VGB PowerTech 3 l 2018 Flue gas flow rate calculation for mass emissions reporting
Flue gas flow rate calculation for
mass emissions reporting.
Part 1: The pathway from DIN 1942, to EN 12952-15,
to EN-ISO 16911-1
Frans Blank, David Graham and Henrik Harnevie
Kurzfassung
Rauchgas-Volumen-Berechnung für die
Emissions-Berichterstattung
Teil 1: Von DIN 1942 zu EN 12952-15
zu EN-ISO 16911-1
Betreiber von Feuerungsanlagen müssen den
Rauchgasdurchsatz ihrer Anlagen bestimmen,
um Massenströme von Emissionen berechnen
zu können. Für viele Standardbrennstoffe lie-
fert die Berechnung des Rauchgasdurchsatzes
zuverlässige Ergebnisse mit definierter Unsi-
cherheit und mit einem relativ einfachen Ver-
fahren. Das berechnete trockene Rauchgasvolu-
men wird mit Emissionskonzentrationen kom-
biniert, die dann auf Basis trockener Mas-
senströme gemeldet werden. Werden Konzent-
rationen zudem auf Basis trockener Massen-
ströme gemessen, wie es bei Großfeuerungsan-
lagen häufig der Fall ist, vermeidet dies die an-
sonsten erforderliche Messung von Wasser-
dampf und damit eine zusätzliche Unsicherheit.
Diese Publikation ist die erste (VGB-For-
schungsprojekt Nr. 338) aus einer Reihe von
drei zu VGB-Forschungsprojekten mit dem Titel
„Berechnung des Rauchgasdurchsatzes für die
Berichterstattung über Massenemissionen“. Die
beiden folgenden erscheinen innerhalb eines
Jahres in dieser Zeitschrift mit denfolgenden
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Untertiteln:
Teil 2: Überprüfung der Rauchgasdurchflussbe-
rechnung mittels Schornsteinprüfung und Da-
tenauswertung nach EN-ISO 16911:2013
(VGB-Forschungsprojekt Nr. 379)
Teil 3: Bewertung der Anlagenleistung mit Hilfe
der Datenbanken Großfeuerungsanlage und E-
PRTR (VGB-Forschungsprojekt Nr. 400)
Authors
M.Sc. Frans Blank
Consultant
DNV GL – Energy
Arnhem, The Netherlands
M.Sc. David Graham
Technical Consultant Gas Turbines
Uniper Technologies Ltd.
Nottingham, United Kingdom
M.Sc. Henrik Harnevie
Senior Research Engineer;
Process & Chemistry
Vattenfall Asset Development
Stenungsund, Sweden
Introduction
Operators of combustion plant need to
know the flue gas flow rate to calculate the
mass release of pollutant emissions. For
many standard fuels, the calculation of flue
gas flow rate gives reliable results, with a
defined uncertainty, using relatively simple
procedures. The calculated dry flue gas
volume is combined with emission concen-
trations that are reported on a dry basis.
When concentrations are also measured on
a dry basis, as is often the case for large
combustion plants, this avoids the meas-
urement of water vapour and hence an ad-
ditional uncertainty.
This publication is the first (VGB Research
Project No. 338) of a series of three VGB Re-
search projects on “Flue gas flow rate calcu-
lation for mass emissions reporting”. The
other two will appear within a year in this
journal, having the following sub-titles:
–– Part 2: Verifying flue gas flow rate calcu-
lation, by means of stack testing and data
evaluation, to EN-ISO 16911:2013 (VGB
Research Project No. 379).
–– Part 3: Plant performance assessment
using the Large Combustion Plant and E-
PRTR databases (VGB Research Project
No. 400).
The authors wish to thank the VGB Re-
search Foundation for their financial con-
tributions, the members of the VGB Techni-
cal Group “Emissions Monitoring”, who
l formed the project oversight committee,
and especially Mr. Volker Hamacher (sec-
retary of the group at the time) for his con-
tinuous enthusiasm for our work.
Motivation and
historicalcontext
Flue gas flow rate is calculated from the
plant net Thermal Input (MWth) and a
Fuel Factor which defines the volume of
dry stack gas produced from a unit of use-
ful thermal input (m3/MJth):
Flue Gas Flow Rate (m3/s) = Thermal
Input (MJth/s) * Fuel Factor (m3/MJth)
In turn, the Thermal Input is calculated
from either the rate of fuel consumption
and the net calorific value (NCV) of the fuel
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(the lower heating value), typically the
case for gaseous and liquid fuels:
Thermal Input (MJth/s) = Fuel Flow
(m3/s or kg/s) * NCV (MJth/m3 or MJ/kg)
or the electrical/thermal output of the
plant and the thermal efficiency, typically
the case for solid fuels:
Thermal Input (MJth/s) = Energy Output
(MJout/s) ÷ Thermal Efficiency
(MJout/MJth)
EN-ISO 16911-1 now defines reference Fuel
Factors for fossil fuels in m3/MJth at 0 % O2,
dry, 273.15 K, 101.325 kPa. These factors
are then corrected to the required reference
oxygen condition. There is little variation
between these specified Fuel Factors since
there is a close correlation between the en-
ergy content of the fuel and the released
volume of combustion products. That is,
only the combustible material within the
fuel has both a heating value and produces
gaseous combustion products. The combus-
tible material within the fuel is principally
Carbon (C) and Hydrogen (H) and the small
variation between Fuel Factors is caused by
differences in the C:H ratio when moving
through the range of fossil fuels from natu-
ral gas to coal. The historic development of
the range of Fuel Factors given in EN-
ISO 16911-1 is described below within the
context of the VGB Research Project 338.
As already mentioned, the Fuel Factor, ‘S’,
specified in m3/MJth at 0 % O2, dry, defines
the amount of flue gas released per unit of
input energy. ‘S’ varies somewhat depend-
ing on the type of fuel, net calorific value,
moisture and ash content. Initially, within
our VGB Research Project, it appeared that
there were no clear references to interna-
tional standards available for the Fuel Fac-
tor. For example, the Fuel Factors applied in
the Netherlands came from DIN 1942:1979,
the standard for acceptance tests [1]. The
Fuel Factor was calculated from the com-
bustion formulas in that standard.
The revised DIN 1942:1994 standard [2]
provided formulas for direct calculation of
the flue gas flow rate. However, the Nether-
lands and many other European countries
continued to use their own historic Fuel
Factors.
59
 Flue gas flow rate calculation for mass emissions reporting VGB PowerTech 3 l 2018

In 2003, the DIN 1942 standard was super-
seded by the European standard EN 12952-
15:2003 [3]. That standard describes the
same basic principles relating to plant per-
formance assessment and provides empiri-
cal formulas for flue gas flow rate calcula-
tion that are similar to the latest DIN stand-
ard. However, this is not at all apparent
from the title: ‘Water-tube boilers and aux-
iliary installations – Part 15: Acceptance
tests’; the relevant formulas are summa-
rised in the closing Annex of that standard
(pages 85-86).
In 2010 the second version of the VGB/EU-
RELECTRIC guidance document for mass
emissions reporting was released [4]. For
flue gas flow calculation, this guidance
document contains a few fixed factors,
with reference to a 1997 International En-
ergy Agency handbook. For lignite or bio-
mass no dedicated calculation formulas
were provided. At that time, neither the
DIN nor EN standard formulas had been as-
sessed by the authors of the guidance doc-
ument.
Meanwhile, for many years, there had been
a NOx-fee system in Sweden. For reporting
the annual NOx mass emission, the flue gas
volume needs to be accurately known. The
use of biomass, with a fuel water content up
to 60 percent and low heating values, is
common in Sweden. Most plants weigh fuel
samples and check for major variations in
the moisture content used for the stack gas
flow and the annual average. The wetter the
fuel, the higher the Fuel Factor, since more
fuel needs to be combusted simply in order
to evaporate the water that is supplied with
that fuel. The Fuel Factor therefore increas-
es by about 20 %, in relative terms, as the
fuel moisture content increases from 20 to
60 % as described later (Ta b l e 3 ). It was
therefore apparent that biomass fuels need-
ed to be incorporated into the VGB Re-
VGB PowerTech - All rights reserved - Alle Rechte vorbehalten - © 2017
EN-ISO standard. Flow calculation can
therefore be used as a reference method,
under certain circumstances [6]. So, even-
tually, versions of the DIN equations have
become a reference method in the interna-
tional standard for the determination of
flue gas flow rate.
Whilst the calculation approach is fully de-
fined in the reference methods standard,
the more common application is for con-
tinuous flow calculation. In that case, the
standard EN-ISO 16911-2:2013: Automat-
ed Measuring Systems needs to be applied
[7]. This permits a calculation approach to
be used for continuous flow monitoring
provided that it is verified using manual ref-
erence methods, i.e., by stack testing. Al-
though the calculation must be initially
verified and then checked annually, ‘cali-
bration factors’ derived from the stack test-
ing results must not be applied to the calcu-
lation.
The performance of the manual reference
methods, and their use in the verification
of calculated flue gas flow rate, will be con-
sidered in Part 2 of this series (VGB Re-
search Project No. 379).
On a regular basis, the flue gas volume for-
mulas are also used for emission perfor-
mance benchmarking. When the annual
energy consumption is available, the cor-
responding flue gas volume can be calcu-
lated easily. Combining this with the an-
nual energy output, the annual concentra-
tion can be estimated. In Part 3 of this
series the results of VGB Research Project
No. 400: “Performance assessment using
the Large Combustion Plant and E-PRTR
databases” will be published.
Fuel Factor calculation formulas
and validation results
dry at 273.15 K, 101.325 kPa, from the as-
received fuel composition based on an ulti-
mate analysis:
VGod = 8.8930 γC + 20.9724 γH +
3.3190 γS – 2.6424 γO + 0.7997 γN
(m3/kg)  [1]
(Formula 8.3-60 on page 42 of
EN 12952-15 and Formula E.3 of
EN-ISO 16911-1)
where γ is the mass fraction of an individu-
al fuel component in the supplied fuel (as
received) and C, H, S, O and N are the ele-
ments carbon, hydrogen, sulphur, oxygen,
and nitrogen, respectively.
Coal and biomass
For solid fuels the empirical relation pro-
vided in EN 12952-15 is a good approxima-
tion for a wide range of solid fuels.
VGod = -0.06018 (1 – γAsh – γH2O) +
0.25437 (H(N) + 2.4425 γH2O)
(m3/kg)  [2]
(Formula A.5N on page 85 of
EN 12952-15)
Where γAsh and γH2O are the mass fraction
of ash and water and H(N) is the net calo-
rific value of the as-received fuel.
In the project report, which is publicly
available at the VGB web site, the emphasis
of the validation was on hard coal and bio-
mass. Two participants had extensive coal
and biomass databases. Vattenfall per-
formed their tests on 163 fuels from the
ECN Phyllis database for biomass and
waste, also including lignite, peat, and
plastics. F i g u r e 1 and F i g u r e 2 show
the calculated Fuel Factors with formula
[1] and formula [2], respectively. The lat-
ter procedure gives almost identical results
for nearly all dry solid fuels. A further very

For solid and liquid fuels, EN 12952-15 de- interesting result is that it also does not
search Project in addition to fossil fuels.
fines a method to determine the mass spe- matter if the heating value is measured or
It should be noted that the uncertainty of cific Fuel Factor, VGod, in m3/kg at 0 % O2 calculated.
the flue gas flow rate also depends on the
uncertainty of the thermal input. For solid
fuels, the thermal input is usually deter- 0.350
mined indirectly – from the plant output
and the thermal efficiency. In this case, the
uncertainty needs to be determined on a
case-by-case basis, at least for a given plant 0.300
type and calculation approach. In many
cases, the Fuel Factor uncertainty then
Fuel factor in m3/MJth

only has a small share in the total flue gas

flow rate uncertainty.
0.250
The authors completed the VGB Research
project 338 “Determination of Flue Gas
Flow” in January 2012 [5]. In the mean-
time, the EN-ISO 16911-1:2013 standard FF
FF
analysis
analysis
(bark)
(char from food industry)
FF
FF
milne
milne
(bark)
(char from food industry)
0.200
for flow manual reference methods was FF analysis (industrial sludge) FF milne (industrial sludge)
FF analysis (brown coal) FF milne (brown coal)
under development [6]. As a direct conse- FF analysis (municipal waste) FF milne (municipal waste)
quence of the technical assessments con- FF analysis (peat) FF milne (peat)
FF analysis (recovered wood) FF milne (recovered wood)
ducted within VGB Research Project 338, FF analysis (straws and grass) FF milne (straws and grass)
FF analysis (untreated wood) FF milne (untreated wood)
which demonstrated the ease of applicabil- 0.150
ity of the calculation methods and their
low uncertainty, the project results were Fig. 1. F uel factor for 163 fuels using formula 1 with measured (analysis) and calculated (milne)
incorporated as a normative Annex E in the net calorific value.

60 >>> VGB DIGITAL <<<

 VGB PowerTech 3 l 2018 Flue gas flow rate calculation for mass emissions reporting

The NSE correction (Ta b l e 2 ) is derived

0.270 from the Annex of EN 12952-15 formulas
[2], [3] and [4]:
S = a / e (N) + b
0.260 where e (N) is the Net Specific Energy of the
as received fuel in MJ/kg (=H(N)).
Fuel factor in m3/MJth

For gaseous fuels, it may be more conveni-

ent to employ the volumetric Net Specific
0.250 Energy (MJ/m3 at 0 °C) in which case a =
0.2 and b = 0.234. This approach is not
FF analysis (bark) FF milne (bark) suitable for low specific energy fuel gases
FF analysis (char from food industry) FF milne (char from food industry)
FF analysis (industrial sludge) FF milne (industrial sludge)
for which the Fuel Factor shall be deter-
FF analysis (brown coal) FF milne (brown coal) mined from the gas composition according
0.240 FF analysis (municipal waste) FF milne (municipal waste)
FF analysis (peat) FF milne (peat)
to EN 12952-15 Section 8.
FF analysis (recovered wood) FF milne (recovered wood) For liquid fuels, this approach is suitable
FF analysis (straws and grass) FF milne (straws and grass)
FF analysis (untreated wood) FF milne (untreated wood) only for light petroleum fractions. Other
liquid fuels should be assessed using the
0.230 measured composition and heating value.
For solid fuels, the mass fractions of ash
Fig. 2. F uel factor for 163 fuels using formula 2 with measured (analysis) and calculated (milne)
net calorific value. and moisture in the as-received fuel need
to be taken into account using the dry,
ash free, fuel mass fraction, γF, where: γF =
The same conclusions were drawn for both Fuel Factors in 1 – γAsh – γH2O
hard coal and biomass fuels. It is generally
ISO 16911-1:2013 and their
better to base a flue gas flow calculation on Fixed Fuel Factors for wet biomass were de-
net calorific value, rather than fuel compo- calculated uncertainty rived in accordance with EN 12952-15 as
sition. For bituminous and sub-bituminous shown in Ta b l e 3 . The uncertainty re-
In the VGB project a set of fixed Fuel
coal the EN formula also showed very good lates to a moisture content variation of
Factors for commercially traded fuels,
agreement with the US EPA factors that ±10 % in each case, e.g., a moisture con-
and their associated uncertainties, was es-
were originally based on Gross Calorific tent of 30 % mass fraction covering a range
tablished and incorporated into the EN-
Values. In the VGB report [5] there is a de- of moisture contents from 20 % to 40 %.
ISO 16911-1 standard as shown in Ta -
tailed explanation of how to then use the The uncertainty increases nonlinearly at
b l e 1.
Fuel Factor to calculate flue gas flow rate high moisture contents.
when the total thermal input is calculated A wider range of fuels may be considered,
from the energy output and thermal effi- and a lower uncertainty can be achieved, Conclusions
ciency of the plant. by applying a correction for the NCV of the
as-received fuel. “As-received” indicates The calculation of flue gas flow rate, for the
Gas and oil fuel that the fuel heating value is reported on purpose of mass emissions reporting, gives
the basis that all moisture and ash-forming reliable results, with a defined uncertainty,
For liquid fuels, the empirical calcula- minerals are present. Note that the NCV is using relatively simple procedures. The
tion of the mass specific Fuel Factor is given referred to as the Net Specific Energy flue gas flow rate calculations within the
as: (NSE) in the standard. However, uncer- German standard DIN 1942:1994 had his-
VGod = 1.76435 + 0.20060 H(N) (m3/kg) tainties for these alternative approaches torically been used by many countries and
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 [3] are not pre-defined and need to be speci- individual companies for these purposes.
fied by the plant operator. The present VGB validation study demon-
(Formula A.10N on page 86 of
EN 12952-15) Tab. 1. Fossil fuel factors (Table E.1 of EN-ISO 16911-1).
In the validation, it showed very good Fuel type
Fuel Factor
agreement with calculation from compo- S Natural gas Gas oil Fuel oil Hard coal
sition and close agreement with US
EPA calculation. There was a distinct dif- m3/MJ at 0 % O2 dry
0.240 0.244 0.248 0.256
273,15 K & 101,325 kPa
ference in the fuel factor from Gas oil and
Fuel oil. Urel,95%, % ±0.7 ±1.0 ±1.0 ±2.0

For gaseous fuels, the empirical relation

provided in EN 12952-15 is applicable to a Tab. 2. NSE correction factors (Table E.3 of EN-ISO 16911-1).
wide range of natural gas compositions
Fuel type
and process fuel gases (but not low calo- Parameter
rific value fuel gas): Gas Liquid Solid

VGod = 0.64972 + 0.22553 H(N) (m /kg) 3 a 0.64972 1.76435 -0.06018 γF

 [4] b 0.22553 0.20060 0.25437 (1+ 2.4425 γH2O / e(N))

(Formula A.15N on page 86 of

EN 12952-15) Tab. 3. Biomass fuel factors (Table E.2 of EN-ISO 16911-1).

This formula was validated with an exact Fuel moisture (% mass fraction) 20 30 40 50 60
calculation from a molar combustion bal-
Fuel factor, S, m3/MJ at 0 % O2 dry 0.260 0.267 0.276 0.290 0.314
ance which was also used to verify a volu-
metric equation for the flue gas volume Uncertainty, Urel,95%, %
2.8 3.6 5.0 7.7 13.9
(±10 % mass fraction moisture)
(described below).

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61
 Flue gas flow rate calculation for mass emissions reporting VGB PowerTech 3 l 2018

strates the low calculation uncertainty
that can be achieved when deriving Fuel
Factors from the net calorific value of the
fuel. A range of fixed Fuel Factors, with de-
fined uncertainties, was developed for
commercially traded fossil fuels and wet
biomass. More detailed estimation meth-
ods, based on the net calorific value and/or
the fuel composition were also derived us-
ing formulas given in EN 12952-15:2003
(the successor to DIN 1942).
In 2013, the VGB project results were suc-
cessfully incorporated into Annex E of EN-
ISO 16911 ”Manual and automatic deter-
mination of velocity and volume flow rate
in ducts – Part 1: Manual reference meth-
od” and this is applicable to a wide range of
gaseous, liquid and solid fuels. Conse- [3] EN 12952-15:2003 Water-tube boilers and
quently, flue gas flow rate calculation was auxiliary installations – Part 15: Acceptance
approved for continuous monitoring, un- tests.
der Part 2 of the same standard, subject to [4] VGB/EURELECTRIC, 2010: European Wide
verification using manual reference meth- Sector Specific Calculation Method for Report-
ing to the European Pollutant Release and
ods which is the subject of our next paper. Transfer Register – 2nd Edition.
The calculation approach can therefore
[5] David Graham, Henrik Harnevie, Rob van
continue to provide a cost effective and ac- Beek and Frans Blank, Validated methods for
curate means of continuously monitoring flue gas flow rate calculation with reference to
the flue gas volume flow rate. EN 12952-15, KEMA, 2012.
[6] EN-ISO 16911-1: 2013 Stationary source
References emissions – Manual and automatic determi-
nation of velocity and volume flow rate in
[1] DIN 1942: 1979 Abnahmeversuche an Damp- ducts – Part 1: Manual reference method.
ferzeugern (VDI – Dampferzeugerregeln). [7] EN-ISO 16911-2: 2013 Stationary source
[2] DIN 1942: 1994 Acceptance test code for emissions – Manual and automatic determina-
steam generators (VDI-rules for steam genera- tion of velocity and volume flow rate in ducts –
tors). Part 2: Automated measuring systems. l

VGB-Standard

Preservation of Steam andGas Turbo-Generator Sets

(2nd edition)
Edition 2017 – VGB-S-036-00-2017-04-EN
VGB-Standard
DIN A4, 42 Pa­ges, Pri­ce for VGB mem­bers* € 190.–, for non mem­bers € 280.–, + VAT, ship­ping and hand­ling Preservation of Steam and
DIN A4, 42 Seiten, Preis für VGB-Mit­glie­der* € 190,–, für Nicht­mit­glie­der € 280,–, + Ver­sand­kos­ten und MwSt. Gas Turbo-Generator Sets

The present VGB-Standard covers all aspects of preservation. This standard provides operators, manufactur- 2nd Edition

ers and planners with a basic framework on how and to what extent the steam turbines, gas turbines and
generators are to be treated.
The editorial team has decided to take the steam turbine and the generator from the VGB-R 116 “Pres-
ervation of Power Plants” (republished as VGB-S-116-00-2016-04-EN “Preservation of Power Plants”), VGB-S-036-00-2017-04-EN

to add a section on the gas turbine and to publish both together in this revised VGB standard “VGB-
S-036-00-2017-04”.
This VGB-Standard can be used analogously to protect other plant components in the power plant against
corrosion. It is prepared to the best of our professional knowledge, but does not claim to be complete.
By its very nature, this VGB-Standard is a recommendation and therefore cannot replace the expertise of the
users.
In principle, however, in addition to the recommendations and measures for protecting the assets by preser-
vation as described below, the manufacturer’s instructions and the specifications from the operating manuals
must also be observed.

* Access for eBooks (PDF files) is included in the membership fees for Ordinary Members of VGB PowerTech e.V.

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Verlag technisch-wissenschaftlicher Schriften Fon: +49 201 8128-200 | Fax: +49 201 8128-302 | E-Mail: mark@vgb.org | www.vgb.org/shop

VGB-Standard

Recommendations for the Inspection and Overhaul

of Steam Turbines (formerly VGB-R 121e)
Ausgabe/edition 2016 – VGB-S-121-00-2016-04-EN
DIN A4, 90 Pa­ges, Pri­ce for VGB mem­bers* € 150.–, for non mem­bers € 210.–, + VAT, ship­ping and hand­ling VGB-Standard
DIN A4, 90 Seiten, Preis für VGB-Mit­glie­der* € 150,–, für Nicht­mit­glie­der € 210,–, + Ver­sand­kos­ten und MwSt. Monitoring, limiting
and protection devices
Monitoring, limiting and protection devices must satisfy stringent requirements in order to afford safe on gas turbine systems
and reliable operation of gas turbine units.
The VGB Technical Group “Gas Turbines” considered it necessary to revise the “Guidelines for Supervision,
Limiting and Protection Devices on Gas Turbine Systems” whose second, revised edition had been published
in 1993. The present revision was aimed at considering the present state of the art and the current codes of
practice and ISO and VDMA standards. This Standard applies to stationary gas turbines (single-shaft and VGB-S-121-00-2016-04-EN

multi-shaft turbines) used to drive generators and other machinery.

* Access for eBooks (PDF files) is included in the membership fees for Ordinary Members of VGB PowerTech e.V.
VGB PowerTech e.V. Te l : +49 201 8128 – 200
Deilbachtal 173 Fax: +49 201 8128 – 302

VGB PowerTech Service GmbH

45257 Essen | Germany www.vgb.org | mark@vgb.org

Deilbachtal 173 | 45257 Essen | P.O. Box 10 39 32 | Germany

Verlag technisch-wissenschaftlicher Schriften Fon: +49 201 8128-200 | Fax: +49 201 8128-302 | E-Mail: mark@vgb.org | www.vgb.org/shop

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 International Journal for Electricity and Heat Generation

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