Madur PHOTON S Online Infrared Flue Gas Analyzer
| Brand | Madur |
|---|---|
| Origin | Austria |
| Model | PHOTON S |
| Instrument Type | Continuous Emission Monitoring System (CEMS) |
| Measurement Principle | Non-Dispersive Infrared (NDIR) + Electrochemical Sensors |
| Accuracy (Indication Error) | ≤3% FS |
| Repeatability | ≤2% FS |
| Response Time (T90) | 45 s |
| Stability | ≤5% FS/7 days |
| Measured Gases | SO₂, NO, NO₂, O₂, CO, CO₂ |
Overview
The Madur PHOTON S Online Infrared Flue Gas Analyzer is a certified, modular CEMS platform engineered for continuous, regulatory-grade monitoring of combustion exhaust gases in industrial boilers, incinerators, cement kilns, and power generation facilities. It operates on dual detection principles: non-dispersive infrared (NDIR) spectroscopy for SO₂, NO, NO₂, CO, CO₂, and hydrocarbons; and electrochemical or paramagnetic sensing for O₂—ensuring compliance with ISO 10396, EN 14789, ISO 12039, ISO 7935, ISO 10849, and US EPA Methods 6, 7E, 10, and CTM-022/030. The system integrates gas conditioning, thermal stabilization, real-time calculation of combustion efficiency (η), excess air ratio (λ), and flue gas loss (qA)—all within a single 19″ rack-mountable architecture designed for unattended operation in harsh stack environments.
Key Features
- Modular, field-expandable design supporting up to 9 NDIR and 4 electrochemical sensors in a thermally isolated measurement chamber—with individual sensor temperature control stabilized to ±0.01°C.
- Dual-path gas conditioning: a dedicated “wet channel” for NO measurement (with automatic moisture management via condensate reservoir and peristaltic pump), and a parallel dried path using NAFION® membrane and Peltier-cooled dryers (dew point ≤0°C).
- Integrated heating system: 3 m (extendable to 5 m or 10 m) heated sampling line with M30×1 probe interface, K-type thermocouple feedback, and hysteresis-controlled heating (±5°C) to prevent water condensation—critical for accurate SO₂ and NO₂ quantification.
- Robust particulate removal: large-surface-area glass-fiber filter upstream of the dryer, plus optional sintered stainless-steel probe filters with programmable reverse-purge cleaning.
- Embedded PC-104 controller running Windows CE 5.0, featuring VGA touchscreen (6.4″, 640×480), SSD data storage (up to 4 GB compressed), and dual USB ports for peripherals.
- Comprehensive analog/digital I/O: 8 × 0–10 V / 4–20 mA outputs, 8 digital inputs/outputs (0–24 V), and 4 SPDT relays (24 V AC / 230 V AC, 5 A max) for alarm triggering and process interlock.
Sample Compatibility & Compliance
The PHOTON S is validated for use with flue gases containing particulates, acid vapors, and variable moisture content—common in coal-, biomass-, and waste-fired plants. Its heated sampling train (probe, tube, and filter) maintains sample integrity across temperature gradients from ambient to >1000°C stack conditions. All sensor modules comply with European emission directives (2010/75/EU—IED), U.S. EPA 40 CFR Part 60, and ISO-certified calibration traceability. Optional paramagnetic O₂ cells meet EN 14789 requirements for high-accuracy stoichiometric control. The system supports full audit trails and electronic signatures in alignment with FDA 21 CFR Part 11 when configured with secure user authentication and data encryption protocols.
Software & Data Management
The embedded Windows CE platform hosts Madur’s proprietary CEMS software suite, enabling real-time visualization of concentration trends, combustion parameters (λ, η, qA, IL), and diagnostic status. Data logging occurs at user-defined intervals (1 s to 1 h) onto internal SSD with automatic rollover and timestamping compliant with EN 15267-3 data integrity requirements. Communication interfaces include RS-232C, Ethernet (RJ45), and optional Wi-Fi module for remote configuration and firmware updates. Export formats include CSV, XML, and MODBUS TCP for seamless integration into DCS/SCADA systems. Calibration verification logs—including zero/span drift, leak test records, and sensor response time validation—are stored with immutable timestamps and operator ID tagging.
Applications
- Regulatory CEMS for continuous reporting under EU IED, U.S. NSPS, and China’s HJ 75–2017 standards.
- Combustion optimization in thermal power plants, district heating systems, and industrial steam boilers.
- Emission verification during commissioning, performance testing, and periodic QA/QC audits.
- Process safety monitoring for CO breakthrough in catalytic cracking units and syngas purification loops.
- Research-grade flue gas characterization in pilot-scale carbon capture and utilization (CCUS) test rigs.
FAQ
What gas species can the PHOTON S measure simultaneously?
SO₂, NO, NO₂, CO, CO₂, O₂, and optionally CH₄, N₂O, H₂S, H₂, or total VOCs—depending on installed sensor configuration.
Does the system support automated calibration and leak checking?
Yes—integrated zero/span valves and pressure decay diagnostics enable fully automated daily calibration checks and system integrity verification per EN 15267-3 Annex B.
Is the PHOTON S suitable for high-humidity or corrosive flue gas streams?
Yes—the dual-stage NAFION®/Peltier drying, heated sampling line, and corrosion-resistant aluminum housing ensure long-term stability in wet, acidic, or particulate-laden environments.
Can it be integrated into existing plant DCS networks?
Yes—via standard MODBUS TCP, analog 4–20 mA outputs, or Ethernet-based OPC UA (optional add-on) for bidirectional control and alarm forwarding.
What are the environmental operating limits?
Operating temperature: 10–50°C; relative humidity: 5–90% non-condensing; storage range: −20 to +55°C; IP54-rated enclosure for indoor CEMS shelter deployment.
