Coal-Fired Utility Power Plants
Coal plants face unique challenges: high particulate environments, turbulent airflows, limited straight-run ductwork, and the constant need for precise coal plant airflow measurement. Without reliable airflow data, plants risk reduced efficiency, higher emissions, and costly unplanned outages.
Air Monitor’s engineered solutions are purpose-built for airflow measurement in coal-fired utility power plants. From primary and secondary air measurement to stack compliance monitoring, our instrumentation delivers rugged, drift-free, and accurate performance—empowering operators to optimize combustion, reduce emissions, and protect critical equipment.
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With Air Monitor Solutions, You Gain
Confidence in Combustion Stability and Safety
Coal-fired utility power plants require stable and repeatable airflow measurement to ensure safe, efficient combustion of pulverized coal-fired boilers, where controlling air ratios is critical. CAMS™ and VOLU-probe/SS™ arrays deliver accurate airflow data even in turbulent, particulate-laden ducts with limited straight runs. This reliability translates into safer burner operation, fewer emergency shutdowns, and predictable combustion behavior.Empowerment Through Precision Control
Precise airflow measurement enables fine-tuned management of primary airflow measurements, secondary airflow, and overfire air in coal-fired power plants. This level of control balances air-to-fuel ratios, improving efficiency and reducing slagging risks. Air Monitor’s systems give engineers and technicians mastery over combustion control, confidently adjusting air-to-fuel ratios, proactively preventing slagging, mill pluggage, and pipe fires, and meeting regulatory emissions limits without guesswork.Pride in Operational Excellence
Operators of coal-fired utility power plants take pride in using long-lasting, industry-trusted airflow measurement systems. From STACK-probe™ and CA Station to AUTO-purge III, Air Monitor solutions are built to withstand decades of service. Teams know they are working with industry-leading, EPA-compliant technology that reflects their commitment to safe, efficient, and clean operations.Coal-Fired Utility Power Plant Airflow Measurement Products
CEM Systems
Continuous Emissions Monitoring (CEM) solutions integrate mass flow, temperature, absolute pressure, and automated purge capabilities to deliver accurate and reliable in-stack flow measurement. Designed to comply with 40 CFR Part 75 reporting requirements, these systems achieve ±3% accuracy of actual flow and include companion mass flow transmitters for full compensation. CEM Systems are ideal for coal-fired power plants that must maintain EPA compliance while reducing NOₓ, CO, and SO₂ emissions.
IBAM
The Individual Burner Airflow Measurement (IBAM) system provides burner-to-burner balancing, which is critical in coal-fired boilers for maintaining stable combustion. By ensuring accurate distribution of airflow to each burner, IBAM helps reduce NOₓ emissions, improve heat rates, and deliver consistent combustion performance across all burners.
AUTO-purge III
AUTO-purge III is an electro-pneumatic system that automates debris purging from sensing ports, ensuring low-maintenance, drift-free performance in dirty, particulate-laden environments. Designed specifically for the harsh conditions of coal-fired utility power plants, AUTO-purge III extends the life of paired airflow transmitters and maintains reliable system performance with minimal operator intervention.
AUTO-purge III/CEM
AUTO-purge III/CEM combines the benefits of electro-pneumatic purging with Continuous Emissions Monitoring applications. This system prevents debris accumulation in sensing ports, keeping CEM airflow measurement accurate and reliable. Built for coal-fired power plant environments, it provides uninterrupted sensor operation, reduces maintenance requirements, and supports long-term compliance performance.
CA Station
The CA Station is a combustion airflow measurement solution designed to measure bulk secondary and primary airflows in ducts with high turbulence and heavy particulate loading. Using a differential pressure Pitot traverse array, the CA Station achieves 2–3% accuracy of actual flow over a wide operating range. Available in both circular and rectangular configurations and capable of handling temperatures up to 800°F, it is fabricated in carbon steel or stainless steel and includes built-in flow conditioning for reliable performance.
CAMS™
The Combustion Airflow Management System (CAMS™) is an integrated solution engineered to monitor combustion airflow while automatically purging debris from sensing ports. Designed for coal-fired utility power plants, CAMS™ pairs purge control with VELTRON differential pressure transmitters and CAMM™ microprocessor-based modules. This combination delivers precise, temperature- and pressure-compensated airflow measurement for real-time combustion control, long-term stability, and reduced emissions.
MASS-tron II/CEM
MASS-tron II/CEM is a complete system of mass flow products designed to meet 40 CFR Part 75 compliance standards. It integrates flow, temperature, and pressure measurement with companion mass flow transmitters and differential pressure calculators to deliver fully compensated, high-accuracy mass flow data. MASS-tron II/CEM is ideal for coal-fired utility power plants requiring dependable emissions reporting and long-term regulatory compliance.
VOLU-probe/SS
The VOLU-probe/SS is a stainless steel airflow traverse probe designed for harsh coal-fired power plant environments with corrosive, abrasive, or high-temperature conditions. Capable of operating from 400 to 10,000 FPM with ±2% accuracy of actual flow, the VOLU-probe/SS has been proven to reduce FD fan operating costs by approximately $50,000 annually, with a typical ROI of 21 months. It is available in materials such as Hastelloy, Inconel, and Kynar, and offers easy installation or removal for maintenance.
STACK-probe
The STACK-probe is a rugged, EPA-compliant airflow traverse probe engineered for stack and duct flow monitoring in Continuous Emissions Monitoring (CEM) systems. With accuracy that meets 40 CFR Part 75 specifications, the STACK-probe operates reliably in temperatures up to 900°F and is available in stainless steel, Hastelloy, or Inconel. Its cantilevered construction with 4- or 6-inch flange connections ensures durable performance in demanding coal industry applications where accurate flue gas flow rate measurement is essential.
VELTRON DPT-Plus
VELTRON DPT-Plus is an advanced multivariable transmitter that measures differential pressure and process temperature to calculate compensated mass flow. It incorporates AUTO-zero technology to maintain drift-free accuracy over time, making it ideal for the demanding airflow conditions of coal-fired utility power plants. With 0.1% accuracy and ultra-low range capability, it reduces recalibration needs, lowers maintenance costs, and ensures continuous reliability.
VELTRON II Transmitter
The VELTRON II Transmitter provides precise measurement of differential pressure and volumetric airflow, delivering 0.1% accuracy with a wide turndown ratio of 100:1. Designed for industrial environments, it is trusted in coal-fired power plant operations for its long-term stability and adaptability, with enclosure options ranging from standard NEMA 1 to more rugged NEMA 4 and 4X. Its reliable performance makes it a versatile choice for multiple airflow measurement applications.
What Advantages Does Airflow Measurement Offer Coal-Fired Utility Power Plants?
Airflow measurement in coal-fired utility power plants is fundamental for safe, efficient, and compliant operation. Whether plants are managing induced draft fans, balancing primary airflow measurements, or adjusting for the type of coal being used, precise airflow data is essential for combustion stability. With Air Monitor’s engineered solutions, operators gain:
- Combustion Efficiency: Balanced burner stoichiometry, reduced unburned carbon, and improved heat rates.
- Emissions Control: Tighter NOₓ, CO, and SO₂ management, opacity reduction, and staged combustion strategies.
- Operational Reliability: Reduced risk of pipe fires, mill pluggage, and forced outages through consistent airflow data.
- Operator Confidence: Clear, accurate measurements that empower teams to run cleaner, more efficient plants.
Coal-Fired Utility Power Plant Airflow FAQs
How does airflow measurement contribute to combustion optimization in coal-fired power plants?
Accurate airflow measurement enables precise control of both primary and secondary air, which is essential for maintaining optimal air-to-fuel ratios. This balance helps ensure consistent burner flame patterns, a uniform furnace temperature profile, and efficient combustion. As a result, plants can reduce emissions such as CO, NOx, and LOI, while improving overall thermal performance and reliability.
What cost savings can be achieved by implementing airflow measurement systems?
Implementing reliable airflow measurement systems can lead to substantial cost savings by reducing forced outages, minimizing fuel waste, and lowering fan energy consumption. Enhanced measurement accuracy allows for better control of forced draft fans and dampers, which can reduce operational costs and improve system efficiency. In some cases, these upgrades have resulted in tens of thousands of dollars in annual savings and short payback periods.
How do airflow measurement systems improve process control in coal-fired power generation?
Real-time airflow data supports better control of combustion dynamics, enabling operators to fine-tune burner and mill performance. This helps prevent issues such as slagging, mill pluggage, and pipe fires. Advanced systems often include features like pressure and temperature compensation and automated purging, which maintain measurement accuracy even in challenging environments.
What additional benefits come from using airflow measurement in coal-fired utility plants?
Beyond optimization and cost savings, airflow measurement systems support regulatory compliance, improve safety by preventing hazardous conditions, and offer versatility across various industrial applications. They are especially valuable in environments with limited straight duct runs, low velocities, and high particulate loads, where traditional measurement methods may fail.
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Explore our downloadable product brochures, catalog sheets, and other essential documents.-
CEM Systems
Continuous Emissions Monitoring (CEM)
System compliant to meet 40 CFR Part 75 data reporting requirements.
Flow, Temperature, ABS Pressure, Purge, Reporting
- In-stack flow measurement
- Accuracy: 3% of actual flow
- Companion mass flow transmitter
- Automated pneumatic purging
- 40CFR75 Compliant
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AUTO-purge III
Automated Air Purge System
Electro-pneumatic system automates sensing port debris purging for low maintenance dirty airflow measurement.
Companion System
- Add to flow and transmitter pairings
- Automated pneumatic purging
- Field-selectable purging intervals
- Maintains flow system performance
- Trouble-free operation
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AUTO-purge III/CEM
Continuous Emissions Monitoring (CEM) with Purging
Electro-pneumatic system automates sensing port debris purging for low maintenance CEM.
Companion System
- Add to flow and transmitter pairings
- Automated pneumatic purging
- Field-selectable purging intervals
- Maintains flow system performance
- Trouble-free operation
-
CA Station
Inline Airflow Measuring Station
Differential pressure Pitot airflow traverse array in rectangular & circular constructions for combustion airflow.
0 to 8,000 FPM
- Accuracy: 2-3% of Actual Flow
- Circular/Rectangular; fabricated to any size
- Temperature: ≤800°F
- Carbon steel, Stainless steel
- Built-in flow conditioning
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CAMS™
Combustion Airflow Management
System designed to monitor combustion airflow and purge debris from sensing ports.
Integrated System
- Accuracy: 0.1%
- Temperature and pressure compensated
- Automated pneumatic purging
- Add to flow measurement pairing
- Trouble-free operation
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MASS-tron II/CEM
Continuous Emissions Monitoring (CEM)
System of mass flow products compliant to meet 40 CFR Part 75 data reporting requirements.
Flow, Temperature, ABS Pressure, Reporting
- Add to flow measurement pairing
- Companion mass flow transmitter
- Flow/Differential Pressure Calculator
- 40CFR75 Compliant
- Fully compensated mass flow
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VOLU-probe/SS
Insertion Airflow Measuring Probes
Stainless steel airflow traverse probe ideal for dirty applications with corrosive, abrasive, and extreme temperatures.
400 to 10,000 FPM
- Accuracy: 2% of Actual Flow
- Temperature: ≤900°F
- Stainless steel, Hastelloy, Inconel, Kynar
- External or Internal mounting
- Easy installation/removal for maintenance
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STACK-probe
Insertion Airflow Measuring Probes
Airflow traverse probe for stack flow monitoring typical for Continuous Emissions Monitoring (CEM) systems.
400 to 10,000 FPM
- Accuracy withing 40CFR75 specs
- Temperature: ≤900°F
- Stainless steel, Hastelloy, Inconel
- 4” or 6” 150lb Flange connections
- Cantilevered construction / installation
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VELTRON DPT-Plus
Multivariable Transmitter
Measures differential pressure and process temperature providing output of calculated mass flow.
Flow, Temperature, or Differential Pressure
- Accuracy: 0.1%
- URL down to 0.05” w.c.
- NEMA 4X
- Class I Div 1, Class II Div 1
- 24VAC, 24VDC
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VELTRON II
Transmitter
Measures differential pressure providing output of differential pressure or volumetric flow.
Flow or Differential Pressure
- Accuracy: 0.1%
- URL down to 0.05” w.c.
- NEMA 1, optional NEMA 4 and 4X
- 24VAC, 24VDC
- Turndown: 100:1
