CalorieSense™ in Fuel Production and Processing

Real-time analysis for process optimisation, emissions control, and regulatory compliance

In fuel production and processing plants—whether refining natural gas, upgrading biogas, or blending hydrogen—accurate calorific value measurement is essential. Variations in gas composition can impact burner efficiency, heat exchanger performance, and downstream product quality. Without reliable BTU data, operators risk energy imbalance, emissions violations, and costly process inefficiencies.
CalorieSense™ offers a resilient, real-time solution. Using pressure-based sensing, it continuously measures the calorific value of fuel streams without relying on optical components. This makes it ideal for deployment in high-moisture, high-particulate environments where conventional analysers struggle. CalorieSense™ integrates directly with control systems, enabling dynamic adjustment of combustion parameters, feedstock blending ratios, and energy recovery operations.

In hydrogen-enriched or variable methane streams, CalorieSense™ provides critical insight into energy content, allowing operators to maintain consistent heating value across fuel batches. This is especially important in modular plants where feedstock sources may change frequently. By delivering stable BTU data, CalorieSense™ supports closed-loop control of burners, reformers, and flare systems, improving thermal efficiency and reducing emissions.

The system is designed for industrial resilience. Its IP-rated enclosure, buffer-isolated data flow, and compatibility with hazardous area certifications (ATEX/IECEx) make it suitable for outdoor and classified zones. Whether installed at the inlet of a reformer, upstream of a flare, or across a blending manifold, CalorieSense™ provides actionable data for both operations and compliance.

Regulatory alignment is built into its architecture. In the United Kingdom, CalorieSense™ supports obligations under the Industrial Emissions Directive and the UK Emissions Trading Scheme, which require accurate monitoring and reporting of fuel combustion and associated CO₂ emissions. It also aligns with Environment Agency guidance on thermal efficiency and waste gas utilisation.

In the United States, fuel processing plants are subject to EPA regulations under 40 CFR Part 60 and Part 63, which mandate continuous monitoring of fuel quality and combustion efficiency. CalorieSense™ enables compliance with these standards, supporting real-time control and audit-ready data logging. It also integrates with state-level frameworks such as those from the California Air Resources Board and the Texas Commission on Environmental Quality.

Across the European Union, CalorieSense™ facilitates compliance with the Industrial Emissions Directive (2010/75/EU), the EU Emissions Trading System, and the Waste Framework Directive. It supports implementation of Best Available Techniques (BAT) for combustion control, as outlined in the BAT Reference Document for Waste Treatment and Energy Efficiency.

By delivering reliable BTU data, CalorieSense™ helps fuel production facilities optimise energy use, reduce emissions, and meet global compliance targets. It’s not just a sensor—it’s a strategic tool for modern fuel processing.

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