Real-Time Heating Value Gas Analyzer


• Real-Time Heating Value Analysis
• Speciated Gas Composition
• Combustion Control Optimization
• EPA Flare Compliance

Introducing the MAX100-BTU

Heating Value and Speciated Hydrogen in Seconds

The MAX100-BTU provides a rapid, high precision measurement of heating value and gas composition for optimal combustion control and environmental compliance.

Variable composition gas streams, like refinery flare vent gas or coke oven off-gas, make efficient combustion control a challenge. Fast, accurate gas analysis is essential to allow operators to maintain critical set points by adding the right amount of supplemental gas or steam.

The MAX100-BTUTM uses cutting-edge quadrupole mass spectrometer technology to deliver a continuous online analysis of fuel gas and vent streams containing hydrocarbons, H2, CO, CO2, H2O, H2S, and other gases.
It has the speed necessary to analyze the total composition of the sample and report the Heating Value in seconds.

Heating Value Analyzer Applications

• Combustion control optimization
• Refinery flare RSR compliance
• Fuel gas analysis
• Cogeneration
• Gas turbine efficiency
• Natural gas processing
and distribution
• Gas mixing/recapture
• Coke oven and blast furnace off-gas
• Landfill vent gas
• Glass plant gas blending

The mass spectrometer uses an ionizer to break sample molecules into charged fragment ions. They are then separated, based on their mass-to-charge ratio, as they move through the electric fields generated by the quadrupole mass filter. The ions register a current at the detector, creating a set of peaks called a mass spectrum. Each compound has a unique spectrum, making mass spectrometry a highly selective, flexible technique.


Real-Time Heating Value Gas Analyzer


For rapid Heating Value analysis and real-time combustion control, the MAX100-BTU offers an impressive list of Extrel Advantanges:

• Heating Value reported in seconds
• Speciated analysis of: H2, C1-C6 hydrocarbons, CO, CO2,
N2, O2, H2O, H2S, and other gases
• Extreme resistance to corrosion from H2S
• Additional parameters available: Wobbe Index, CARI,
Specific Gravity, Density, etc.
• Multiport sample selector for up to 46 sample streams
• Low maintenance, utility, and calibration requirements

Performance Specifications:
• Detectable compounds: H2, C1-C6 hydrocarbons,
CO, CO2, N2, O2, H2O, H2S, and other gases
• Detection range: 100%-100 ppm*
• Number of sample streams: 16, 31, 46
• Analysis rate: ~1 second per component
• Number of components: Unlimited
• Number of analysis routines: Unlimited
• Number of user configurable data tags: Unlimited
• Precision: <0.75% RSD**
• Dual Filaments
• Analyzer maintenance: 1-3 years†
• Roughing pump: 6-12 months†
• Manual or fully automated calibration and validation
- 3-12 month calibration intervals
• Mass range: 1-100 amu
* Matrix dependent.
** Based on the analysis of 1% argon, scan speed 1 second per analysis.
†Application dependent.


Net Heating Value (NHV) changes rapidly as
regulated material is sent to a refinery flare. Of
the 14 hydrocarbons being measured, the five
primary contributors to NHV are shown along
with hydrogen. The MAX100-BTU analysis
provides the refinery with the NHV required
by the regulation, as well as speciated
component concentrations for use by
operations, or for effective root cause analysis.


Low Maintenance, Easy to Use
The Questor5TM control software that drives the MAX100-BTU measures all fuel or flare gas streams in a fully customizable sequence for site-specific, automated combustion control. The intuitive web-based interface allows the user to check instrument status, review data, or run a validation sequence from anywhere on the plant network, while maintaining government and industry security standards for login and electronic record keeping (21 CFR 11).


A speciated MAX100-BTU analysis of a
certified gas mixture containing hydrocarbons
and hydrogen to simulate refinery vent gas.
The high precision of the concentration data
transfers through the calculation to produce
a highly repeatable Net Heating Value (NHV).
Recent RSR updates permit the use of 1212
BTU/scf for calculating hydrogen’s NHV
contribution. This makes hydrogen speciation a
critical component of accurate NHV reporting.

The MAX100-BTU is a 24-7 online gas analyzer for combustion control and environmental compliance.

MAX100-BTU System Specifications

Power Supply Options:
• 110 VAC, 50/60 Hz, Two 15 Amp circuits
• 230 VAC, 50/60 Hz, One 20 Amp circuit
Power Consumption:
• Nominal 2740 Watts
• Heat Load: 2700 Watts (9215 BTU/h)

• Standard Enclosure: 450 lbs (205 kg)
• Optional cart: 40 lbs (18 kg)

Ambient Requirements:
• Temperature: -4°F to 120°F (-20°C to 49°C)
• With A/C, cold start ≥54°F (12°C)
• Area Classification Options:
- General Purpose
- Class 1, Division 2, Groups B, C, D, T4

Additional Utilities:
• Purge gas (for hazardous area installations)
• Base calibration requirement: 2 gas bottles

Data System and Communications:
• Login security levels: Administrator, User, Viewer
• External communications:
- Ethernet, Modbus serial, digital I/O, analog I/O, OPC


Exceptional Worldwide Service and Support: For over 50 years, Extrel has been committed to providing the highest quality support services for the thousands of instruments installed worldwide. Factory trained and certified personnel offer industry-leading support to Extrel customers at every stage of the combustion control application.

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