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Gasmet EMISSIONS MONITORING HANDBOOK

This document provides an overview of emissions monitoring, including typical setups, suitable technologies such as FTIR and CVAF, and quality assurance. It discusses the WI BAT and LCP BAT conclusions and their requirements for emissions monitoring. The document also presents Gasmet's emissions monitoring solutions.

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0% found this document useful (0 votes)
158 views36 pages

Gasmet EMISSIONS MONITORING HANDBOOK

This document provides an overview of emissions monitoring, including typical setups, suitable technologies such as FTIR and CVAF, and quality assurance. It discusses the WI BAT and LCP BAT conclusions and their requirements for emissions monitoring. The document also presents Gasmet's emissions monitoring solutions.

Uploaded by

Chakir Kasdarli
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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GUIDE

Emissions Monitoring
Handbook

> Know what’s in the air


Emissions Monitoring

Foreword
This handbook aims to cover the topic of emissions monitoring holistically and
to provide you a comprehensive picture of emission monitoring in the context of
continuous and long-term monitoring for large industrial and combustion plants.

The handbook is divided into five main sections, which are:

• Industrial Emissions Monitoring & Suitable Technologies


• Quality Assurance
• WI BAT Conclusions for waste incinerators and co-incinerators
• LCP BAT Conclusions for large combustion plants
• Gasmet’s Solutions for Emissions Monitoring

Each section is strongly linked to each other, which is why it is important they are
examined as one coherent handbook.

After reading this guide you are familiar with various emissions monitoring
technologies, available solutions and quality assurance of continuous emission
monitoring systems, and much more.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


Mestarintie 6 Email: contact@gasmet.fi
01730 Vantaa
2
Emissions Monitoring

CONTENTS

1 Industrial Emissions Monitoring & Suitable Technologies 4


How Emissions Monitoring Works 5
Typical set-up and representative measurement site 5
FTIR in Emissions Monitoring 7
How FTIR works 7
Difference between NDIR and FTIR in a nutshell 7
Main benefits of FTIR in emissions monitoring 8
CVAF in Mercury Emissions Monitoring 9
Introduction to Mercury Monitoring 9
Principle of CVAF 10
CVAF provides the highest sensitivity 10
Technical Properties to Consider 11
Continuous or Non-continuous Mercury Emission Monitoring 12

2 Quality Assurance of Continuous Emissions Monitoring Systems 13


QAL1 14
QAL2 14
QAL3 14
AST 15
Roles and Responsibilities 15

3 WI BAT Conclusions 16
Upcoming changes 17
Key Findings for Emissions Monitoring 17

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

4 LCP BAT Conclusions 20


Who does LCP BAT Conclusions concern? 21
New continuous measurement requirements 22
New emission limits 23
Checklist: How to Prepare in Practice 25
Gasmet’s EN 15267 certified solutions 25

5 Monitoring solutions 27
Continuous Emissions Monitoring Systems 28
CEMS II e 28
FID (Flame Ionization Detector) 29
Oxygen Analyzer 29
Continuous Mercury Monitoring Systems 29
CMM AutoQAL and CMM 29
New World Record 31
Dioxin Sampling Systems 31
GT90 Dioxin+ 31
Gasmet Software 33
FTIR Analyzers: Calcmet software 33
Mercury Analyzers: MAUI software 33
Customer Data 33

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

1 Industrial Emissions
Monitoring & Suitable
Technologies
In the era of bustling industrial activity and growing number of industrial plants,
regulation and continuous monitoring of emissions have become increasingly
important.

Despite emissions monitoring being a standard and fairly straightforward process


for all industrial plants, it is of utmost importance: it protects nature and human
beings proactively and ensures the safety of us all. What is more, by effective process
optimization we can save a lot of valuable resources.

What makes emissions monitoring challenging is the changing operational


environment where regulations, standards and processes can change. As the
operational environment changes, the emission limits and allowed gas concentrations
change, too. This, in turn, requires continuous adaptability and capability to reassess
the procedures and technologies by the emissions monitoring stakeholders.

In this section we will introduce you to various technologies, such as FTIR, CVAF and
dilution in emissions monitoring, and explain what needs to be taken into consideration
in an effective set-up for emissions monitoring. The guide is aimed at all emissions
monitoring professionals but is ideal for everyone interested in the field.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

How Emissions Monitoring Works


Typical set-up and representative measurement site
Suitable measurement sections and measurement sites are necessary in order to
obtain reliable and comparable emission measurement results. Therefore, appropriate
measurement sections and sites shall be planned when designing a plant.

1. Measurement sections and sites


The measurement section shall be selected based on a location where the disturbance of
the gas flow is as minimal as possible. The most important thing to consider is, however,
the homogeneity of the sample gas. This is why the foot of a stack is not necessarily the
most favorable location for measurement, as gas flow and monitoring can be affected by
the turbulent circumstances of the foot area that make the gas ununiform.

2. Measurement ports and working platforms


Emission measurements also require appropriate measurement ports and working
platforms. Therefore, the installation of measurement ports and working platforms
have to be taken into account in the planning phase of a measurement section.

3. Equipment and safety conditions


Sufficient and safeguarded power connections in accordance with national requirement
need to be installed at the measurement site. Compressed air, water connections
and wastewater disposal should also be considered if necessary. The instalments of
measurement sites must comply with national safety at work requirements.

Plant operators and measurers should consider the following aspects:


• Easy and safe access to the measurement site
• Ensuring that personnel carrying out the emission measurements are informed of
any operating faults which would endanger them
• Protection of the working area from heat and dust
• Weather protection and heating to ensure the necessary environmental conditions
for the personnel and the equipment

4. Typical setup for hot extractive system


Often the sample gas is heated and wet and contains a high number of gas
compounds. In order to prevent the condensation in the analyzer, heated sample
probes and sample lines are used. The CEM cabinet should include a heated sampling
system and an analyzer that enables wet sample gases to be pumped through
the analyzer. This prevents condensation and sample loss, and simplifies sample
preparation, for example.

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Emissions Monitoring

5. Choosing the Right Monitoring System


As stated by the European Commission, The Directive 2010/75/EU of the European
Parliament and the Council on industrial emissions (the Industrial Emissions Directive
or IED) is the main EU instrument regulating pollutant emissions from industrial
installations. Around 50,000 installations undertaking the industrial activities are
required to operate in accordance with a permit (granted by the authorities in the
Member States). This permit should contain conditions set in accordance with the
principles and provisions of the IED.

The measured components depend on various factors, such as the industry, the burned
fuel and the size of the plant. Environmental permit of a plant defines which gases and
components are required to monitor and what their set limits are. For example, both
small and large coal-fired power plants have their own regulations.

It is paramount that plants choose appropriate technologies and devices for the
emissions monitoring. It should be secured that the device is sensitive enough to
detect even the smallest levels of a component, as some industrial plants have very
low and strict emission limit values for certain gases.

Once the most suitable certified system for the continuous emissions monitoring
has been decided, purchased and commissioned, the operator needs to follow the
quality assurance procedure and verify the measurement results of each reported
component. This quality assurance procedure is explained in detail in the chapter 2 of
this Handbook.

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Emissions Monitoring

FTIR in Emissions Monitoring


FTIR (Fourier Transform Infrared) is one of the most reliable and effective technologies
out there for emissions monitoring. It is the most powerful technology for simultaneous
measurements of multiple gases and the industry standard in many emissions
monitoring applications. What is more, its flexibility and versatility make it a very cost-
effective and multipurpose tool for measurements of a wide range of gas components in
various industrial processes requiring continuous emissions monitoring.

Examples of industrial processes:


• Waste Incinerations
• Power Plants
• Cement Plants
• Raw Gas Measurements
• Compliance Measurements
• Aluminum production
• Fertilizer & Nitric Acid Production

Read more about these applications of Gasmet website: Industrial Emissions


Applications.

How FTIR works


Nearly all molecules can be identified by their characteristic absorption spectrum
as each molecule absorbs infrared radiation at its characteristic frequencies. Every
molecular structure has a unique combination of atoms and bonds between them,
which produces a unique spectrum when exposed to infrared light. The only exceptions
are noble gases and diatomic elements such as O2, which do not absorb IR light. IR
absorption spectrum can be thought of as a fingerprint unique to each molecule.

The infrared spectrum is a plot of infrared radiation related quantities as a function of


wavelength or wavenumber. According to Lambert-Beer’s law, the absorption strength
(peak height) is directly proportional to concentration, and this way the IR spectrum
can be used to determine concentrations of gases in the sample.

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Emissions Monitoring

Difference between NDIR and FTIR in a nutshell


• Non-Dispersive IR instruments (NDIR) measure only separate wavelength bands, no
information from other parts of the spectrum. Only one component can be analyzed
from a single measurement and interference cannot be compensated.

• Fourier Transform Infrared (FTIR) spectrometer measures all the IR wavelengths


simultaneously and produces a full spectrum. All components can be analyzed
from a single measurement and interferences are resolved.

Main benefits of FTIR in emissions monitoring


• It is futureproof
Quick changes to measurement ranges and additions to the list of measured
gases are possible and easily done. New gases and gas ranges can be added to
the analysis at any time without any changes to hardware. This can be done by the
users themselves.

• Multicomponent capability
FTIR is the only technology that measures such a wide range of gases
simultaneously. All key emissions monitoring compounds such as NOx, SO2 and CO
can be measured. In case of waste incineration, also HCl, HF and TOC are added to
the measured gases, and NH3 if SCR or SNCR is used.

• Proven technology
Gasmet FTIR analyzers hold TÜV and MCERTS certificates (QAL1). All Gasmet’s
FTIR emissions monitoring systems have been certified throughout their history.

• Reliability
FTIR is extremely sensitive, accurate and robust technology. It provides low
maintenance cost for the user and long system lifetime combined with low
uncertainty. Additionally, its high availability provides low downtime for the
operators.

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Emissions Monitoring

CVAF in Mercury Emissions Monitoring


Introduction to Mercury Monitoring
Mercury (Hg) is a heavy metal, commonly known as quicksilver. It’s the only metal that
is liquid at room temperature.

Mercury occurs naturally in the environment, in rocks and coal, in various forms, such
as metallic mercury and organic and inorganic mercury compounds.

Mercury can be harmful to the environment and is toxic to humans. Exposure to even
small doses can have serious health effects and exposure to large amounts can be
fatal. The largest sources of anthropogenic mercury emissions are:

• Mining industry
• Coal combustion
• Cement production
• Waste incineration

Many pollutants such as CO2, NOx and SO2 have been monitored continuously already
for decades. In the last years the awareness for the need to measure mercury has also
grown, and continuous mercury monitoring is becoming more and more relevant.

Especially industries burning coal, oil or waste, share the responsibility to monitor their
mercury emissions. All measuring techniques need to be able to tackle the challenges
mercury monitoring presents.

Mercury can occur in various forms and can even be bound to dust particles. Flue gas
includes elemental mercury Hg0 and oxidized mercury Hg2+ in the form of HgCl2. As
most measurement methods are based on measuring elemental mercury, it means that
the oxidized mercury compounds must be converted to elemental mercury.

Different methods of measuring mercury include:


• Cold vapor atomic absorption spectroscopy CVAA
• Cold vapor atomic fluorescence spectroscopy CVAF
• Differential Optical Absorption Spectrometry DOAS
• Sorbent Trap method (non-continuous)

CVAA, CVAF and DOAS are all measurement technologies used in certified systems.
Selecting the right technique depends on your analytical needs. The choice of analyzing
method may also be determined by regulatory compliance. Therefore, it’s vital to check
which regulatory methods you need to comply with when choosing a mercury analyzer.

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Emissions Monitoring

Principle of CVAF
CVAF measurement principle is explained below via the main parts of the mercury
analyzer:

1. Mercury vapor lamp: Lamp acts as a UV light source. Lamp emits UV light at a
wavelength specific for mercury. The light is directed to the sample cell.

2. Sample cell: Mercury atoms in sample gas are excited by UV light. The excited
atoms then start to re-radiate the absorbed energy (fluorescence).

3. Photon-counting detector: Fluorescence light is detected by a photon-counting


detector, mounted at 90° to the UV lamp.

2
SCEN
ORE
FLU LIGH
UV
LI

3
GH
T

PHOTON
COUNTING 1
DETECTOR
UV LIGHT
SOURCE

The photon counting detector is usually placed at a 90 ° angle to the light source, to
reduce stray light entering the detector, since fluorescence is omnidirectional, meaning
the light is emitted in all directions. This way, only the photons derived from the
mercury atoms can be detected.

For more information and answers to frequently asked question, navigate to our blog:

TO CVAF BLOG

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Emissions Monitoring

CVAF provides the highest sensitivity


Gasmet mercury analyzer is based on Cold Vapor Atomic Fluorescence (CVAF)
measurement principle, which offers the highest sensitivity in the world.

Measurement uncertainty in traditional analyzers increases by the presence of


moisture and oxygen which reduces the fluorescence signal from mercury in the
sample. Gasmet has avoided this ‘quenching effect’ in the CMM AutoQAL and CMM by
developing a dilution sampling approach. By lowering the concentration of interfering
gases, the quenching effect is avoided, but with the both systems’ extremely low
detection limit, the sensitivity of the mercury measurement is unaffected.

Thanks to the CVAF technology and Gasmet design, continuous and precise
measurement with no need for sample pre-concentration is achieved. The integrated
thermal converter converts all mercury compounds to elemental mercury to measure
total gaseous mercury. The converter is directly connected to the sample cell to prevent
recombination reactions, where atomic mercury converts back to oxidized forms.

Technical Properties to Consider


1. Representative sampling: Firstly, as discussed earlier, most continuous mercury
measurement methods are based on measuring elemental mercury. This means
that the oxidized mercury compounds must be converted to elemental mercury
before the measurement. It must be ensured that none of the mercury compounds
are lost before the conversion, and that there is no recombination of mercury
compounds afterwards. Therefore, placing the converter right before the sample
cell is important.

2. Low detection limit: Secondly, the mercury concentrations are extremely low
compared to other emission gas compounds. The concentrations are generally few
μg/m3 in waste incineration and power plants. These extremely low concentrations
naturally require that the measurement technique has low detection limits. It
should be noted that depending on the plant or process, there can be relatively
high concentrations of mercury from time to time. Because of occasionally varying
concentrations of mercury, the measuring system needs to be able to withstand
and detect the Hg peaks as reliably as the lower concentrations.

3. Cross-interferences: Thirdly, other features expected from mercury monitoring


systems are low cross-sensitivity and stable calibration check routines. Cross-
interference effects need to be minimized especially as the mercury concentrations
are very low compared to other components’ concentrations in flue gas. The quality
of the measurements can be tested with frequent calibrations and checks. Check
routines are preferred to be automatic and adjustable by the user if needed.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

Continuous or Non-continuous Mercury Emission Monitoring


Continuous monitoring is a particular advantage where abatement systems can
be adjusted according to the mercury levels in the plant emissions. Where flue gas
treatment is used to achieve lower mercury emissions, continuous monitoring data can
be used for example to optimize sorbent injection rates.

Non-continuous methods do not provide sufficient insight for process control. In


addition, by measuring process emissions over a short period of time, non-continuous
methods risk failing to provide sufficient information on the variability of mercury
emissions over time and between different feedstocks.

In general, the key requirements of a mercury monitoring system are as follows:

• measures mercury continuously


• measures total gaseous mercury
• measures at low levels with high sensitivity during all process conditions
• measures excursions to higher concentrations
• low cross-interference from gases such as Sulphur dioxide
• no analyte loss or other sampling issues in high dust loading
• stable calibration and simplified calibration check routine

These requirements have been met through the development of CMM AutoQAL and
CMM systems. This paper will describe the main features of the systems employing
CVAF technology.

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Emissions Monitoring

2 Quality Assurance of
Continuous Emissions
Monitoring Systems
EN 14181 sets the quality criteria for permanently installed measuring equipment at
the industrial plants.

Quality Assurance of Continuous Emissions Monitoring Systems (CEMS) is divided


into four Quality Assurance Levels: QAL1, QAL2, QAL3 and AST (Annual Surveillance
Tests).

QAL1
QAL1 requires that instruments are shown to be suitable for purpose based upon a set
of laboratory and field tests, as set out in the EU Standard EN 15267. Testing must be
carried out by an approved laboratory accredited to EN ISO/IEC 17025 by a national
body.

QAL1 aims to find out whether the selected measuring equipment for a plant is
effective enough and meets not only the required legal criteria, but also the needs of an
industry operator. This includes the analyzer system itself (such as an FTIR), as well as
the sample delivery and sample conditioning system (sample probe, sample lines etc.),
so it is an assessment of a complete measuring system.

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Emissions Monitoring

QAL2
The requirements of QAL2 cover the calibration of the CEMS / AMS against nationally
approved analytical methods applied by a test organization typically accredited to EN
ISO/IEC 17025 (and MCERTS in the UK) by a national body.

This stage of quality assurance specifies the procedures to ensure that the continuous
emissions monitoring system has been correctly installed, calibrated by comparison
measurement and independently verified.

Typically, QAL2 tests are carried out every 5 years (as defined in the site’s environmental
permit). It is, however, important to point out that if there are any major changes made
to the plant or process being measured that might affect the emissions (both positively
and negatively) or the ability of the CEMS to measure a parameter, an operator must have
the AMS evaluated and conduct another QAL2 assessment. A major change could mean,
for example, a change in the fuel types, an alteration to combustion or incarceration
processes, or anything that might radically change the emissions.

QAL3
QAL3 refers to the ongoing monitoring of a CEMS between the QAL2 tests. Operators are
required to keep an eye on the stability and performance of their monitoring systems.

EN 14181 recommends that plant operators start collecting data for QAL3 immediately
after the CEMS has been installed and commissioned. This ensures that there is
enough reported information of the performance and functionality of the monitoring
system and helps reduce the chances of the measurement system not meeting the
requirements as set out in QAL2. This bedding-in period is typically around 3 months,
though on very stable processes with good performing systems, this period is often
reduced. Minimum interval for QAL3 is defined in the QAL1 field test.

With QAL3 monitoring, industrial plants are able to spot any drifts in the zero/span
levels and point out if the system has any needs for maintenance.

AST
Annual Surveillance Tests are very similar to QAL2 test but are carried out in a smaller
scale. These mini-QAL2 tests are functional laboratory spot tests that map out the
performance of a CEMS.

Their purpose is to verify the continuing validity of the calibration function, and the
requirements and responsibilities for carrying out the AST tests are the same as for QAL2.

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Emissions Monitoring

Roles and Responsibilities


QAL1, QAL2, AST and QAL3 require co-operation of a number of parties.

Suppliers and Manufacturers of CEMS:

• QAL1 certificates for CEMS


• Appropriate and safe installing of a CEMS
• Cooperation with the plant operator before QAL2 and AST tests (and during, if
necessary)

Test Laboratories:

• Maintenance of accredited Standard Reference Methods for QAL2 and ASTs.


• Functional tests (QAL2 and AST): sampling or auditing the test results by other
parties

Note: Functional tests can be carried out by the manufacturer / supplier / System
integrator. It is the responsibility of the Test Laboratory to ensure that such tests are
carried out correctly.

Industrial Plants / Process Operators:

• QAL2, QAL3 & AST reporting to regulators and local authorities


• Performing QAL3

Regulators / Local Emission Authorities:

• Assessing operator compliance


• Assessing test laboratories
• Providing guidance on EN 14181

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

3 WI BAT Conclusions
This section introduces the key findings of conclusions for Best Available Technology
Reference document for Waste Incineration (WI BREF). It was accepted by European
Integrated Pollution Prevention and Control Bureau (EIPPCB) in summer 2019 and the WI
BAT conclusions published on 3rd December 2019, under the IED Directive 2010/75/EU.

In the following chapters we will introduce the upcoming changes and the ranges for
daily average limits for new plants and existing plants.

Abbreviations:
BAT-AEL: BAT-associated emission levels

Dioxin-like PCBs: PCBs showing a similar toxicity to the 2,3,7,8-substituted


PCDD/PCDF according to the World Health Organization (WHO).

EIPPCB: European Integrated Pollution Prevention and Control Bureau

ELV: Emissions Limit Value

PCDD/F: Polychlorinated dibenzo-p-dioxins and -furans

TVOC: Total volatile organic carbon, expressed as C (in air).

WI BREF: Best Available Technology Reference document for


Waste Incineration

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Emissions Monitoring

Upcoming changes
The revised BREF defines the technical basis and BAT-associated emission levels (BAT-
AELs) for national authorities in the EU to set operating permits for installations. The
BAT-AELs work as a framework for authorities to set plant-specific ELVs (Emissions
Limit Values).
Regardless of whether the BAT-AELs change or not, all environmental permits of
existing waste incineration installations in Europe need to be reviewed during the
implementation period of four years. This may cause changes in the plant-specific
ELVs (within the limits defined by the BAT-AELs).
New installations must comply with the new requirements immediately without any
implementation period. Even though in different countries and plants, the specific ELVs
may differ, they need to be set according to the BAT-AEL requirements.

Key Findings for Emissions Monitoring


Key findings for emissions monitoring in the BAT conclusions for Waste Incineration
are summarized in the table below:

BAT-associated emission levels (BAT-AELs) for channelled emissions to air of TVOC,


PCDD/F and dioxin-like PCBs from the incineration of waste

2006 2019
Daily Daily average for Daily average for
Component IED limit Unit
average New plant Existing plant

HF <1 1(±0.4) <1 <1 mg/m3


HCI 1-8 10(±4) <2-6 <2-8 mg/m3
SO2 1-40 50(±10) 5-30 5-40 mg/m3
NH3 <10 - 2-10 2-10 mg/m3
NOX 40-100 200(±40) 50-150 50-150 mg/m3
СО 5-30 50(±5) 10-50 10-50 mg/m3
TOC 1-10 10(±3) <3-10 <3-10 mg/m3
Hg - - <5-20 <5-20 mg/m3
Dust 1-5 10 <2-5 <2-5 mg/m3

Source: EUR-Lex: Official Journal of The European Union L312

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Emissions Monitoring

The BAT-AELs set for mercury (Hg) emissions for incineration and co-incinerations of
waste happens for the first time at the EU level. Continuous monitoring is required if it
cannot be proven that the waste incinerated has low and stable mercury content.
The mercury content of different waste feeds can vary significantly, which can be
clearly spotted with continuous mercury monitoring. During the day, the new feed is
introduced approximately every four hours, resulting in mercury peaks as the waste is
incinerated, as seen in the graph below:

Continuous mercury monitoring from waste incinerator

700
Total mercury concentration (μg/m3)

600

500

400

300

200

100

0
12.00 AM 6.00 AM 12.00 PM 6.00 PM 12.00 AM
Time

In addition, the BAT Conclusions for Waste Incineration sets new BAT-AELs for the
following compounds: TVOC/PCDD/F and dioxin-like PCBs (see table below):

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Emissions Monitoring

BAT-associated emission levels (BAT-AELs) for channelled emissions to air of TVOC,


PCDD/F and dioxin-like PCBs from the incineration of waste

BAT-AEL
Parameter Unit Averaging period
New Plant Existing Plant

TVOC mg/Nm3 <3–10 <3–10 Daily average

<0,01–0,04 <0,01–0,06 Average over the sampling period


PCDD/F (1) ng I-TEQ/Nm3
<0,01–0,06 <0,01–0,08 Long-term sampling period (2)

PCDD/F+ <0,01–0,06 <0,01–0,08 Average over the sampling period


dioxin-like ng WHO-TEQ/Nm3
PCBs (1) <0,01–0,08 <0,01–0,1 Long-term sampling period (2)

(1) Either the BAT-AEL for PCDD/F or the BAT-AEL for PCDD/F + dioxin-like PCBs applies.
(2) The BAT-AEL does not apply if the emission levels are proven to be sufficiently stable.

The associated monitoring is in BAT 4.

Source: EUR-Lex: Official Journal of The European Union L312/81

To summarize, plant operators need to prepare for the following changes/actions:

1. For the first time in history, BAT-AELs for Mercury were introduced for incineration
and co-incinerations of waste.

2. Continuous Mercury Monitoring will become obligatory, unless it can be proven that
the waste incinerated has low and stable mercury content.

3. All environmental permits will be reviewed by 2023, which might cause changes to
plant specific ELVs.

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Emissions Monitoring

4 LCP BAT Conclusions


Members of the European Union accepted new air pollution limits for large combustion
plants in April 2017. The new limits may require utilities to invest in new pollution
reduction technology. This strengthens the requirements of the Industrial Emissions
Directive (DIRECTIVE 2010/75/EU) for both reduction and monitoring requirements,
both of which are addressed in the “Best Available Techniques Conclusions for Large
Combustion Plants” (BATC LCP).

The LCP BAT Conclusions explain new emission limits values (ELVs) for sulfur dioxide,
nitrogen oxides, mercury, and particulate matter, and require large combustion plants in
Europe to comply with those limits by 2021.

BAT-AELs (best available technology associated emission levels) are set as a range
and based on evidence from plants that are in operation all over the world. The concept
of BAT covers not only the environmental performance of the technique but also that it
is currently used and economically viable. The BAT AEL-ranges shall be the reference
for setting these emission limit values, taking into account fuel type, combustion
technology and other relevant conditions.

Abbreviations:
LCP BREF: Best Available Techniques Conclusions for Large Combustion Plants
reference document.

LCP BATC / LCP BAT Conclusions: A document containing the parts of a BAT reference
document (LCP BREF) laying down the conclusions on best available techniques.

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Emissions Monitoring

Who Does LCP BAT Conclusions concern?


LCP BAT Conclusion regards combustion installations with a total rated thermal input
exceeding 50 MW taking place at combustion plants. Nonetheless, plants with a
≤ 50MWth are discussed where technically relevant because smaller units can
potentially be added to a plant to build one larger installation exceeding 50MW. These
BAT conclusions concern also the following activities:

• Gasification of coal or other fuels in installations with a ≥ 20MWth or more, only


when this activity is directly associated with a combustion plant.

• Disposal or recovery of waste in waste co-incineration plants for non-hazardous waste


with a capacity exceeding 3 tons per hour or for hazardous waste with a capacity
exceeding 10 tons per day, only when this activity takes place in combustion plants.

Different variations of conventional power plants used for mechanical power and
heat generation are covered in the BREF. Industrial combustion installations are
covered if they use conventional fuel. The conventional fuels considered in these BAT
conclusions are any solid, liquid and/or gaseous combustible material including:

• solid fuels (e.g. coal, lignite, peat);


• biomass
• liquid fuels
• gaseous fuels
• industry-specific fuels (e.g. by-products from the chemical and iron and steel industries)
• waste (excluding mixed municipal waste)

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Emissions Monitoring

New Continuous Measurement Requirements


In the cases of following components, a continuous emission monitoring will be required:

• Ammonia NH3, when SCR and/or SNCR is used


• Mercury Hg, when LCP ≥ 300 MWth, when coal and/or lignite used,
including waste co-incineration
• Hydrogen chloride HCl, when solid biomass and/or peat used in LCP,
or waste co-incineration

Compound Measurement requirement


NH3 (when SCR and/or SNCR used) Continuous
Hg (LCP ≥ 300 MWth) Continuous
HCl (solid biomass and/or peat used) Continuous
HCl (Waste co-incineration) Continuous
HCl (coal, lignite, process fuels from chemical industry) Once every three months
HF (Waste co-incineration) Continuous
HF (coal, lignite, process fuels from chemical industry) Once every three months
TVOC (Waste co-incineration with coal, lignite, solid biomass and/or peat) Continuous

Gasmet delivers continuous emission monitoring technology, which is up to date with


the LCP BREF 2017 requirements.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

New Emission Limits


Please note that the list below contains the most relevant changes to Gasmet and our
clientele. Therefore, some changes in the LCP BATC, such as those concerning dust
and periodic emissions monitoring, will not be covered in this section.

In conclusion, the relevant changes to the new emission limits concern:

• the emissions to air of mercury*


• hydrogen chloride and hydrogen fluoride from the combustion of solid fuels in LCPs
• pollutants including sulphur dioxide (SO2) and nitrogen oxides (NOx).

*BAT-AELs for mercury emissions to air are specified for coal and lignite burning power
plants. E.g. A new coal-fired power plant with ≥ 300 MWth has a BAT-AEL of <1-2 μg/Nm3
mercury (yearly average), and an existing lignite-fired power station with a thermal input
under 300 MW has a BAT-AEL of <1-10 μg/Nm3 mercury. Permits will have to be updated.

Table 2. BAT-associated emission levels for mercury emissions to air from the
combustion of coal and lignite.

BAT-AELs (μg/Nm3)
Combustion plant total rated
thermal input (MWth) Yearly average or average of samples
obtained during one year

New Plant Existing Plant


Coal <300 <1–3 <1–9
Coal ≥300 <1–2 <1–4
Lignite <300 <1–5 <1–10
Lignite ≥300 <1–4 <1–7

Table 3. BAT-associated emission levels for HCl emissions to air from the combustion
of solid biomass and/or peat.

BAT-AELs (μg/Nm3)
Combustion plant total rated thermal input
(MWth) Yearly average or average of samples
obtained during one year

New Plant Existing Plant


<100 <1–7 <1–15
100–300 <1–5 <1–9
≥300 <1–5 <1–5

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Emissions Monitoring

Table 4. BAT-associated emission levels for NOx emissions to air from the combustion
of coal and/or lignite

BAT-AELs (μg/Nm3)
Combustion plant total rated thermal input (MWth)
Yearly average
New Plant Existing Plant
<100 100–150 100–270
100–300 50–100 100–180
≥300, FBC boiler combusting coal and/
or lignite and lignite-fired PC boiler 50–85 <85–150

≥300, coal-fired PC boiler 65–85 65–150

Table 5. BAT-associated emission levels for SO2 emissions to air from the combustion
of coal and/or lignite.

BAT-AELs (μg/Nm3)
Combustion plant total rated thermal input (MWth)
Yearly average
New Plant Existing Plant
<100 150–200 150–360
100–300 80–150 95–200
≥300, boiler 10–75 10–130
≥300, Fluidized bed boiler 20–75 20–180

Table 5. BAT-associated emission levels for SO2 emissions to air from the combustion
of coal and/or lignite.

Combustion plant total rated BAT-AELs (μg/Nm3)


thermal input (MWth) Yearly average NOx Yearly average SO2
New Plant Existing Plant New Plant Existing Plant
50–100 / <100 (SO2) 150–200 150–360 15–70 15–100
100–300 80–150 95–200 <10–50 <10–70
≥300 10–75 10–130 <10–35 <10–50

NB: BAT conclusions are the technical basis for national authorities in the EU
countries to set permit conditions for LCPs. If the authorities use the BAT conclusions
to set permit conditions at the lowest end of the indicated emission level ranges,
this can drive a sizeable reduction of emissions from the plants subject to the new
environmental standards.

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Emissions Monitoring

Checklist: How to Prepare in Practice


As a result, you need to know whether your installation fulfils the new emissions
regulations, and which Best Available Techniques are most cost effective for you.

Checklist:

• Each EU country will set their own emission limit values (ELVs) based on BAT-AELs.
Find out the ELVs You need to comply with.

• Invest in emission monitoring technology that is up to date with the LCP BREF and
meet the new requirements.

• Pay special attention to lower emission limits and new continuous monitoring
requirements

• Make adjustments to the combustion system or to the existing SCR/SNCR system


if needed.

• If necessary, install a SCR or SNCR system.

• Please note that if SCR or SNCR is used, NH3 needs to be measured continuously.

• Make sure You comply with the new requirements by 2021.

Gasmet’s EN 15267 Certified Solutions


In accordance with the LCP BREF and WI BREF regulations, Gasmet provides
technology that fulfils the regulations set in the reference document. Gasmet
manufactures complete CEM (Continuous Emission Monitoring) systems based on
FTIR technology and CMM (Continuous Mercury Monitoring) systems based on CVAF
technology and GT90 Dioxin+ system for measurements of dioxins and furans.

Gasmet CEMS II e is EN 15267 certified for measurement of CO, NO, NO2, N2O, SO2,
HCl, HF, NH3, CO2, H2O, O2, CH4 and CH2O in extended ranges.

The certification ranges can be found here: Certificate of Product Conformity (QAL 1) -
Gasmet CEMS II e

Also see: The MCERTS Product Conformity Certificate for CMM system.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

Gasmet’s CMM has the lowest certified Hg measuring range in the world, from 0 to 5
μg/m3.

Gasmet’s GT90 Dioxin+ is designed specifically for long-term monitoring of dioxin


emissions. The automatic system represents the cutting-edge technology for dioxin
sampling and fulfills all requirements of the dioxin measurement standard

Gasmet offers both stationary and portable monitoring systems and technology for
continuous gas measurements. Gasmet is up to date with the changes in emissions
measuring legislations and makes sure that its systems meet the requirements of the
future.

CEMS II e, CMM, CMM AutoQAL and GT90 Dioxin+ systems will be introduced in the
next chapters. Also see more information on our website:

CEMS II e for continuous emissions monitoring

CMM and CMM AutoQAL for continuous mercury monitoring

GT90 Dioxin+ for continuous dioxin monitoring

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

5 Monitoring Solutions
This section introduces you to the emissions monitoring solutions that Gasmet offers
for continuous emission monitoring needs.

Gasmet manufactures two kinds of complete continuous emissions monitoring


systems:

• The Continuous Emission Monitoring System CEMS II e offers TÜV and MCERTS
certified solution (QAL1) for a wide range of demanding emission monitoring
applications. The system is generally used to simultaneously measure several
gaseous components, such as CO and NO2.

• The Continuous Mercury Monitoring systems CMM AutoQAL and CMM have the
lowest certified range in the world (0-5 µg/m3). CMM AutoQAL has an automatic
and integrated QAL3 validation tool. Systems are perfect for monitoring mercury
continuously from hot, wet and corrosive flue gases.

The Dioxin Monitoring System GT90 Dioxin+ is a device designed for long-term
sampling of dioxin emissions in conformity to the European standard EN 1948-1 and
EN 15267. The system represents the cutting-edge technology for dioxin long-term
sampling and fulfills all the requirements of the dioxin measurement standard.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

Continuous Emissions Monitoring Systems


CEMS II e
Gasmet Continuous Emissions Monitoring System CEMS
II e is a solution for a broad range of demanding emissions
monitoring applications. CEMS II e has both TÜV and
MCERTS certificates. All parts of the system are heated to
180 °C and this extractive system is ideal for measuring
pollutants from hot, wet and corrosive gas streams.

Gasmet CEMS II e is typically used to simultaneously


measure the following 16 gases: H2O, CO2, CO, N2O, NO,
NO2, SO2, HCl, HF, NH3, CH4, C2H6, C3H8, C2H4, CH2O
and C6H14. On top of these, an FTIR analyzer can also
measure Total Organic Carbon (TOC) and NOx.

Standard Gasmet CEMS II e consist of the following


modules:
• Industrial computer
• Sampling system
• Oxygen analyzer (optional)
• FTIR Analyzer
• Flame Ionization Detector, GFID (optional)

CEMS II e is a fully automatic system and it has a variety of I/O configuration options.
Gas component concentrations and alarm information can be transferred to other
automation or reporting systems in analog or digital format.The system has options for
TCP/IP and Profibus DP. CEMS II e system is also equipped with the possibility to use
analog and digital inputs for external data, for example from eternal analyzers like flow
and dust.

Key benefits of CEMS II e:


• Certified (QAL1) according to standards EN 15267-1 (2009), EN 15267-2 (2009), EN
15267-3 (2007) and EN 14181 (2004)
• 6-month maintenance interval for all certified
• components
• Excellent annual availability of 98,4%
• Flexible solution
• Gasmet’s own design and manufacture with 30 years of experience
• Local, trusted and trained, service and support

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

FID (Flame Ionization Detector)


Gasmet Flame Ionization Detector (GFID) measures continuous total hydrocarbon
(THC) concentration. GFID analyzer is TÜV certified (QAL1) and the device measures
pollutants from hot, wet and corrosive flue gases.

The measurement is based on flame ionization detection. The certified measuring


ranges are from 0-15 to 0-500 mg/m3. The GFID analyzer is integrated to the
Continuous Emissions Monitoring System CEMS ll e.

Oxygen Analyzer
Gasmet oxygen analyzer measures oxygen concentration continuously from wet or dry
flue gases. The analyzer is suitable for several industrial applications where accurate
and reliable oxygen measurement is required.

The measurement is made with a ZrO2 sensor. The analyzer can measure oxygen from
1 ppm to 25 vol-%.

The oxygen analyzer can be integrated to the Gasmet Continuous Emissions


Monitoring System CEMS ll e.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

Continuous Mercury Monitoring Systems


CMM AutoQAL and CMM
Gasmet offers two solutions for Continuous Mercury
Monitoring, the CMM and CMM AutoQAL.

Both systems provide the highest sensitivity and annual


availability on the market. CMM AutoQAL is the only TÜV
and MCERTS certified solution with automatic and truly
integrated QAL3 validation tool. Systems offer certified
measurement with the lowest certified range in the world
(0-5 μg/m3). The highest certified measurement range of
the system is 1000 μg/m3 and even higher concentration
peaks can be measured without any hardware changes.
CMM has both TÜV and MCERTS (QAL1) certificates.

CMM AutoQAL and CMM both consist of:


• Dilution probe
• Heated sample line
• Mercury analyzer
• Test gas generator

Gasmet mercury analyzer is based on Cold Vapor Atomic


Fluorescence (CVAF) measurement principle, which gives the highest sensitivity in the
world. The system is fully automatic, and the automatic calibrations are done by user-
defined intervals. CMM AutoQAL has an integrated and certified test gas generator with
possibility to do both Hg0 and HgCl2 checks means that there is no longer a need for
an external gas generator for QAL3 operations.

CVAF technology and Gasmet design guarantee a continuous and precise measurement
without the need for sample pre-concentration. The integrated thermal converter converts
all mercury compounds to elemental mercury to measure total gaseous mercury.

Key benefits of CMM AutoQAL and CMM:


• Certified (QAL1) according to standards EN 15267-1 (2009), EN 15267-2 (2009), EN
15267-3 (2007) and EN 14181 (2014) with the lowest certified range in the world
• Access to online results
• No interferences
• Quick response of <120 sec
• Excellent annual availability of 99%
• Future-proof with the highest sensitivity in the market
• Worldwide technical service and support

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Emissions Monitoring

Additional benefits of the CMM AutoQAL:


• Fast and easy integrated QAL3 functionality
• Software giving immediate results: Pass / Fail
• Minimal operation costs

Expenses estimate for Different QAL3 Methods


• Capex and Opex calculations when using different QAL3 validation methods
• Parameters used in calculation:
• RoE: 8%
• System lifetime: 10 years
• Validation every 3 months

QAL3 validation 1st year Annual 10 years total Opex comments

Purchase Opex Capex Opex Capex Opex TOTAL

CMM AutoQAL 15 000 € 200 € 1738 € 200 € 32 384 € 2 000 € 34 384 € Liquid only

Liquid, own manpower,


HovaCAL 30 000 € 4 000 € 3477 € 4 000 € 64 768 € 40 000 € 104 768 € Hovacal annual service

Validation as service from


Validation 6 000 € 6 000 € 60 000 € 60 000 € competitor using Hovacal

New World Record


Gasmet CMM AutoQAL and CMM have successfully completed the EN 15267-3 testing
with the world’s lowest certified range (0 to 5 μg/m3) for measurements of mercury.
This new world record makes these systems future-proof for declining emission limits.

See the MCERTS certification for CMM here.


See the MCERTS certification for CMM AutoQAL here.
See the TÜV certification for CMM here.
See the TÜV certification for CMM AutoQAL here.
See all Gasmet’s TÜV certifications here.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

Dioxin Sampling Systems


GT90 Dioxin+
The GT90 Dioxin+ is designed specifically for long-term
sampling of dioxin emissions. The automatic system
represents the cutting-edge technology for dioxin sampling
and fulfills all requirements of the dioxin measurement
standard. Monitoring is done in conformity to the European
standard EN 1948-1.

There are two versions available:

GT90 Dioxin+ Standard


• Two-probe version of GT90 Dioxin+
• Especially designed for improving the sampling
representativity of stacks with large diameters
• Options for fine dust and heavy metal sampling available
(ParTrace®)
• Fine dust option: For collecting and separating of
PM10, PM2.5 and optionally PM1
• Heavy metal option: For collecting heavy metals and
dust by using an
• additional separation step (the collection takes place at
a lower temperature

GT90 Dioxin+ Compact


• Single probe version of GT90 Dioxin+
• Suitable for stacks with a smaller diameter
• Main power: 230 V 16 A, + neutral + ground
• Partrace option not available

High quality measurements can be achieved with both versions.

Both versions are also perfect for continuous isokinetic


sampling of hazardous organic compounds in industrial and
domestic waste incineration plants. In addition to dioxins, the
system is capable of measuring furans and other persistent
organic pollutants (POPs), such as polychlorinated biphenyls
(PCBs) and polycyclic aromatic hydrocarbons (PAHs). GT90
Dioxin+ can also be equipped with the ParTrace option,
enabling heavy metal and fine dust collection.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

The GT90 Dioxin+ was designed to sample even the lowest dioxin and dioxin-like
compound concentrations in harsh industrial environments. The system has been
performance tested and validated, allowing measurements down to 0.0003 – 0.252 ng
I-TEQ /m3. The system can withstand dust loads up to 150 mg/m3 and velocities up to
30 m/s without any effect to the performance.

Key benefits of GT90 Dioxin+:


• Long-term isokinetic sampling
• Conformity to EN 1948-1
• Sampling of dioxins, furans and other persistent organic pollutants (POPs)
• High sensitivity
• Availability of 100%

Gasmet Software
FTIR analyzers: Calcmet software
All Gasmet FTIR analyzers come with the Calcmet software. The software collects,
stores and visualizes the FTIR spectra of the sample gas and analyzes the sample
spectra for the gas concentrations.

The Calcmet software analyzes the sample spectrum using a sophisticated algorithm.
It can simultaneously detect, identify and quantify up to 50 different gas components
from a single sample. Cross-interference effects are compensated, and analysis
accuracy is maintained even when analyzing complex gas mixtures where gases have
overlapping absorption spectra.

Calcmet software comes with a user interface allowing simultaneous viewing of


concentration results, sample and reference spectra and time trends for the analyzed
gases.

Sample spectra can be easily re-analyzed, since the sample spectra are stored as
separate files on an external computer.

Calcmet software can also identify previously unknown components – a feature that
has often shown its value in process control.

Gasmet Technologies Phone: +358 9 7590 0400 www.gasmet.com


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Emissions Monitoring

Mercury Analyzers: MAUI software


Our mercury analyzer technologies are controlled with Mercury Analyzer User Interface
(MAUI) software. MAUI controls the analyzer, test gas generator and sampling probe
blowback. The key features of MAUI are:
• User-friendly interface with a touch panel access
• Trend view of latest measurements on screen (60 min/24 hrs)
• User-defined automatic calibration intervals and probe blowback routines
• Status and warning signals sorted into four categories (system alarm, service
request, maintenance, result valid)
• Possibility to make a Support package with latest measurement data for remote
support

Customer Data
Real-life example data measured with Gasmet CEMS II e from Municipal waste
incineration plant on oil burner during commissioning. Online data is updated every 60
seconds (1 min measurement time).

80%

70%
Concentration percent of range (%)

60%

50%

CO
40%
H20
NO
30% NH3

20%

10%

0%
12.00 AM 1.00 AM 2.00 AM 3.00 AM 4.00 AM 5.00 AM 6.00 AM 7.00 AM

Time

Real-life example data measured with Gasmet CMM system from coal-fired power
plant in Europe. Zero calibration of the system takes place at 4:50 am and span
calibration for 5 μg/m3 at 5:50 am

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> Know what’s in the air

Gasmet is a Finnish high-technology company that develops, manufactures and markets


gas analyzers and monitoring systems for a variety of industrial, environmental and
safety applications. Our customers worldwide include, but are not limited to, power
plants, waste incinerators, first responders and universities.

In the field of gas analysis, our company have established a global reputation for
high-tech, customer-driven and reliable solutions. As a global company, we place a
heavy emphasis on high levels of pre- and post-sale technical support.

In addition to our acknowledged global presence, our main assets are:

30 years of FTIR experience


Gasmet has 30 years of FTIR experience and it has introduced several breakthrough
innovations. Gasmet teams of experts provide continuous improvements of the
products and ensure that their clients FTIR analyzer investment is continually
future-proofed.

Handmade from the very beginning


All Gasmet products are handmade in Finland from the very beginning. A strong
value chain management allows Gasmet to create high value for the customers. Gasmet
has developed the finest technology that ensures the highest possible quality of the
products.

Local technical support globally


Gasmet highlights the importance of local support, globally. With the service and
support network covering more than 70 countries, Gasmet ensures local, high
quality technical support for the customers and secures continuous availability of
the spare parts to Gasmet systems during their entire lifetime.

For more information, please contact:

Gasmet Technologies Oy
Mestarintie 6, 01730 Vantaa

email: contact@gasmet.fi
phone: +358 9 7590 0400
www.gasmet.com

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