The ceramic industry uses high-temperature kilns, furnaces, burners, and heating systems for processes such as drying, firing, glazing, and sintering. These processes require controlled combustion and can generate flue gases containing gases such as oxygen (O₂), carbon monoxide (CO), carbon dioxide (CO₂), nitrogen oxides (NO and NO₂), and sulfur dioxide (SO₂).
Monitoring these gases helps plant engineers understand combustion conditions and identify changes in flue gas composition. A portable flue gas analyzer provides a practical solution for measuring combustion gases and stack temperature at different points within a ceramic manufacturing facility.
What Is a Portable Flue Gas Analyzer?
A portable flue gas analyzer is an instrument designed to measure gases present in combustion exhaust. The SERRAX FGA100 Flue Gas Analyzer measures CO₂ using NDIR technology and SO₂, NO₂, NO, CO, and O₂ using electrochemical measurement principles. It also measures stack temperature using a K-Type thermocouple.
Because the analyzer is portable and supplied with a stainless-steel sampling probe and temperature probe, it can be used for measurements at different combustion and exhaust points. The FGA100 also provides programmable data logging and USB data storage for recording measurements.
Why Is Flue Gas Monitoring Important in the Ceramic Industry?
1. Monitoring Combustion Conditions
Ceramic kilns and furnaces operate at high temperatures, making combustion control an important part of the manufacturing process.
Measuring gases such as O₂, CO and CO₂ provides useful information about the composition of combustion exhaust. This data can help engineers assess operating conditions and investigate changes in combustion performance.
2. Identifying Changes in Fuel Combustion
Changes in combustion conditions can affect the composition of flue gases. Regular measurements allow plant personnel to compare readings from different operating conditions and identify unusual changes.
The FGA100 can measure CO₂ from 0–100%, CO from 0–1000 PPM and O₂ from 0–100%, providing measurement capability for these key combustion gases.
3. Monitoring Carbon Monoxide
Carbon monoxide (CO) is an important parameter when evaluating combustion exhaust. Changes in CO concentration can provide information about combustion conditions.
The FGA100 uses an electrochemical measurement principle for CO and has a measurement range of 0–1000 PPM, with a resolution of 0.1 PPM.
4. Monitoring NOx and SO₂
Ceramic manufacturing processes involving combustion can produce gases such as nitrogen oxides and sulfur dioxide.
The FGA100 measures NO, NO₂ and SO₂ using electrochemical sensors. NO, NO₂ and SO₂ each have a measurement range of 0–2000 PPM, with a resolution of 0.1 PPM.
Regular measurement can help plants understand their flue gas composition and support their environmental monitoring activities.
5. Measuring Stack Temperature
Temperature is another important measurement when evaluating combustion and exhaust conditions.
The FGA100 uses a K-Type thermocouple for stack temperature measurement. The catalogue specifies stack temperature measurement ranges of 0–450°C / 0–1200°C, with a resolution of 0.1°C.
Applications of Flue Gas Analyzer in Ceramic Plants
A portable flue gas analyzer can be used for measurement and monitoring activities around different combustion systems, including:
- Ceramic kilns
- Industrial furnaces
- Burners and combustion systems
- Heating systems
- Chimneys and exhaust points
- Combustion troubleshooting
- Periodic flue gas measurements
- Environmental monitoring
- Stack temperature measurement
The portability of the analyzer makes it possible to perform measurements at different points rather than relying on a single fixed measurement location.
Key Parameters Measured by SERRAX FGA100
The FGA100 is designed to measure multiple combustion gases and stack temperature.
| Parameter | Measuring Principle | Measurement Range | Resolution |
| CO₂ | NDIR | 0–100% | 0.1% |
| SO₂ | Electrochemical | 0–2000 PPM | 0.1 PPM |
| NO₂ | Electrochemical | 0–2000 PPM | 0.1 PPM |
| NO | Electrochemical | 0–2000 PPM | 0.1 PPM |
| CO | Electrochemical | 0–1000 PPM | 0.1 PPM |
| O₂ | Electrochemical | 0–100% | 0.1% |
| Stack Temperature | K-Type Thermocouple | 0–450°C / 0–1200°C | 0.1°C |
These specifications are taken directly from the SERRAX FGA100 product catalogue.
Features of the SERRAX FGA100
The FGA100 is designed for portable flue gas measurement and includes several features useful for industrial applications.
Multiple Gas Measurement
The analyzer can measure CO₂, SO₂, NO₂, NO, CO and O₂, along with stack temperature.
Portable Sampling Probe
The instrument is supplied with a 700 mm stainless-steel sampling probe with a 6 mm sampling tube, allowing flue gas samples to be collected from combustion exhaust points.
Temperature Measurement
A 700 mm thermocouple with a 1–3 metre K-Type cable is provided for stack temperature measurement.
Programmable Data Logging
The FGA100 supports a programmable logging interval from 1 minute to 1 hour, allowing measurements to be recorded at selected intervals.
USB Data Storage
The analyzer supports data storage through a USB pendrive, which can be useful when measurements need to be recorded and reviewed later.
Graphic LCD Display
The instrument uses a Graphic LCD for displaying measurement information.
Benefits of Portable Flue Gas Measurement
Using a portable flue gas analyzer in a ceramic plant can help engineers and technical teams:
- Measure multiple combustion gases
- Monitor stack temperature
- Take measurements at different locations
- Investigate changes in combustion conditions
- Support combustion troubleshooting
- Record measurements at programmable intervals
- Store measurement data through USB
- Perform periodic environmental monitoring
- Collect data for process evaluation
Portable Flue Gas Analyzer vs. Permanent Monitoring System
Portable and permanent monitoring systems serve different purposes.
A permanent system is generally installed at a specific emission point when continuous monitoring is required. A portable analyzer, on the other hand, can be moved between different kilns, furnaces, burners, and exhaust points.
For ceramic plants where engineers need flexibility for periodic measurements, troubleshooting, maintenance, and process evaluation, a portable analyzer can be a practical measurement solution.
The appropriate monitoring method should ultimately depend on the plant’s monitoring requirements and applicable regulatory requirements.
Why Choose SERRAX FGA100 for Ceramic Applications?
The SERRAX FGA100 combines multiple gas measurement with stack temperature measurement in a portable instrument. It measures CO₂ using NDIR and SO₂, NO₂, NO, CO and O₂ using electrochemical sensors, while stack temperature is measured using a K-Type thermocouple.
With its stainless-steel sampling probe, programmable logging, rechargeable battery and USB data storage, the FGA100 is designed for practical flue gas measurement in industrial environments.
Conclusion
Flue gas measurement plays an important role in understanding combustion conditions in ceramic manufacturing. Kilns, furnaces and burners can be monitored for gases such as O₂, CO, CO₂, NO, NO₂ and SO₂, along with stack temperature.
The SERRAX FGA100 Portable Flue Gas Analyzer provides multi-gas measurement, stack temperature measurement, programmable data logging and USB data storage in a portable instrument.
For ceramic manufacturers, engineers and environmental monitoring teams, portable flue gas analysis can provide useful measurement data for combustion assessment, troubleshooting, periodic monitoring and process evaluation.
SERRAX FGA100 — Portable measurement for better understanding of industrial combustion and flue gas conditions.