AIR MONITORING
Table 1: Measuring points, typical analyzers and AGT-PSG sample handling offerings in CCUS plants (IR=infrared, CLD=chemiluminescence, UV=Ultraviolet, GC=gas chromatograph, EC=electrolytic conductivity)
Measuring Point 1 2 Boiler Flue gas pre-treatment Measuring Task Combustion control
Measuring Components
CO, O2 Treatment optimization SOx, CO2 3 CO2 Absorption Treatment optimization SOx 4 Stack , CO2 , NO, NO2 Amines , O2 , NO, NO3
Emission monitoring CO, CO2, NOx SO2
5 CO2 separation CO2
6a Dehydration / Deoxygenation
quality monitoring O2 CO2 quality control 6b CO2 compression CO2 (traces, impurities) , H2 , H2 (traces, impurities) H2 quality control CO2
H2S, COS, R-SH, C2 alcohols
, H2 O, H2 O, O2
, Ar, CO, ,
EC, paramagnetic O2 moisture analyzers
GC, (IR) , , O, Amines , Typical
process analyzers IR, paramagnetic O2
IR, CLD, UV IR, CLD, UV IR GC, IR
AGT-PSG sample handling solutions
Gas sample probes, heated lines, sample gas coolers
Gas sample probes, heated lines, sample gas coolers
Gas sample probes, heated lines, sample gas coolers
Gas sample probes, heated lines, sample gas coolers
Gas sample probes, heated lines
Gas sample probes, heated lines
Complete sample conditioning systems and system integration
Gas Conditioning System
Gas conditioning is the fi nal step before analysis, following sample extraction via the Gas Sampling Probe and transport through the Heated Sample Line. While probe and line placement is often dictated by plant layout and ATEX/IECEx requirements, conditioning and analyzer systems are typically housed in a controlled analyzer shelter or container. If this is not possible, all components—including the Sample Gas Cooler, Dryer, Pump, and analyzer—must comply with hazardous area classifi cations. Certifi ed solutions like the PSG Process Cooler BCR ATEX provide fl exible confi gurations with one to four gas paths for reliable operation. For sample gas drying, alternatives to traditional condensate coolers, adsorption, or permeation dryers include Nafi on®
membrane dryers, which preserve gas composition via
selective water transport. Nafi on technology operates using only instrument air, with no electrical components, making it inherently safe for hazardous environments. Proper evaluation of process parameters is necessary to determine feasibility for a given application.
4 Conclusion
The CO₂ economy represents a key pillar in global decarbonization efforts. Ensuring consistent product quality is essential to the successful development of sustainable CO₂- based products. To maintain high quality and reliability in Carbon Capture and CO₂ pipeline management, the integration of process analytics throughout the network is strongly recommended.
under high dust conditions. For toxic gas measurements, the sample stream must be fully shut off when necessary. This requires a shut-off valve at the probe’s entry, integrated into the probe’s heating system to avoid cold spots and condensation. Implementing this safely is technically complex but essential for accurate and safe operation.
Heated Sample Line for Gas Transportation Figure 2: PSG Plus Probe
Minimizing human presence in hazardous areas is crucial. Although CO₂ capture systems typically process clean gas streams, dust can be present at the extraction point—especially in combustion or cement processes. Reliable sampling and fi ltration technology are key to maintaining measurement accuracy and system uptime. Therefore, maintenance can be reduced by maximizing fi lter surface area— PSG utilizes a fi lter design offering one of the largest active surface areas on the market. — and by employing back-purging options for self-cleaning
After primary gas extraction via the sampling probe, the sample must be transported to the conditioning or analyzer system. Maintaining temperatures between 150–180°C (or up to 200°C) is crucial to prevent acid dewpoint condensation, and interfaces must be free of cold spots to avoid altering gas composition. High-temperature heating technologies for heated sample lines are limited, and safety remains paramount. Modern standards, such as DIN EN IEC 60079-0, require assessment of the entire line, including electrostatic discharge risks. Safe operation is ensured using conductive jackets with proper grounding. Cut-to- length technology is also important, as lines are often ordered longer than necessary, which can increase energy demand. Effective insulation is essential to maintain temperature and reduce energy loss. Innovations like PSG Basic Extruded heated cables offer up to 25% energy savings while providing a durable outer jacket for industrial use.
Flexibility is essential when adapting technical equipment to sustainable processes such as those within the carbon capture economy—and the same holds true for process analytics. Superior analytical performance depends on robust, solution- oriented concepts. In this context, not only the gas analyzers themselves but also the sampling probes and conditioning systems play a vital role in ensuring the effi ciency and reliability of the overall analytical setup.
Ultimately, sustainability must become second nature - and process analytics is a key enabler in making this a reality.
5 References
[1] Waters T 2013 Industrial Sampling Systems – Reliable Design and Maintenance for Process Analyzers, Swagelock
[2] Erens J, Reisinger T 2025 Probe Sampling in Hazardous Areas under Extreme Conditions, CEM Middle East 2025 – Emissions & Air Quality Monitoring
[3] DVGW C 260 (A) 2022 Quality of Carbon Dioxide and Carbon Dioxide Streams
[4] Steiner K, Schrader A 2022 Anlagen in CO2-Transportsystemen – das DVGW-Arbeitsblatt C491 (Plants in CO2 transport systems - the DVGW Code of Practice C491)
[5] Mahler H, Reisinger T 2022 Superior plant effi ciency through seamless system integration of process gas chromatographs, petro online (
https://www.petro-online.com/ article/measurement-and-testing/14/siemens/superior-plant- effi ciency-through-seamless-system-integration-of-process-gas- chromatographs/3138)
Figure 3: PSG Basic Extruded
Table 2 shows typical key features of the various sample preparation steps using the example of an emission monitoring system (measuring point 4 on the chimney).
Component Function
Gas Sampling Probe Extracts representative samples
Key Features
Holding temperatures at 150-180”C (optional ATEX-certifi ed) to prevent condensation High fi lter capacity to extend mainentance frequency Temperatured shut-off valve to avoid cold spots and secure safety isolation Back-purge option for self-cleaning against high dust-loads Built-in temperature limiters to simplify installation and ATEX compliance
Heated Sample Line Transports gas without condensation
Gas Conditioning System
Prepares gas for analysis (Coolers, dryers, pumps, fi lters, etc.)
Holding temperatures at 150-180”C (optional ATEX-certifi ed) to prevent condensation Robust and effective insulation to maintain temperature and reduce energy loss Cut-to-length technology to reduce cost and energy loss
Flexible confi guration with multiple gas paths for reliable operation Membrane drying alternatives with reduced supply media (only instrument air, no electrical components) - inherently safe for hazardeous area.
Harald Mahler AGT-PSG GmbH Hajo-Rüter-Str. 23
D-65239 Hochheim am Main, Germany Email:
info@perfectsamplegas.de Web:
www.perfectsamplegas.de
READ, SHARE or COMMENT on this article at:
envirotech-online.com/article
[6] Mahler H 2025 Energy-effi cient and sustainable over the entire life cycle,
Environtech-online.com (Energy-effi cient and sustainable over the entire life cycle - Sep 10 2025 - Harald Mahler - Environmental Science News Articles - Envirotech Online)
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