in the packaging sector. VOCs (volatile organic compounds) are emitted during the manufacture of many packaging production processes, but these harmful pollutants are tightly regulated so continuous monitoring is necessary. In addition, it would not be possible, for example, to label a recyclable product as more sustainable if it caused an increase in VOC emissions.

“The packaging industry is currently under enormous pressure,” explains Signal MD James Clements. “Firstly, most of the major players have made commitments under their ESG policies to improve the sustainability of their products. They are doing this because their customers demand it, consumers want it, and of course it’s the right thing to do, but sustainability means different things to different people,” he says. “Secondly, new regulations such as the UK’s Extended Producer Responsibility (EPR) and the EU's Packaging and Packaging Waste Regulation (PPWR) are strongly encouraging packaging manufacturers to increase the use of recycled materials and to develop recyclable and reusable products.”

According to a recent McKinsey report: “The global packaging sector continues to be attractive and is expected to grow faster than global GDP. Industry demand for—or at least interest in piloting—sustainable packaging is also rising as a result of pledges by companies across the value chain to reduce material use, increase circularity, and make more use of recycled materials.”

However, as James Clements explains: “It’s not as simple as that. Yes, waste reduction is enormously important, but the development of new packaging products can be a bit like ‘whack-a-mole’ because sustainability objectives also include other important factors such as carbon footprint and environmental emissions.

“Whilst seeking to develop new, more sustainable and recyclable products, packaging companies are also looking to ensure that they do not inadvertently increase their emissions of pollutants such as VOCs, and this where we are seeing a large increase in demand for continuous analysers,” he adds.

VOC Sources.
VOCs are released by a variety of packaging manufacture processes. Plastics, resins, fibres, textiles, elastomers, solvents, pigments, adhesives and many other products can be manufactured from fossil fuels, chemicals, catalysts and recycled materials, but many of the processes by which these materials are transformed into packaging result in VOC emissions. During polymerisation, for example, unreacted monomers and residual catalysts can be released as VOCs. In addition, the chemicals that are added to the polymers can also be volatile and become VOCs, and during processing at high temperatures, polymers can degrade into smaller, volatile compounds, which are also VOCs.

The manufacture of some food packaging involves the application of a plastic membrane (PET, HDPE, LDPE, PP etc.) to cardboard or paper. This is a good example of a process that releases VOCs which have to be abated. Typically, a Regenerative Thermal Oxidizer (RTO) is used to destroy the VOCs and other industrial pollutants in exhaust gases by oxidizing them into harmless substances like carbon dioxide and water vapour. RTO abatement systems have to be controlled by a gas analyser. For example, a Signal FID can take samples from both ends of the RTO to check abatement performance and demonstrate regulatory performance. This can be achieved with two FIDs or with one FID and a switched sampling system.

Monitoring technology.
The standard reference method for the analysis of VOC emissions is by a Flame Ionisation Detector (FID), which for many years has been at the heart of Signal’s VOC analysers. The FID method is specifically designed to detect carbon-hydrogen (C-H) bonds, making it highly selective for VOCs.

Signal manufactures two main types of FID – fixed and portable. The fixed analysers are permanently deployed to measure VOC emissions in one location, and the portable analysers can be used at multiple sites, where discontinuous monitoring is permissible. These are generally sites with lower emissions where periodic measurements suffice.

In many countries, the monitoring of VOCs for regulatory compliance requires certification to specific performance standards. For example, Signal’s latest FID, the SOLAR CEMNEX, recently passed a rigorous program of tests at TÜV in Germany. As a consequence, this monitor has MCERTS approval verifying that it complies with the performance and uncertainty requirements specified in the UK’s Environment Agency Guidance: MCERTS for stack emissions monitoring equipment at industrial installations - Continuous emissions monitoring systems (CEMS) Updated 28 August 2024, EN 15267-1:2023, EN15267-2:2023, EN 15267-3:2007 and QAL 1 as defined in EN 14181: 2014.

Summary.
It is possible to claim that a product is more sustainable if it has a lower carbon footprint, produces less environmentally harmful emissions, uses less energy and/or water, or if it results in less waste. However, if it only achieves one of these admirable goals, it is important to check that it is not doing so at the expense of the others, and that is why packaging manufacturers are using more VOC analysers.

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* ‘whack-a-mole’ = situation characterized by a series of futile, Sisyphean tasks, where the successful completion of one just yields another popping up elsewhere.

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New VOC emissions monitor approved.

Signal Group has announced the launch of SOLAR CEMNEX, a continuous emissions monitoring (CEM) system with MCERTS approval for the measurement of total organic carbon concentration in sample gas. Designed for regulatory compliance and process control, employing a reference method flame ionisation detector (FID), the new analyser will be ideal for monitoring a wide variety of applications. These include incinerators, medium and large combustion plants, VOC abatement equipment, packaging, and solvent using processes such as paint, print, textiles and adhesives.

The SOLAR CEMNEX is a self-contained monitoring system with a rack mounted VOC analyser, a heated filter, heated sample lines, and an automated calibration system.

“We have been developing and manufacturing FID analysers for over 50 years, and the SOLAR CEMNEX is our most advanced system yet,” explains Signal MD, James Clements. “Customers can order these analysers very simply via the website – they just need to answer four yes/no questions, such as whether they want a detachable tablet/screen, and that’s it – they can place an order and a brand-new SOLAR CEMNEX will be delivered ready for immediate deployment.”

Following a rigorous program of tests at TÜV in Germany, MCERTS approval verifies that the complete monitoring system complies with the performance and uncertainty requirements specified in Britain’s Environment Agency Guidance: MCERTS for stack emissions monitoring equipment at industrial installations - Continuous emissions monitoring systems (CEMS) Updated 28 August 2024, EN 15267-1:2023, EN15267-2:2023, EN 15267-3:2007 and QAL 1 as defined in EN 14181: 2014.

Certification for the SOLAR CEMNEX covers the complete system, including the SOLAR FID analyser, Signal’s heated line and sample probes, and Signal’s 363 SM heated sample filter. Consequently, systems integrators can deploy these items with other MCERTS approved equipment for regulatory compliance monitoring.

The SOLAR CEMNEX can be supplied with a detachable tablet/screen, which allows users to operate the analyser from up to 50 metres away, via inbuilt 802.11 Wi-Fi. In addition, each unit has its own IP address, and is compatible with 3G, 4G, 5G, GPRS, Bluetooth and satellite communications. This provides users with simple and secure access to their analysers at any time, from anywhere.

Summarizing, James Clements says: “In recent years we have ramped up the development of our gas analysers to enhance their accuracy, simplicity and connectivity, so we are delighted to now add MCERTS approval for those customers with a regulatory requirement.”

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The Flame Ionisation Detection (FID) method for monitoring emissions.

The Flame Ionisation Detection (FID) method was first developed in the 1950s for the laboratory analysis of organic chemicals. Later, when environmental regulations began to limit the emissions of volatile organic chemicals (VOCs) in the 1970’s and 1980’s, the FID method was adapted for emissions monitoring. Signal Group was one of the first companies in the world to develop VOC emissions analysers, and in this article James Clements, Managing Director, explains why FID became the reference method, and why it lasted the test of time.

Background
Organic chemicals have always been widely used in industrial processes, but awareness of the harmful effects of VOCs on health and the environment did not become significant until the 1970s. At that time, President Richard Nixon presented proposals on environmental protection which included the establishment of a federal Environmental Protection Agency (EPA). This led to the development of maximum allowable concentrations for pollutants, many of which were subsequently adopted around the world.

VOCs are common constituents in the emissions of processes that involve petrochemicals, paints, coatings, adhesives, waxes, disinfectants and cleaning chemicals. In many of these processes, solvents play a major role and the release of VOCs represents a risk to health and the environment. Similarly, combustion processes give rise to VOC emissions, particularly where combustion involves the use of an organic fuel. This includes fossil fuels such as petrol, diesel and oil, as well as wastes and biofuels.

By monitoring total organic carbon (TOC) concentration in emissions, process operators can demonstrate compliance with relevant legislation. However, such measurements also provide insights for process optimisation, because, for example, the presence of organic compounds may be an indicator of incomplete combustion. In addition, TOC is frequently measured post-abatement in order to measure abatement efficiency.

Why was FID chosen as the reference method for VOC emissions monitoring?
It is normal practice for regulators to specify a standard reference method for monitoring pollutants, so that compliance measurements are accurate and directly comparable with the limits, and with measurements from other process operators. FID has been widely acknowledged as the reference method for VOCs for over 50 years, and there are many reasons for this:

1. Already proven - initially developed as a detection method for laboratory Gas Chromatographs, FID was already well-established as a reliable technology for the detection of hydrocarbons. Adaptation for measuring VOC emissions was therefore relatively straightforward. As a consequence, Signal Group has been developing and supplying thousands of FID analysers all over the world for almost as long as FID has been the reference method.
2. Cost – in comparison with methods such as mass spectrometry (MS) or Fourier transform infrared spectroscopy (FTIR), FID is relatively simple and therefore less costly to manufacture. This is important because, globally, the number of processes that generate VOC emissions is enormous, so it is important that reference method technology is affordable for the organisations, large and small, that are required to monitor their hydrocarbon emissions, or that need to monitor for other purposes such as process control or abatement management.
3. Specificity – the FID detection method is specifically designed to detect carbon-hydrogen (C-H) bonds, making it highly selective for organic compounds. Unlike some other detection methods, FID does not respond significantly to inorganic gases which helps to minimise interference from non-VOCs, providing more accurate and reliable emissions measurements.
4. High sensitivity – the FID method is highly sensitive to hydrocarbons, which makes it ideal for even low-level measurements, particularly as environmental regulations become more stringent. Signal Group’s latest FIDs, for example, offer measurement resolution down to 0.01ppm. It is also important to note that FID sensitivity is much less variable than other techniques. Photoionisation detection (PID) for example exhibits widely varying response factors for individual hydrocarbons, rendering it inappropriate for the measurement of hydrocarbon mixtures. In contrast, FID is ideal for the measurement of total hydrocarbon content, whether the hydrocarbon is an individual compound or a mixture of species.
5. 
   Wide range – in addition to their high sensitivity, FIDs are also able to make measurements at significantly higher ranges. The S4 Solar FID (shown right) for example, has a number of user-selectable ranges, all the way from 0 to 1ppm with a resolution of 0.01ppm, up to 0 to 300,000 ppm with a resolution of 1ppm.
6. Fast response - FID analysers provide an almost immediate response to a sample gas, which is extremely important for regulatory compliance, particularly with processes emissions that can vary significantly from one minute to the next. The typical response time for Signal’s latest FIDs can be less than 1 second. This is also important for process control and engine emissions testing.
7. Stability and reproducibility - decades of experience in a wide variety of applications have shown FID’s ability to produce stable measurements in the long-term. Similarly, when identical FID units measure the same sample gas, the same results are given. This is an extremely important feature of standard reference methods because it provides confidence in measurements – for both the user and the regulator.
8. Applicable to continuous monitoring – many VOC emissions regulations necessitate continuous monitoring, so an important feature of FIDs is their compatibility with Continuous Emissions Monitoring Systems (CEMS). Nevertheless, FIDs should be sufficiently flexible to be suitable for discontinuous monitoring with portable instruments. Consequently, Signal Group developed lightweight ruggedised versions of its FID technology so that, where regulations permit, a single portable FID can be used to measure the VOC emissions of multiple sources – at the same site or at different sites.

FID development – manufacturer’s perspective.
Although the latest range of FIDs from Signal Group feature a fourth-generation detector, it is truly remarkable that the core measurement technology has changed very little since the company first developed a FID in the 1970s. The main reason for this is that each generation of Signal’s FID has featured the company’s unique precision-machined monobloc detector which guarantees uniformity of production in a compact, leak-free design.

Most of Signal’s FID development work has therefore focused on issues outside of the core technology. These issues have either been application specific, or have addressed ease of operation, connectivity and data management.

In addition to fixed and portable FIDs, the company has developed both hot and cold FIDs for ambient or post-combustion applications. Dual FIDs have also been developed, featuring two FIDs in one instrument, so that methane and non-methane hydrocarbons (NMHCs) can be monitored simultaneously. This is an important differentiation because methane’s primary significance is as a greenhouse gas (around 30 times more powerful as a greenhouse gas than carbon dioxide), whereas NMHCs contribute to the photochemical generation of smog and atmospheric ozone. So, methane emissions are important because of their role in climate change, whereas NMHC emissions affect air quality and health.

Their development work  has also focused on automation, datalogging, sample conditioning and advanced calibration tools. In addition, the most recent generation of instruments features a wireless tablet capable of connecting via Wi-Fi to the analyser from a distance of up to 50 metres. This provides users with the ability to view live data in a different location, and even manage datalogging, alarms and calibration from a distance.

In addition, all Series IV instruments, including the new SOLAR XPLORE (right), have their own IP address, and are compatible with 3G, 4G, 5G, GPRS, Bluetooth and satellite communications. This provides users with simple and secure access to their analysers at any time, from anywhere.

Conclusion.
In summary, Signal’s first FID analysers in the 1970s were able to provide accurate consistent measurements for total hydrocarbons. Now, thousands of instruments later, their successors are still producing the same reliable data, but with built-in tools and accessories that make the monitoring process easier and less prone to human error. Employing the standard reference method, supported by over 50 years of rigorous work in every conceivable application, FID has stood the test of time, offering operators and regulators confidence and trust in VOC measurements.

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Tee-shirts to intrigue!

Intriguingly, the Signal Group stand at AQE 2024 (9/10 October Birmingham GB), will be staffed by gas analysis experts wearing T-shirts saying ‘Ask me about MCERTS!’ It’s too early to say more, but anyone interested in VOC emissions monitoring should head for Stand-L5…if only to try out the detachable tablets.

With a heavy focus on technology development, Signal’s MD James Clements is keen for visitors to see the latest advances in gas analysis equipment. “For many people this will be the first opportunity to see the detachable tablets that now sit where our instrument screens used to be. These tablets are now standard across our entire range, opening up a new world of opportunities, and we look forward to demonstrating them at AQE,” he explains.

“Detachable tablets allow remote operation for safety and convenience, but our Series 4 (S4) instruments also have their own IP address, and are compatible with multiple communications methods, which means that users have secure access to their analysers at any time, from anywhere.”

In addition to the latest technologies, Signal’s stand will also feature some of the company’s gas sampling, handling and calibration equipment, much of which has been well-proven in the field and has not changed for years. “Our Gas Dividers are a good example of great design that has stood the test of time,” James explains. “They have been proven to be highly accurate, and can help reduce the cost and uncertainty that comes with multiple calibration bottles. This will be of interest to both AQE visitors and exhibitors.”

Signal Group experts will be available on the company’s AQE stand to discuss gas analysis issues such as sampling methods, sample treatment, analytical technologies, calibration and remote communications.

Summarising, James says: “Even those visitors that don’t currently need any gas analysis equipment should visit our stand - for the same reason that everyone should test-drive an electric car; everyone should come and play with our removeable tablets.”

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Gas analysis sales rise.

Signal Group experienced a significant rise in sales during 2023, with strong demand for its gas analysis and associated equipment. Signal Group Managing Director James Clements says: “The growth in our business has continued in 2024, and as a result we are undertaking a major recruitment drive to ensure that we will continue to develop the market’s most advanced gas analysers, calibrators and sample handling equipment.”

He attributes the company’s growth to its long-term commitment to research and development. “Around 20% of our turnover is invested in product development,” he explains. “This ensures that we are able to respond quickly to changing customer needs, whilst taking advantage of the latest technologies. For example, our latest Series 4 analysers offer remote connectivity, as well as a removable screen which can function as a tablet. These innovative features are proving extremely popular with customers and help explain the expansion of our market share.”

With its focus on innovation, most of the company’s recruitment needs are for software and firmware engineers, as well as experienced service and installation engineers.

In addition to product innovation, He also attributes Signal’s growth saying "In our experience, customers greatly appreciate a fast and comprehensive after-sales service capability.” 

Sales growth at Signal has been from both the domestic and international markets, but James says: “The greatest increase in demand has come from UK research, particularly from those involved with engine development, working with clean low-carbon fuels.”

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Ye olde analyser!

Competition to find Signal’s oldest working gas analyser

A competition to find the oldest working Signal gas analyser in the world has been inaugurated by the company. Any Signal customer can enter by emailing the serial number of their instrument along with a couple of photos, before 14th June 2024. There will also be a prize for the best photo – irrespective of the instrument’s age.

“We know that many customers have been using their analysers for significantly longer than ten years,” explains Signal MD James Clements. “Our factory has been located in Camberley, near London since 1984, and over the last 40 years we have supplied thousands of analysers to customers all over the world. Many of these regularly come back to the factory for service, so we know that these instruments are lasting really well, which is a credit to my father John Clements who started and ran the business for several decades.”

The two competition winners (1. Oldest instrument & 2. Best instrument photo) will each receive a free service to rejuvenate their instrument (parts and transport not included).

The idea for the competition was prompted by a refurbishment request from a customer in the USA with a Signal 3010 portable FID analyser that had obviously been “used enthusiastically” over an extended period. Signal Service Manager Roy Kinslow said: “This analyser had clearly been subjected to long-standing and wide-ranging physical challenges, but we were able to restore full functionality, and with a new casing, it looked almost as good as new.”

As good as new!

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Anyone interested in entering either of the competitions should email their photos and serial numbers to competition@signal-group.com.

@GasAnalysers @_Enviro_News #PAuto 

Gas analysis in Korea.

Signal Group has announced the further expansion of its network of international distributors with the appointment of Y&J Eng in South Korea. “Asia is fast becoming one of our major markets, so it is important that we have a local partner in the Korean market,” explains Signal MD James Clements. “We recently welcomed two members of Y&J Eng staff to our factory in Camberley for training, and were impressed by their levels of expertise and experience in emissions sampling, monitoring and analysis.

“Factory training is important for our distributors because it instils high levels of confidence when serving customers when they return home, and provides us with an ideal opportunity to learn more about their local markets.

“The appointment of Y&J Eng as our distributor is great news for customers in Korea because they will be able to rely on local support from factory trained experts with over 12 years’ experience in environmental monitoring instrumentation.”

The partnership between Y&J Eng and Signal began with a successful evaluation of the Signal 3010 MiniFID, and prompted the requirement for factory training in Great Britain. Initially, the Y&J Eng staff were mainly interested in portable VOC measurement instruments, but following the training, they are now able to offer and support the full range of Signal gas sampling, handling and analysis instruments.

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Gas analyser safeguards packaging environmental compliance.

A global packaging company is monitoring VOC emissions (volatile organic compounds) continuously at its facility in Ireland - primarily to manage and improve the plant’s environmental performance and to demonstrate regulatory compliance. Due to a changeover in equipment, a short-term requirement arose for VOC monitoring with a flame ionisation detector (FID) that was hired from the Signal Group.

Feedback from the project indicated that the Signal analyser proved to be accurate and reliable, and provided the packaging manufacturer with a problem-free transition as it updated its monitoring regime. However, there was a delay in the work, and the rental of the Signal analyser was extended for several months.

The plant’s VOC emissions arise from printing and laminating processes, and are treated by an oxidiser, after which an FID analyser measures the total organic hydrocarbon content post-oxidation. By monitoring the emissions continuously, the plant’s operators are able to refine their processes to improve efficiency, and to minimise emissions.

The hired Signal equipment included a heated FID analyser, a heated line with controller, and a filter. “We manufacture all of these items, whihc means that the complete system is delivered ready-to-go, so that clients can be assured of compatibility, accuracy and reliability,” explains Signal MD, James Clements. We have hundreds of these systems in operation all over the world, so our staff are highly skilled and experienced in delivering support.

“As the world strives to meet the COP28 goals, manufacturers are looking to reduce their carbon footprint, as well as the carbon footprint of their supply chains. Lowering VOC emissions is one of the ways in which companies can help achieve these critically important objectives.”

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Monitoring methane and carbon dioxide emissions - Industrial and Environmental.

With the COP-28 climate conference starting in Dubai today (30 Nov 2023), political and media attention will focus on greenhouse gas emissions, and as a specialist manufacturer of methane and carbon dioxide emissions analysers, Signal Group is well-positioned to comment on the role of industrial process emissions on air quality and climate change. Here Signal’s Managing Director James Clements explains. 

First, it is important to be clear about the difference between air quality and the pollutants that exacerbate climate change. Basically air quality is affected by pollutants that can have a harmful effect, above certain concentrations, on living organisms, whereas climate change is caused by greenhouse gas emissions (GHGs). 

Air Quality.

Most process emissions regulations focus on limiting the release of gases and particulates that can be deleterious to the health of humans and other organisms. Nitrogen dioxide for example, is known to be particularly harmful to human health, and sulphur dioxide can cause acid rain which harms trees and vegetation. Many Volatile Organic Compounds (VOCs) are hazardous to health, but they also have environmental effects, which include the formation of ozone, a constituent of photochemical smog. At ground level, ozone is generated when VOCs react with nitrogen oxides (NOx) in the presence of sunlight. Ozone can have both acute and chronic effects on humans; affecting the respiratory, cardiovascular and central nervous system, as well as reproductive health. Ground level ozone can also have harmful effects on vegetation and sensitive ecosystems.

Process emissions are tightly controlled by regulations, forcing businesses to implement abatement measures and to monitor emissions and demonstrate regulatory compliance. However, diesel and petrol vehicles are also combustion processes, and whilst their emissions are also tightly regulated, the potential problem with vehicle emissions is that they often take place in poorly ventilated urban areas where pollution can accumulate and affect large numbers of citizens. As a consequence, governments and local authorities around the world are looking for ways to lower pollution exposure on busy streets and near schools for example.

One of the ways in which urban areas can be protected from the most polluting vehicles is to implement ‘Low Emission Zones’ (LEZs) such as London’s ULEZ (Ultra LEZ). Under this scheme, the owners of older, more polluting vehicles have to pay a daily penalty if they wish to travel within the zone. This is naturally a politically sensitive issue, because many people rely on such vehicles and may not be able to afford a newer ULEZ compliant vehicle. However, there is no doubt that LEZs do improve air quality.

The manufacturers of industrial and vehicle engines and boilers are therefore constantly seeking to develop equipment which is both efficient and produces low levels of pollutants. Increasingly, however, there is a need to also reduce GHG emissions.

Greenhouse Gases.
GHGs are so-called because they absorb some of the heat that the Earth radiates after it warms from sunlight, and thereby trap this heat in the Earth's lower atmosphere, causing global warming – the greenhouse effect. The gases which behave in this way include carbon dioxide (CO2), methane (CH4), nitrous oxide (N2O), and ozone (O3). CO2 is responsible for about three quarters of global warming and can persist for thousands of years. Methane causes most of the remaining warming but only persists in the atmosphere for about 12 years. Importantly, methane emission reduction initiatives therefore offer faster improvements in the fight against climate change.

The combustion of fossil fuels such as oil, gas and coal has increased atmospheric methane concentrations by over 150% and carbon dioxide by over 50% since the beginning of the Industrial Revolution. Urgent initiatives are therefore underway to reduce CO2 emissions with many countries committing to significant reductions in GHG emissions as they strive to meet their Net Zero targets.

The old adage goes: ‘you can’t manage what you don’t monitor’ and this is a major driver for analyser sales at Signal, with increasingly large numbers of customers looking to develop engines and processes that offer improved efficiency as well as lower emissions of both air quality pollutants and GHGs.

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• See also Hyperspectral cameras for orbit! (29/11/2023)

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Gas analyser enables carbon capture pilot.

Gas analyser & sampling system allow carbon capture pilot project to proceed.

Several abortive attempts were made to monitor potentially hazardous methane gas in a boiler’s emissions feeding a pilot carbon capture unit at a natural gas combustion plant in southern Arkansas (US). Engineers from Aqualung Carbon Capture eventually contacted Signal Group looking for a solution.

Pilot plant in Arkansas

Aqualung is trialling its novel carbon capture technology on a generic gas-fired boiler, and for safety reasons it is necessary to continuously check for non-combusted hydrocarbons in the boiler’s emissions. Measurement data are continuously fed to the on-site PLC, and the plant would be automatically shut down if unacceptable levels of hydrocarbons are found in the exhaust. Potential causes would be the boiler’s flame failing or the boiler management system failing to shut-off the fuel gas.

“We trialled a number of gas detection solutions, but they all failed,” explains Aqualung’s project manager Jonathan Garbett. “This represented an important challenge because the project could not proceed without gas safety detection in place, so there was an urgent requirement to find a reliable solution. During our research, we came across an article which described Signal’s gas analysis expertise, so we visited their facilities in Camberley (GB).

“During our visit, we explained the situation to Signal’s MD, James Clements, who said that there were two possible sources of error. Either the analysers that we had tried were unable to handle the conditions, and/or the sample handling method was inadequate.

“It transpired that the measurement of combustion emissions is a particular speciality of Signal’s, so they recommended a complete sample handling and analysis system, and given the urgency of our requirement, we decided to rent the equipment immediately.”

Carbon capture on a gas-fired boiler.
The pilot plant is designed to evaluate Aqualung’s carbon capture technology, and was built by a partnership between Aqualung Carbon Capture, Standard Lithium, a technology and lithium project development company, and Mission Creek Resources, the owner and operator of the natural gas processing site.

Standard Lithium is investigating the potential of Aqualung’s carbon capture technology as it seeks to build on its strategy for sustainable development; focusing on minimising all CO₂ emissions that may result from its future operations and related supply-chain activities. The company has also identified several areas where CO₂-rich gas streams may be used to optimise its process and reduce reagent costs, as well as potentially sequestering CO₂.

In a 2021 Standard Lithium press release, President and COO Dr Andy Robinson said: “We are very pleased to be working in partnership with Aqualung and Mission Creek on this exciting project; the future of the lithium industry rests on being able to produce sustainable battery-quality chemicals with the lowest carbon footprint. We feel that successful proof of this carbon capture technology in southern Arkansas may demonstrate another important technological step towards making the Gulf Coast region an industry-leading producer of sustainable lithium chemicals.”

Unique carbon capture technology.
Global urgency to reduce greenhouse gas (GHG) emissions, whilst maintaining vital infrastructure and energy resources, means that there is an enormous demand for technologies that can capture GHGs such as CO₂. As a leader in membrane carbon capture, Aqualung is seeking to accelerate the decarbonisation of heavy industry and transport.

Explaining the advantages of Aqualung’s membrane technology, Jonathan Garbett says: “Traditional carbon capture techniques such as absorption with amines are relatively expensive, with a requirement for amine, heat and a steady stream, so they are only used commercially in larger applications. In contrast, our patented membrane technology requires less power and works well on smaller, de-centralised plants. No raw material, such as monoethanolamine, is required, and we are able to handle lower CO₂ concentrations. However, the product is completely scalable so it can be applied in a wide variety of applications.

“Many of the advantages of our technology are derived from the unique characteristics of the membrane and the selectivity of the nano-film coating Aqualung applies which provides a constantly renewable carbon capture capability.”

Membranes are simple systems, analogous to filtration, which enable gases like CO₂ to permeate much faster and in larger quantities than other gases such as N₂, O₂ and CH₄, due to the nature of the separation material. Aqualung membranes are in dynamic equilibrium, using the partial pressure differential across two sides of the membrane to constantly separate the gases from one side to the other. Aqualung’s membrane also encompasses CO₂-reactive groups and mobile carriers which provide facilitated transport.

Reliable gas measurements.
The gas analysis equipment from Signal Group was initially rented for a few weeks. “The system worked very well, with no problems at all,” explains Jonathan Garbett. “We therefore purchased the equipment in late August 2023, and look forward to demonstrating the unique advantages of our technology, and working with our partners to optimise both carbon capture and CO₂ utilisation.”

The installation of Signal Group Analysers at plant

Signal’s gas analysis system included an S4 SOLAR heated FID VOC analyser with a heated line and model 346 front-end filter. In most countries, FID (flame ionisation detection) is the standard reference method for the measurement of total hydrocarbons, and the sampling handling system is designed to ensure that the sample being delivered to the analyser is truly representative of the emissions, with no possibility of condensation in the sample line, or the analyser.

Expressing his enthusiasm for this project, James Clements says: “This is an ideal application for our equipment, and we were pleased to learn that our gas analysis equipment had enabled the project to proceed. However, it was particularly gratifying to be able to make a significant contribution to a project which is seeking to not just capture CO2, but to also utilise a local sink for the captured gas in the battery metal industry, which itself is helping to decarbonise transportation globally. This project is a great example of a win/win in the battle against climate change.”

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Gas analysis in fuel and energy.

The 2nd FERIA Conference, the European Conference on Fuel and Energy Research and Its Applications, will take place at the University of Sheffield (GB) from 4th to 6th September 2023.

“This is an ideal sponsorship opportunity for us,” explains Signal Group MD, James Clements. “The majority of our gas analysers are used for the analysis of combustion emissions, and a good proportion of our order intake comes from the research and development sector, so the FERIA Conference will provide us with an opportunity to learn about the changing needs of our customers, and to show them the latest technological developments in gas analysis instrumentation, communications and software.”

The FERIA Conferences are organised by the Fuel and Energy Research Forum which brings together wide-ranging international interests in fuel and energy research, with a particular focus on biomass, waste and fossil fuels. In addition to a poster display, there will be three sessions running concurrently, offering delegates over 100 different presentations on themes such as carbon capture, hydrogen, ammonia and blended fuels, anaerobic digestion, gasification, pyrolysis of plastic waste, NOx emissions reduction, combustion efficiency and much more. 

“Almost all of the presentations will involve gas analysis,” comments James Clements, “So this will be a great opportunity for us to discuss the bespoke monitoring solutions that we are able to deliver.”

The Signal Group FERIA exhibition stand will feature the company’s latest gas analysers with detachable tablet screens, as well as the remote connectivity which is built into all of the company’s Series 4 instruments.

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Safe, convenient and obvious!

The Managing Director of Signal Group, James Clements believes that it should be possible to remove the screens of all gas analysers, and connect with them wirelessly. “It no longer makes sense to fix the screen into the analyser,” he explains. “Everyone is completely comfortable with portable keypads and screens, and analysers are often in inconvenient or even unsafe locations, so we have designed detachable screens into all of our latest instruments.

For decades, the users of gas analysers have become accustomed to managing them and viewing readings on a fixed screen, but with the technology that is now available, that doesn’t make sense – why not just grab the screen and take it somewhere safer and more convenient? Seems obvious when you think about it!?

“For many of our customers, it was either inconvenient or impossible to be physically next to their analysers to view readings and manage their instruments, so we integrated detachable tablets into the designs, and have been delighted with how popular this has been.”

The detachable tablets in Signal’s analysers are rugged with an IP67 rating, which means that they can even be used outdoors. Typically, customers find them most useful when it is necessary to install the analyser in a location with difficult access – such as: in vehicle exhaust gas test cells; in an ATEX enclosure; with a raised gantry on a stack; in a combustion test rig, or on any site where the location of analysis is not an ideal or safe working space.

With inbuilt 802.11 Wi-Fi, Signal’s tablet connects wirelessly to the analyser from a distance of up to 50 metres. This provides users with the ability to view live data in a different location, and even manage datalogging, alarms and calibration from a distance.

In addition to wireless connectivity between the analyser and the display, all Series IV instruments have their own IP address, and are compatible with 3G, 4G, 5G, GPRS, Bluetooth, Wi-Fi and satellite communications. This provides users with simple and secure access to their analysers at any time, from anywhere.

The removable tablets are supplied as standard with all Series IV gas analysers, including the new SOLAR XPLORE, and James says: “The most exciting thing about this new technology is that it all comes at no extra cost!”

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Importance of testing for gas analysers.

Levels of uncertainty in gas measurements can be increased, for example, by calibration gases that offer poor levels of accuracy. For this reason, Signal Group manufactures gas handling and calibration equipment as well as gas analysers. “The linearity check is particularly important,” explains Managing Director James Clements. “Our Model 821S Gas Divider, for example, has been tested independently against our main competitor globally, and found to be dramatically superior.”

Conducted in North Carolina (USA), the trial found the slope accuracy for the Signal 821S to be just 0.25% for a NO/N2 gas mixture, whereas the competitor gas divider offered 1.6% slope accuracy. Similarly, for a SO2/N2 mixture Signal’s slope accuracy was 0.74% and the competitor’s was a disappointing 2.5%.

“Sources of uncertainty are incremental,” James explains, “so it makes no sense to introduce extra error unnecessarily, which is why the 821S Gas Divider is popular with both our customers and with other gas analyser manufacturers.”

The European standard EN14181 describes the quality assurance procedures for Automated Measurement Systems (AMS) installed to measure emissions to air. Under this standard, an analyser’s linearity must be checked using five different reference concentrations, including zero. The reference concentrations should be approximately 20%, 40%, 60% and 80% of the range of two times the emission limit, and the test concentrations should be applied in a randomised sequence.

It is common practice to employ a gas divider to create the different reference concentrations, however, it is of course also necessary to be able to validate the gas divider. To protect accuracy and reliability, the Signal Group Model 821S Gas Divider does not use mass flow controllers. A manifold block with ten identical capillaries and a precision pressure balance regulator ensure the high levels of accuracy demonstrated in the USA trial.

The procedure for checking the accuracy of the 821S Gas Divider is simple. Users connect the zero and calibration gas to the opposite connections and repeat the test, and if the gas divider is operating correctly, the gas analyser will show exactly the same readings.

Summarising, James Clements says: “Bottles of calibration gas have a fixed ‘use-by’ date and can be expensive to purchase and store, so it makes sense to employ a gas divider to conduct multi-point calibrations. However, purchased calibration gas itself incurs a level of uncertainty, so we designed the 821S Gas Divider to minimise increases in uncertainty, and I am grateful to the researchers in North Carolina for highlighting this technical superiority.”

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Gas monitoring fleet!

Responding to a demand for short-term monitoring, Signal Group has established a fleet of gas measurement instruments that are available for hire. 

“Some of our customers only need the equipment for a specific project or for a short-term investigation,” explains MD James Clements. “In these circumstances it would not be sensible to purchase the equipment, because it may not be required at the end of the project, and the capital cost may be preclusive. We have therefore established a small range of our more popular instruments, which are now available for rent.”

The rental equipment includes Signal analysers employing FID for VOC and non-methane hydrocarbons; chemiluminescent analysers for NO/NOx; NDIR for multiple species such as CO, CO2, CH4, NO, N2O, SO2 and HCl. 

In addition to reference method gas analysers, Signal Group also manufactures a comprehensive range of ancillary instruments including heated lines, sample conditioners, filters, cooler/dryers, methane cutters, NOx converters, sample dividers and calibration equipment. These instruments are all available for hire on a first-come, first-served basis.

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"If it ain't broke, don't fix it!"

Signal Group is probably best known for leading innovation in industrial gas analysis using reference methods such as FID, CLD and NDIR. However, since its inception in 1979, the company has developed a fleet of ancillary equipment to ensure that the gas analysers operate as accurately and reliably as possible. This has included cooler/dryers that help to condition sample gas prior to analysis, and remarkably, the designs for these devices have changed very little in the last 30 years.

“Simplicity and reliability have always been our guiding mantra in product design,” explains Signal’s MD James Clements. “So, once we had developed models that met our needs precisely, further development was unnecessary, and we now have hundreds of cooler/dryers operating all over the world.”

Globally, regulations dictate that stack, flue or exhaust emission samples should usually be conditioned in some way before analysis, and it is important that this conditioning should be compatible with the analysis method. Cooler/dryers remove moisture from the sample gas so that it does not enter the gas analyser where it may affect the readings or even harm the analyser. However, cooler/dryers are not normally employed with acid gas samples because acidic gases may dissolve in the condensed water and therefore not form part of the measurement.

Signal Group offers two types of cooler/dryer; both with a thermoelectric cooling system and a special gas labyrinth design to eliminate the possibility of losing non-soluble sample gas with the removed water. Signal’s portable (Model 250) Cooler/dryer weighs 15kg and runs on mains power, and a 19” rack version (Model 200SM) is available as a 1, 2 or 3 channel unit. Summarising, James says: “It is incredible that there has never really been any need to update or re-design our cooler/dryers, but they do say: if it ain’t broke, don’t fix it!”

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Meeting Ecodesign requirements.

For the last 20 years, Powrmatic a leading British manufacturer of HVAC equipment, has been using Signal Group analysers to check the regulatory compliance of its products, which include gas burning warm air heaters, radiant heaters and ventilation equipment.

Powrmatic’s Engineering Manager, Dr Lee Herbert, says: “It’s incredible that the same analyser rack has delivered consistently reliable measurements over such a long period of time, but we attribute this longevity to the quality of the analysers themselves and to the excellent service that Signal Group delivers.
“Under our agreement with Signal, they visit the factory twice a year for routine maintenance, and provide a rapid call-out service if necessary.”

Many types of energy-related products (ErP) are regulated to ensure that they meet specific criteria relating to their energy usage. This reduces their environmental impact, improves their energy efficiency, and cuts greenhouse gas emissions. All products must have supporting technical documentation to demonstrate compliance, as well as a Declaration of Conformity, and they must display the appropriate conformity marking.

During 2021 the Ecodesign requirements in the ErP regulation reduced the maximum levels of Nitrogen Oxides (NOx) emissions allowable for space heaters. This regulation also raised the efficiency requirements for this type of equipment. Powrmatic’s products are therefore tested with the Signal analysers, and supplied with a BSI verified Declaration of Conformity with ErP 2021.

In addition to NOx, the Signal analysers also measure carbon monoxide and carbon dioxide, and are used by both the production team and the R&D department, where they help develop new HVAC products with lower emissions and even better efficiency.

Looking forward, Dr Herbert says: “I have seen Signal’s latest analysers, and would very much like to benefit from their new technologies, but with 20 years under their belt, our current analysers are still going strong, so for the time being, we’ll just have to wait for the day when they can be upgraded.”

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VOC Analysers for certification.

Signal Group has submitted both portable and fixed VOC analysers for MCERTS certification.

The 3010 MINIFID rugged, portable, heated FID VOC analyser has been designed to demonstrate compliance by hydrocarbon emissions measurements from multiple stacks or sites. The S4 SOLAR heated FID VOC analyser is a rack-mounted instrument for continuous monitoring, offering the accuracy and reliability that Signal customers expect, but with the additional benefits of a detachable tablet and software for RS232 or Ethernet connectivity.

The company’s stand (D11) at AQE 2022 will feature both instruments. Visitors will also be able to see the new S4 SOLAR XPLORE portable heated FID, and anyone with an interest in QAL2 audits will be able to see the 821s Gas Divider and the NOXGEN NOx converter efficiency tester. They will see first-hand, how an innovative detachable tablet makes emissions monitoring easier and safer – putting data where it matters… in the customer's hands!

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Carbon canister performance.

Many Signal Group customers employ the company’s gas analysers to measure the combustion emissions from engines that are under development. However, internal combustion engine vehicles also represent an opportunity for evaporative emissions, so vehicles are fitted with a carbon canister to prevent such releases. MAHLE ANAND Filter Systems, a leading global manufacturer of carbon canisters is using a flame ionisation detector (FID), Signal’s S4 SOLAR analyser, as part of its ongoing research and development programme, to optimise the performance of the carbon canisters which it supplies to global and domestic automotive manufacturers.

Based at the MAHLE ANAND Filter Systems facility in Pune,(IND), test laboratory manager Sagar Awate has been using Signal’s heated FID analyser for over two years for measuring total hydrocarbons (THC). “The S4 SOLAR FID Analyser is an important instrument within our research and development programme,” he explains. “We are constantly trialling new fuels and investigating the emission level (DBL – diurnal breathing loss) of our carbon canisters over a range of different temperatures as per the CARB and EPA procedures which are used worldwide. A temperature profile gradient is created with the use of a programmed environmental chamber.

“By collecting and analysing evaporative emissions from the carbon canister over a specific temperature profile, we are able to fully assess the canister’s bleed emission level. The analyser therefore plays a vital role in finding the THC ppm value from the gas sample collected inside a Kynar bag, and we are pleased to report that S4 SOLAR FID Analyser has performed very well. With a user-friendly interface and operating software that is simple to configure, our staff are very comfortable with the use of the instrument.”

Carbon canisters
The main function of carbon canisters is to reduce the amount of air pollution that vehicles create, whilst also increasing fuel efficiency. Hydrocarbon vapours arise from fuel in the fuel tank, even when the engine is turned off, and carbon canisters are designed to trap that vapour and feed it back into the engine.

Carbon canisters are filled with charcoal or carbon pellets that are able to adsorb hydrocarbon vapours. The canister input (tank port) connects to the fuel tank, while the canister output (purge port) connects to the purge valve in the vehicle's intake manifold. The vent port of the canister is open to the atmosphere.

When a vehicle is turned off, there is a pressure imbalance within the fuel tank which causes fuel to evaporate. As the tank is connected to the canister by means of hoses/pipes, all of the vapours generated inside the fuel tank enter the carbon canister. In line with the canister’s design capacity, it holds the vapours coming from tank whilst the vehicle is in the parked condition. Whenever the engine is started, the purge valve opens and the vapours inside the canister are desorbed into the air passing to the engine, where they are combusted. This process is known as “purging” of the carbon canister. During the purging process, fresh air from the atmosphere enters into the canister through the vent port and flows toward the engine, carrying fuel vapour with it. It takes a few minutes to complete the purging process; after which the ‘fresh’ canister is able to absorb vapour from subsequent cycles. Canisters remain functional while vehicles are running.

Monitoring evaporative hydrocarbons
The carbon canister tests are based on the procedures outlined in the United States Council for Automotive Research (USCAR) LEVIII / TIER 3 Bleed Emission Test Procedure (BETP)) Recommendations.

The USCAR procedure enables equipment manufacturers to produce repeatable and reproducible results. Two methods of hydrocarbon capture are specified in the document; the Bag Method and the SHED (sealed housing evaporative determination) Method; both of which require the use of a FID. Signal Group is able to provide FID analysers for both methods.

FID is a standard reference method for the analysis of gaseous hydrocarbons. The FID is a highly sensitive but non-selective sensor which employs a flame to strip hydrogen atoms from a hydrocarbon molecule, forming carbon radicals and electrons. This is usually a short-lived condition with the charged components quickly recombining, however, in an electrostatic field, components with opposite charges are driven towards electrodes. This creates an effective current within the flame, which is proportional to the number of molecules of hydrocarbon present.

The SOLAR range of FIDs are the latest 4th generation design; benefitting from knowledge and experience gained over 40 years to deliver accuracy, reliability and ease of use. Commenting on the advantages of this latest technology Signal Group Managing Director James Clements says: “Every S4 analyser is supplied with software to enable operation of the analyser remotely using LAN/RS232. This means customers can access their monitoring data from anywhere and at any time, and if they have any service questions, we are able to log in remotely.”

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