Using blower air (aeration flow) is necessary to oxygenate aeration basins in that it assists in the process of breaking down municipal waste. A dissolved oxygen meter (DO meter) provides the primary signal to assure that conditions are optimal for bacterial growth; whereas, air flow provides oxygen to maintain the proper environment for breaking down raw sewage. Furthermore, closely controlling the aeration process can reduce energy consumption by as much as 25%, and accurate measurement is critical to achieving this goal.

Sage Thermal Mass Flow Meters are ideal to monitor the main blower air header, as well as the branches leading to the aeration basin. In larger systems, even the drop lines can be monitored. By monitoring the Air Mass Flow and feeding back the data to a blower control system, the proper DO level is achieved. This results in an optimal bio-chemical reaction; hence, more effective sludge breakdown, as well as better odor control. Furthermore, effective control of the blowers can reduce energy costs by as much as 25% (in contrast to manually adjusting the blowers, or at some older plants, leaving the blowers on permanently). The fast response time, ease-of-installation, and low pressure drop of the Sage TMFM offer an ideal solution to Waste Water control.

Aeration flow, air injection flow, air purging, batching vessel inlet air flow, blow molding air, blower air, combustion air flow, compressed air flow, condenser air flow, cooling air flow, drying air flow, engine inlet air flow, exhaust air flow, heat exchanger air flow, HVAC, incineration flow, leak testing, pulverizing air flow, pump flow, sealed air flow, secondary treatment air and vent air flow.

Thermal Mass Flow Meters have the inherent Mass Flow measurement (i.e., no separate temperature and pressure measurements needed), low pressure drop, and sensitivity to measure flow rates of the typical Alkanes, which are common in petrochemical and refining applications. Methane is the simplest Alkane, and most common of these gases. Other Alkanes that may need flow measurement include Ethane, Propane, Butane, Pentane and Isobutane.

Ammonia measurement in the power industry is required for environmental control. It helps reduce NOx and SOx reduction in Selective Catalytic Reduction systems.

Monitoring the argon (and nitrogen) flow rate, for bottom stirring of molten steel, helps to eliminate bubbles and other impurities. The proper mix of nitrogen and argon have a direct impact on the quality of the steel. Thermal Mass Flow Meters, with dual range calibration, are a perfect solution for this important application. Argon, helium, and hydrogen can be used in heat treating, where its measurement will be required. Thermal Mass Flow Meters have fast response and turndown to help control the proper mixture for heat treating. Argon is also used in leak detection, and a sensitive measurement device such as a Thermal Mass Flow Meter is ideal for this application.

Biogas is produced when organic matter such as household food waste, plant matter, or industrial waste decomposes in the absence of oxygen. This may take place in an anaerobic digester to produce biogas. Biogas is primarily a mixture of methane (about 70%) and carbon dioxide (about 30%). The complete biogas production process involves gas creation, cleansing, storage, and ultimately, the use of biogas as a fuel source for heating or generating electricity.

The Sage Biogas TMFM serves an integral part for the safety of this process, whether involved with food processing, fermentation towers, or slaughterhouses. Measuring biogas flow at several points in the system provides operators with critical information for optimal gas production, control and safety. Furthermore, many recovery systems comply with Greenhouse Gas Protocols such as the Organic Waste Project Protocol and the KYOTO Protocols, both of which require measurement of biogas. Such requirements include Certified Emission Reductions (CER), a credit system, and the Clean Development Mechanism (CDM), which encourages investment in sustainable development projects to reduce emissions. Sage Thermal Mass Flow Meters help quantify the captured emissions by measuring the mass flow rate, even at very low flows, and by providing a very easy way to conduct the required periodic calibration field checks with its unique In-Situ Calibration procedure.

Thermal Mass Flow Meters have the inherent Mass Flow measurement (i.e., no separate temperature and pressure measurements needed), low pressure drop, and sensitivity to measure flow rates of the typical Alkanes (such as Butane), which are common in petrochemical and refining applications. Other Alkanes that may need flow measurement include Propane, Ethane, Pentane and Isobutane, and of course, Methane.

Thermal Mass Flow Meters are frequently used to comply with Greenhouse Gas protocols because they measure the flow rate of carbon dioxide and methane mixes in landfills (typically 50% CH4/ 50% CO2), as well as digester gas and bio gas (typically 65% CH4/ 35% CO2). Also, flare gas is primarily carbon dioxide, and needs to be measured. TMFM applications for carbon dioxide flow rate and consumptions are common in the petrochemical, cement, pulp and paper, and steel industries.

Municipal water districts and waste water treatment facilities use chlorine to disinfect water. Proper, real-time control of the concentration of chlorine is critical for the effectiveness and safety of the operation. Thermal Mass Flow Meters, with optional Hastelloy construction (all wetted parts), provide real time flow rate data; they accurately control the chlorine dosage for optimal water purification. Additionally, chlorine gas measurement is common in vacuum chlorinators. The wide turndown, and low pressure drop of Thermal Mass Flow Meters are very beneficial for this application.

One of the most important ways to reduce energy consumption in a manufacturing environment is to optimize the combustion control on industrial boilers, steam generators, furnaces, ovens, smelters and process heaters. By monitoring the air and fuel rates to burners, optimal air to fuel ratios can be achieved. This results in significant reductions in energy costs of natural gas (or propane), and also improves process efficiency, as well as product quality and yields. As part of an overall strategy to reduce plant wide emissions, many local and state-wide jurisdictions have (and require) environmental regulations for flow meters that are on all medium and large size heating units. Finally, the newly promulgated ISO 50001 standards define the best practice for energy management, and fuel line monitoring will play a big role. Common applications for combustion control monitoring will be found in a variety of industries including Textile, Glass Manufacturing, Automotive, Aluminum & Steel, Food & Beverage, Pulp & Paper, Power, Chemical, and Refining.

Sage Metering provides both easy-to-install Insertion Thermal Mass Flow Meters as well as In-Line Thermal Mass Flow Meters, with built in flow conditioners that monitor the air and fuel flow rates to the burner. These direct Mass Flow Meters do not require separate temperature or pressure transmitters, have no moving parts, are highly accurate and repeatable, and have negligible pressure drop. The Sage Thermal Mass Flow Meters have extraordinary rangeability of at least 100 to 1, as well as the fast response necessary for proper combustion control. In addition to the 4 – 20 mA control output of flow rate, the meters also provide pulsed outputs of consumption, in conjunction with fully Modbus compliant RS485 RTU communications. The meters also feature bright graphical displays of flow rate, totalized flow and gas temperature, plus continuous diagnostics. For difficult to reach burner lines, or for locations with extreme radiant heat, Sage also offers a Remote Style Flow Meter, with up to 1000 feet of lead length compensated cable – all electronics and powering are done at the transmitter – thus, the probe, or flow body, simply has a terminal junction box.

Compressed air generally uses more electricity than any other type of equipment, and accounts for as much as 1/3 of the Energy Usage in an Industrial facility. Insertion Style Thermal Mass Flow Meters help identify leaks in compressor systems, track overall usage to improve plant efficiency, and help departments reduce consumption. This often results in savings of countless thousands of dollars per month in large industrial applications. For instance, the Compressed Air Flow Meter can be used with energy management systems to help determine the optimal number of compressor units that need to be in operation at any given time; this helps to meet the demand needed by the various departments and processes. Furthermore, Thermal Mass Flow Meters are sensitive enough to determine leaks. For example, if a typical compressor system running at 100 psi had total leaks throughout its fittings and seals of 1/4", it would pass 100 CFM of unused compressed air. That alone would waste over $20,000 worth of power per year!

Sage Metering provides easy-to-install Insertion Thermal Mass Flow Meters for typical compressor lines and also offers a convenient isolation assembly valve for mounting.  These direct Mass Flow Meters do not require separate temperature or pressure transmitters, have no moving parts, are highly accurate and repeatable, and have negligible pressure drop. The Sage Thermal Mass Meters have extraordinary rangeability of at least 100 to 1, as well as fast response. Additionally, Sage Thermal Mass Flow Meters are digitally driven, resulting in extreme low-end sensitivity without sacrificing performance at the upper end. Sage Flow Meters with sensitivity as low as 5 SFPM (1 SCFM in a 6” pipe), permit leak detection by assessing whether compressed air lines, thought to be unused, are actually wasting expensive air through its previous undetected leaks. Sage Flow Meters have 4 – 20 mA outputs of flow rate, pulsed outputs of consumption, in conjunction with fully Modbus compliant RS485 RTU communications, which are all ideal for sophisticated energy management systems. The meters also feature bright graphical displays of flow rate, a non- resettable totalizer (often a requirement for Environmental reporting), a temperature reading, plus, continuous diagnostics. For difficult to reach pipes, or for locations with extreme radiant heat, Sage also offers a Remote Style Flow Meter, with up to 1000 feet of lead length compensated cable – all electronics and powering are done at the transmitter – thus, the probe simply has a terminal junction box.

Digester gas from farming and other agricultural operations is generated from the breakdown of livestock waste when the gas is captured within a large plastic cover, known as a digester. The manure decomposes in the absence of oxygen. Normally, the decomposition of livestock waste on farming operations, or dairies, results in vast sums of methane naturally venting to the atmosphere. However, by capturing this methane with an anaerobic digester, the biochemical reaction converts the methane into a mix of 65% methane and 35% carbon dioxide. Since methane is 21 times more effective at trapping heat in the atmosphere than carbon dioxide, it is highly beneficial to reduce the composition of the methane in the digester mix to lower greenhouse gas emissions. This is known as “methane destruction”.  Furthermore, a digester system can provide a source of fuel for heating or generating electricity. There are hundreds of farming operations which reduce greenhouse gas emissions and accrue emissions credits to meet the Environmental Protection Agency’s (EPA) reporting standards, the US Livestock Project Protocol or to comply with Kyoto protocols.

Sage Thermal Mass Flow Meters help quantify the emissions that are saved by measuring the mass flow rate, even at very low flows, and by providing a very easy way to conduct the required periodic calibration field checks with its unique In-Situ Calibration procedure. In addition, Sage provides flare gas Flow Meters, engine Flow Meters, and a variety of other Thermal Mass Flow Meters that are involved in digester gas monitoring and reporting.

Digester gas (typically 65% methane and 35% carbon dioxide) is produced when organic matter, such as raw sewage, decomposes in the absence of oxygen. Modern WWT processes incorporate digester gas flow measurement systems for the plant’s process performance and control, as well as a source of fuel to generate engines for supplemental plant power. The excess gas can run onsite generators or pumps, and in some cases is added to a larger power grid.

Sage Thermal Mass Flow Meters are ideal for monitoring the digester gas flow rate of the WWTP digesters to improve overall system balance and operation. Additionally the flow meters are utilized for measuring the flow rate of gas for co-generation systems, measuring the amount of excess gas being stored, and monitoring flare gas. The latter is important to comply with environmental regulations and/ or to report on greenhouse gas reduction credits.

Thermal Mass Flow Meters have inherent mass flow measurement (i.e., no separate temperature and pressure measurements needed), the sensitivity, and low pressure drop to measure flow rates of the typical alkanes, such as ethane, which is common in petrochemical and refining applications.. Other alkanes that may need flow measurement include, propane, butane, pentane and isobutane, and of course, methane.

Ethanol production is a complex process involving both fermentation tanks and distillation tanks. Thermal Mass Flow Meters measure the flow of air and fuel going into the distillation tanks to improve the air/ fuel ratio. Better combustion control improves boiler efficiency and helps reduce emissions. Thermal Mass Flow Meters measure the CO2 leaving fermentation tanks, which is essential in assessing process inefficiencies or meeting requirements for Environmental compliance.

Sage Insertion Style Thermal Mass Flow Meters are easy to install in existing boiler lines. Their wide turndown and fast response to flow changes provide an ideal solution to help optimize the combustion efficiency associated with the distillation process. The Sage Flow Meters have negligible pressure drop, and can handle very low flows, such as vent gases from the process.

Oil Refineries, well drilling operations (such as off shore oil rigs), waste water treatment plants chemical processing plants, natural gas plants, and landfills are but a sampling of applications where waste gases are flared. Flares are subject to stringent regulations, requiring operators to measure, record and report the amount of flared gases. Requirements to monitor the flow rate and consumption of flare gas may involve measurement at points within a complex series of feeder and header pipes, as well as the actual flare stack. In addition, monitoring of the flare output provides important information for process control.

Sage Insertion Style Thermal Mass Flow Meters provide the wide turndown required to cover both the extremely low flows (low velocities) associated with normal venting, as well as the extremely high flows (high velocities) associated with an upset condition. Their fast response to flow changes, low pressure drop, and reproducibility are significant characteristics for a flare application. In addition, Sage Flow Meters provide the customer with a unique procedure, the In-Situ calibration Check, at a “No Flow” (0 SCFM) condition. This important procedure, assures that the Flow Meter has retained the original NIST traceable calibration, verifies the meter’s accuracy, confirms that the sensors are clean, and that the Flow Meter hasn’t drifted or shifted. This is a tremendous benefit, since it eliminates the cost and inconvenience of annual calibrations on the flow meter, and also provides the data needed to comply with a number of Environmental protocols.

Flue gases are a by-product of a combustion process. They usually consist of nitrogen and carbon dioxide with traces of sulfur dioxide, nitrogen oxides, carbon monoxide, other trace gases and miscellaneous particulates. Most flue gases generally contain pollutants, and as such are regulated by local or regional air quality districts, and/ or the federal government. Thus, the stacks, ducts, chimneys, large pipes or other process venting systems often require flow metering to comply with environmental reporting.

Sage Insertion Style Thermal Mass Flow Meters provide the wide turndown required to cover both the extremely low flows (low velocities) associated with normal venting, as well as the extremely high flows (high velocities) associated with wide swings in output. Their fast response to flow changes, low pressure drop, and reproducibility are significant characteristics for flue gas reporting applications. In addition, Sage Flow Meters provide the customer with a unique procedure, the In-Situ calibration Check, at a “No Flow” (0 SCFM) condition. This important procedure, assures that the Flow Meter has retained the original NIST Traceable calibration, verifies the meter’s accuracy, confirms that the sensors are clean, and that the Flow Meter hasn’t drifted or shifted. This is a tremendous benefit, since it eliminates the cost and inconvenience of annual calibrations on the flow meter, and also provides the data needed to comply with a number of Environmental protocols.

The US EPA mandate per 40 CFR Part 98 requires reporting of greenhouse gas emissions (in tons of mass flow), effective January 1, 2010. Over 10,000 facilities have operations that fall under these reporting requirements. Some of those applications are described in this Environmental Section in other specific listings: See Landfill Gas, Digester Gas –Farming Operations, Bio Gas, Ethanol Distillation & Refining, Flare Gas and Flue Gas.

Sage Thermal Mass Flow Meters helps quantif the emissions that are saved. This is done by measuring the mass flow rate, even at very low flows, and by providing a very easy way to conduct the required periodic calibration field checks with its unique In-Situ Calibration procedure. In addition, Sage provides non-resettable totalizers and a variety of outputs, all of which comply with the US EPA Greenhouse Reporting protocols, as well as other Environmental protocols.

Helium (and also, argon and hydrogen), can be used in heat treating. where its measurement is required. Thermal Mass Flow Meters have the fast response and turndown to help control the proper mixture for heat treating. Helium is also used as a coolant for reactor vessels, and its flow rate can be measured by a Thermal Mass Flow Meter.

Monitoring hydrogen (and nitrogen) in solar cell manufacturing is an important part of the quality control in polysilicon manufacturing. In-Line Thermal Mass Flow Meters do not require separate temperature and pressure measurement, have fast response time, and low pressure drop. They are important instruments for controlling and monitoring the process of polysilicon manufacturing. Other hydrogen applications where Thermal Mass Flow meters are used include: measuring the flow rate to hydrogen reactors in batching operations and in gas distribution systems, and also, monitoring the hydrogen flow (used to cool the turbines) to detect leaks in the plant turbine generators. Hydrogen, along with other gases, such as Argon and Helium, can also be used in heat treating where its measurement is required.

Landfill gas is generated from the breakdown of municipal solid waste. There are hundreds of municipal landfills, all of which produce a mixture of methane and carbon dioxide with traces of nitrogen, oxygen and other gases. In active landfills, these gases are extracted from multiple wellheads and collected through a network of pipes to a common header pipe. Typically, the gas is about half methane and half carbon dioxide and can be used to replace traditional fossil fuels to heat buildings, boilers and kilns, run generators to make electricity, and even produce fuel to power vehicles. A typical municipal landfill can produce enough energy from landfill gas to power thousands of homes for many years. In addition to generating power, landfills are frequently involved with Carbon Offset projects. There are over 1000 landfills worldwide where landfill gas is collected. This collection reduces greenhouse gas emissions and accrues emissions credits, both of which meet the Environmental Protection Agency’s (EPA) reporting standards, and comply with the Kyoto protocols.

Sage Thermal Mass Flow Meters help quantify the captured emissions by measuring the mass flow rate, even at very low flows, and by providing a very easy way to conduct the required periodic calibration field checks with its unique In-Situ Calibration procedure. In addition, Sage provides Flare Gas Flow Meters, Engine Flow Meters, Wellhead Monitoring Portable Datalogging Flow Meters, and a variety of other Thermal Mass Flow Meters that are involved in landfill gas monitoring and reporting.

Methane is a powerful greenhouse gas that remains in the atmosphere for over 10 years and accounts for approximately 1/3 of all methane emissions in landfills (landfills are the largest human-related source of methane in the U.S.). It is 21 times more effective at trapping heat in the atmosphere than carbon dioxide and is of growing environmental concern. As a result, it is a major focus of Greenhouse Gas reduction initiatives. Furthermore, methane is a primary constituent of natural gas and is an important energy source. Efforts to utilize methane emissions can provide significant energy, as well as economic and environmental benefits.

Sage Thermal Mass Flow Meters help quantify captured emissions from landfills, including biogas and digester gas. Carbon Offset projects use these meters for measuring mass flow rate, even when the flow is low. Additionally, the Sage TMFM provides a very easy way to conduct the required periodic calibration field checks using its unique In-Situ Calibration procedure.

Important applications that measure Natural Gas Flow with a Thermal Mass Flow Meter include: facilities monitoring in industry, metering the main supply at manufacturing plants, sub-metering in industrial, commercial and government facilities, combustion control, boiler, generator and dryer inlet flow, building management systems. Many of these applications are driven by the need to reduce energy costs. In the case of industry, opportunities to increase efficiency and product throughput can also benefit.

Sage Metering provides both easy-to-install Insertion Thermal Mass Flow Meters, as well as In-Line Thermal Mass Flow Meters, with built in flow conditioners that measure and report the mass flow rate of natural gas in each gas line. These direct Mass Flow Meters do not require separate temperature or pressure transmitters, have no moving parts, are highly accurate and repeatable, and have negligible pressure drop. Most importantly, Sage Thermal Mass Meters have extraordinary rangeability, of at least 100 to 1, with resolution as much as 1000 to 1; this provides the dynamic operating range and sensitivity necessary for modern plant processes. These meters have bright graphical displays of flow rate, totalized flow and gas temperature, plus, continuous diagnostics, 4 -20 mA output of flow rate, pulsed outputs of consumption, in conjunction with fully Modbus compliant RS485 RTU communications. For harsh, or difficult to reach applications, Sage offers a Remote Style Flow Meter, with up to 1000 feet of lead length compensated cable – all electronics and powering are done at the transmitter – thus, the probe, or flow body, simply has a terminal junction box.

Nitrogen tank blanketing is involved in a variety of manufacturing industries worldwide, especially in the petrochemical and pharmaceutical industries. In the tank blanketing process, nitrogen serves as a low pressure “blanket” of inert gas and is injected into a vapor space of a storage tank, above the liquid. The primary reason this is done is to avoid emission of toxic fumes, and to prevent fire or explosion. Given the safety implications of this requirement, measuring the nitrogen flow is very important. Thermal Mass Flow Meters are an excellent choice for this important measurement, especially given their wide turndown and reproducibility. Furthermore, nitrogen is commonly used in the food industry for blanketing, and for packaging and “aerating” food products such as Mayonnaise. Lastly, nitrogen is often used as a substitute for compressed air. The Thermal Mass Flow Meter, with its wide turndown and low pressure drop, is ideal for these applications.

At large Municipal Waste Water Treatment Plants, deodorizing aeration basins may be required. Deodorizing is achieved by blending a controlled quantity of a fragrancing agent with oxygen. The fragrance-infused oxygen is then injected directly into the aeration basins as a deodorant, which minimizes the effect on nearby communities. Thermal Mass Flow Meters provide an accurate, real-time measurement of the mass flow rate of oxygen. Therefore, the dosage of the fragrancing agent is controlled. Oxygen furnaces also require measurement to improve combustion control.

For combustion control, Sage Metering provides both easy-to-install Insertion Thermal Mass Flow Meters, as well as In-Line Thermal Mass Flow Meters, with built in flow conditioners that monitor the air and fuel flow rates to the burner. These direct Mass Flow Meters do not require separate temperature or pressure transmitters, have no moving parts, are highly accurate and repeatable, and have negligible pressure drop. Sage Thermal Mass Meters have extraordinary rangeability of at least 100 to 1, as well as the fast response necessary for proper combustion control. In addition to the 4 – 20 mA control output of flow rate, the meters also provide pulsed outputs of consumption, in conjunction with fully Modbus compliant RS485 RTU communications. The Meters also feature bright graphical displays of flow rate, totalized flow and gas temperature, plus, continuous diagnostics. For difficult to reach burner lines, or for locations with extreme radiant heat, Sage also offers a Remote Style Flow Meter, with up to 1000 feet of lead length compensated cable – all electronics and powering are done at the transmitter – thus, the probe, or flow body, simply has a terminal junction box.

Ozone systems are frequently offered as an alternative to chlorination in water treatment plants. This method is environmentally friendly and dependable. Generally, a mix of 10% ozone (O3) and 90% oxygen (O2) is employed, sometimes with a trace amount of nitrogen.

The Sage In-Line Style TMFM is calibrated for the exact mix of ozone and oxygen. When it is calibrated for that exact mix, it optimally and accurately delivers the ozone and oxygen to safely purify the water. Direct Mass Flow, fast response, and extraordinary reproducibility are notable benefits for this important application.

Propane is a fuel that is greater than double the BTU content of Methane. It is frequently used as a back up fuel to natural gas. Measuring the flow rate to the boiler, or heater, is often necessary for improving combustion efficiency and to meet environmental requirements. Thermal Mass Flow Meters have the low pressure drop and wide turndown to meet this requirement.

The turndown and sensitivity of Thermal Mass Flow Meters provide an excellent solution for measuring supply air, exhaust air or flue gas in incineration, vent air for environmental compliance, exhaust flow in stacks, test pumps for leaks, air flow for heat treating furnaces, or drying air. Furthermore, the ease-of-installation, negligible pressure drop, and ability to provide direct mass flow (no need for separate temperature and pressure instrumentation) are significant characteristics of the Thermal Mass Flow Meter, and are beneficial to air flow applications.

Sage Thermal Mass Flow Meters have extraordinary rangeability of at least 100 to 1, as well as fast response. They are digitally driven, resulting in extreme low-end sensitivity (as low as 5 SFPM) and extraordinary reproducibility. Furthermore, Sage Flow Meters have 4 – 20 mA outputs of flow rate, pulsed outputs of consumption, in conjunction with fully Modbus compliant RS485 RTU communications. The Meters also feature bright graphical displays of flow rate, a non- resettable totalizer (often a requirement for Environmental reporting), a temperature reading, plus, continuous diagnostics. For difficult to reach pipes, or for locations with extreme radiant heat, Sage also offers a Remote Style Flow Meter, with up to 1000 feet of lead length compensated cable – all electronics and powering are done at the transmitter – thus, the probe simply has a terminal junction box.