Future

Subject: Optimizing Landfill Gas (LFG) Flow Monitoring with Thermal Instrument Company Equipment: Model 62-9TEF Insertion Probe / Integral 9500P Electronics

Author: Thermal Instrument Company Engineering Team

Abstract

Landfill Gas (LFG) extraction and flare/energy monitoring present harsh operational environments characterized by variable gas compositions, moisture, particulate build-up, and wide dynamic flow ranges. Regulatory compliance mandates accurate, repeatable flow rate monitoring for both environmental reporting and bio-energy production efficiency. This paper details the operational advantages of applying the Thermal Instrument Company (TIC) Model 62-9TEF Insertion Probe paired with Integral 9500P Electronics, highlighting sensor architecture, operational durability, and TIC’s comprehensive lifecycle support programs (recalibration, loaner meter support, and field service).

1. Landfill Gas Generation & Regulatory Context

Landfill Gas is produced as solid organic waste undergoes anaerobic decomposition within sealed landfill cells. Isolated from oxygen, groundwater, and ambient air by composite liners and soil covers, methanogenic bacteria break down organic matter into a combustible gas stream consisting primarily of:

Methane (CH4): 50% – 60% by volume

Carbon Dioxide (CO2): 35% – 45% by volume

Trace Components: Nitrogen (N2), Oxygen (O2), moisture (H2O vapor), hydrogen sulfide (H2S), and non-methane organic compounds (NMOCs).

Federal environmental regulations dictate that landfill operators capture LFG via a network of extraction wells, header pipes, and blower skids. Captured gas must be utilized for renewable energy generation (e.g., direct-use boilers, gas-to-grid processing, or power generation) or destroyed via thermal flaring. Environmental authorities mandate continuous, accurate mass flow rate measurement and data logging for emissions accounting and compliance verification.

Process:

2. Technical Challenges of LFG Flow Measurement

Measuring LFG accurately presents severe technical challenges for traditional flow measurement technologies:

Compositional Variations: Fluctuations in the CH4/CO2 ratio affect thermodynamic gas properties.

Dynamic Range Requirements: Seasonal changes, well field balancing, and blower output lead to wide velocity swings between peak production and low-flow flare conditions.

Contaminants & Condensate: Entrained particulate matter, siloxanes, and moisture build up on exposed flow elements, drift sensor calibration, and increase maintenance cycles.

Pressure Drops: Unnecessary pressure drops burden blower skids and decrease system extraction efficiency.

3. Technology Principles: Model 62-9TEF Thermal Mass Flow Sensor

Thermal Mass Flow Measurement operates on the principle of thermal dispersion, measuring mass flow directly without requiring separate pressure or temperature compensation inputs.

Key Engineering Features of the Model 62-9TEF:

Direct Mass Flow Measurement: Automatically compensates for process temperature and pressure variations.

100:1 Dynamic Turndown Ratio: Accurately registers low ambient flare flows as well as high-velocity production runs.

Non-Obstructive / Low Pressure Drop: Insertion probe geometry minimizes head loss across the header line, optimizing blower power consumption.

Solid-State Construction (No Moving Parts): Eliminates mechanical wear, bearing failures, and jammed impellers.

Protected Sensor Architecture: Unlike standard thermal sensors where RTDs are directly exposed to process fluids, TIC sensors are housed inside our 316SS insertion probe, ensuring the sensing elements never come into direct contact with the LFG stream.

Teflon Coating: Protects the sensor tip area from sticky particulate, moisture, and siloxane build-up, preserving flow profile consistency and reducing cleaning frequency.

Redundant Back-Up Sensors: Built-in redundancy inside every probe tip extends operating life and ensures continuous uptime in remote, harsh monitoring environments.

4. Advanced Signal Processing: Integral 9500P Electronics

When paired with the Model 62-9TEF Insertion Probe, the Integral 9500P Electronics transmitter converts raw thermal dispersion signals into precision flow measurements.

Key Features & Benefits:

Factory-Calibrated Gas Curve (Exact CH4 / CO2 Mix). Ready to go right out of the box

Temperature & Pressure Compensation

Linearized Output Signal: Standard 4-20mA Current Loop

Integrated Diagnostic Routines & Local Display Capability

System Configuration Comparison

Operational Feature Standard Flow Meters Thermal Instrument 62-9TEF/9500P

Pressure / Temperature Compensation Requires external sensors & computers Inherent (Direct Mass Flow)

Turndown Ratio 10:1 to 15:1 Average 100:1 Wide Dynamic Range

Sensor Protection Exposed Sensing Elements Fully Protected. No Direct Contact

Sensor Redundancy Single point of failure Built-in Redundant Back-up Sensors

Pressure Drop Moderate to high (Orifice Plate / Turbines Negligible

Maintenance Impact High (frequent cleaning) Low (No Moving Parts, Single Piece Construction, Teflon Coated)

5. Lifecycle, Recalibration & Compliance Support

Accurate flow monitoring over years of continuous operation requires reliable field support and calibration maintenance. Thermal Instrument Company provides tailored service structures to ensure zero downtime and ongoing regulatory compliance:

Factory Gas-Specific Recalibration: Recalibration services tailored to your exact site gas composition and line dimensions, easily managed via TIC's streamlined web-based order system.

On-Site Field Service & Calibration Options: Factory-trained technicians conduct on-site verification, functional testing, and field calibration to ensure zero interruption to reporting schedules.

Loaner Meter Program: To ensure continuous compliance and uncompromised flow logging during routine factory maintenance or recalibration, TIC provides temporary loaner meters.

4-Year Factory Warranty: Backed by decades of dedicated service to the landfill and biogas industries, TIC delivers long-term operational confidence.

6. Conclusion

Accurate landfill gas monitoring requires equipment capable of handling fluctuating gas ratios, harsh environments, and wide flow ranges without maintenance-heavy downtime. The Thermal Instrument Model 62-9TEF Mass Flow Insertion Probe combined with Integral 9500P Electronics offers a robust, low-maintenance, and highly accurate solution tailored to regulatory and bio-energy monitoring demands.

For more information please contact us.

Thermal Instrument Company

217 Sterner Mill Road, Trevose, PA 19053

Phone: (215) 355-8400 | Fax: (215) 355-1789

Web:

www.thermalinstrument.com | Email: Office@thermalinstrument.com

Executive Summary

Nitrogen blanketing is a critical process in liquid bulk storage operations, preventing fires, explosions, and product degradation by maintaining an inert atmosphere inside storage vessels. Precise control and measurement of nitrogen flow are crucial to optimizing gas consumption while ensuring regulatory compliance and asset protection. This paper details the performance advantages of the Thermal Instrument Model 600-9 Inline Thermal Mass Flow Meter within these systems, highlighting a proven deployment at the Liquid Storage Tank Terminal outside Cincinnati, Ohio. Operating under specific process parameters (0 to 100 SCFM, 20 to 120 ­­°F, and pressures <= 50 PSIG through a 1" MNPT connection), the Model 600-9 provides unmatched accuracy, reliability, and long-term operating cost benefits compared to traditional flow measurement technologies.

1. Introduction to Nitrogen Blanketing in Liquid Bulk Storage

In liquid bulk storage facilities, volatile, flammable, or moisture-sensitive products must be protected from contact with oxygen and ambient humidity. Nitrogen gas (N₂) blanketing injects an inert layer above the liquid level inside the tank. As liquid levels fluctuate during loading and unloading, or as ambient temperatures change, the blanketing system must rapidly respond to pressure differentials:

• Exhalation (Tank Emptying / Cooling): Nitrogen must be quickly introduced to prevent a vacuum that could collapse the tank.

• Inhalation (Tank Filling / Heating): Excess gas must be safely vented while maintaining the blanket seal.

Accurate mass flow measurement allows operators to identify leaks, detect malfunctioning conservation valves, track exact gas consumption for cost accounting, and maintain rigorous safety baselines.

2. Technical Profile: Thermal Instrument Model 600-9

The Model 600-9 is a premier inline thermal dispersion mass flow meter engineered specifically for demanding industrial environments. Unlike conventional thermal meters that insert a probe directly into the stream, the Model 600-9 utilizes a proprietary unobstructed flow path design.

Operating Principle & Sensor Design

• Non-Intrusive Sensor Design: The Resistance Temperature Detector (RTD) sensors are mounted to the outer circumference of the flow tube. The sensors do not make direct contact with the process fluid.

• Direct Mass Flow Measurement: The meter operates on the principle of thermal dispersion, measuring the mass flow rate of the nitrogen directly. It eliminates the need for separate temperature or pressure compensation instruments.

• Redundant Configuration: Standard configurations include built-in redundant sensors to maximize operational lifespan and provide fail-safe process monitoring.

3. Performance Analysis Under Specified Operating Conditions

The application parameters at the liquid bulk storage tanks demand a robust instrument capable of precision across varying environmental conditions. The Model 600-9 matches these requirements through the following criteria:

Technical Benefits of the Unobstructed Design

Because nitrogen lines in bulk terminals can occasionally carry vaporized product carryover, moisture, or particulate matter from storage tank vents, traditional intrusive meters face accelerated wear. The Model 600-9 circumvents these hazards entirely:

1. Zero Flow Obstruction: The interior of the meter is a smooth, continuous section of 316 Stainless Steel piping. It introduces no pressure drop (∆P = 0), minimizing the pressure required to deliver nitrogen to the tank blanket.

2. Contamination Resistance: With no probes, orifices, or moving components exposed to the stream, the meter cannot clog, foul, or suffer structural damage from line debris or liquid slugs.

3. Low-End Sensitivity: Thermal mass technology excels at capturing flows close to zero. It tracks minor leakage through tank seals or conservation vents that other meters miss.

4. Field Implementation: Liquid Storage Terminal (Cincinnati, OH)

The practical validation of the Model 600-9 is demonstrated through its successful deployment at the liquid bulk storage terminal outside Cincinnati, Ohio.

In this application, multiple units are installed directly on the nitrogen supply lines feeding the liquid bulk storage tanks. Prior to utilizing the Model 600-9, terminal operators were challenged by the seasonal fluctuations of the Ohio Valley, where temperatures range from below 20°F in winter to over 90°F with high humidity in summer. The temperature compensation of the Model 600-9 ensured that changing ambient gas densities did not skew the flow data.

Furthermore, the 1" MNPT inline process connection allowed for an efficient drop-in replacement during maintenance windows. Since installation, these units have consistently provided real-time 4-20mA mass flow data directly to the terminal's centralized control system, allowing for accurate custody transfer monitoring of nitrogen gas and instantaneous confirmation of tank blanket integrity.

5. Comparative Advantage Over Alternative Technologies

To highlight the operational advantages of the Thermal Instrument Model 600-9, the table below contrasts it against other common flow technologies used in gas applications:

6. Conclusion

For nitrogen blanketing operations in liquid bulk storage tanks, the choice of flow instrumentation directly impacts operational safety and variable gas costs. The Thermal Instrument Model 600-9 provides an engineered solution that addresses the precise pain points of terminal operators.

By delivering direct mass flow data without obstructing the process loop, operating reliably across extreme seasonal temperatures (20 to 120 °F), and capturing low-flow leakage up to , the Model 600-9 stands out as the optimal choice for modern bulk storage infrastructure. The long-term field success at the Bulk Storage Terminal reinforces the meter’s capability to lower the total cost of ownership while protecting vital terminal assets.

As our nation prepares to celebrate its milestone 250th anniversary, we find ourselves reflecting on what it truly means to be "Made in America." For us, it’s more than just a label—it is a core philosophy that drives our business every single day.

Thermal Instrument Company is proud to manufacture our premier flow measurement instrumentation right here in the USA. Based just outside Philadelphia, Pennsylvania—the very birthplace of American independence—we operate with a deeply rooted local ecosystem. Our key vendors are local, our precision assembly is local, and our state-of-the-art calibration is local.

On this historic Semiquincentennial, the entire team at Thermal Instrument wants to extend a heartfelt thank you to our customers, partners, and representatives who have supported us over our 65+ years in the flow measurement business. For those who haven’t worked with us yet, we invite you to experience the reliability of our American-made flow meters and the dedication of our customer-focused team.

Why Industry Leaders Choose Thermal Instrument Company

Manufacturing locally allows us to maintain a level of quality control, agility, and technical expertise that is hard to find in today's global market. When you partner with Thermal Instrument for your flow measurement needs, you benefit from:

• An Unmatched Legacy (Since 1959): With over six decades of experience, our employees possess deep-seated industry knowledge and decades of specialized calibration expertise.

• Dual Gas & Liquid Calibration: We are one of the few flow measurement manufacturers in the United States equipped with both gas and liquid calibration stands. This unique capability allows us to precision-calibrate for complex gas mixes, hydrocarbons, natural gas, clean gases, and liquids ranging from water to oils and other Newtonian fluids.

• Proprietary, Robust Design Features: Our flow meters offer exclusive advantages you won't find anywhere else, including redundant sensors for ultimate reliability, unobstructed in-line designs that prevent pressure drops, and custom engineering to accommodate virtually any process connection.

• Versatility Across Critical Industries: We proudly support the domestic and global manufacturing landscape, providing rugged flow meters and switches to vital sectors such as:

  • Landfill & Bio-Gas

  • Environmental Compliance

  • Semiconductor & Electronics

  • Petrochemical & Refining

  • Food & Beverage

• The "Right Size" Partner: We pride ourselves on being large enough to solve your most complex engineering challenges, yet agile enough to offer highly personalized, solution-oriented support.

• Comprehensive Post-Sales Support: Our relationship doesn't end at delivery. We back our products with ongoing technical expertise, rapid recalibration services, and dedicated field service to keep your operations running smoothly.

Happy Independence Day from Our Family to Yours

As we look forward to the upcoming holiday period, we hope you take the time to relax and celebrate with your family, friends, and neighbors.

Thank you for keeping American manufacturing strong. We look forward to collaborating with you in the near future to solve your toughest flow challenges.

Ready to discuss your next project?

Contact our customer-focused team today to learn more about our reliable, accurate, and American-made flow solutions.

Sales@thermalinstrument.com

P:215-355-8400

About Thermal Instrument Company

Thermal Instrument Company (TIC), established in 1959, headquartered in Trevose, Pennsylvania, provides leading edge instrumentation solutions for measuring the mass flow rate of liquids and gases.  TIC has been providing flow measurement solutions for more than 60 years to a variety of industries across the globe, and has an installed base in excess of 20,000 thermal mass flow measurement devices. TIC has provided flow measurement solutions for: Landfill Gas and Methane from Landfill and Wastewater sites; Natural Gas to boilers, furnaces, and in pipelines; Clean gases used in manufacturing processes; Water for cooling and pharmaceutical applications; and numerous other liquids and gasses used in environmental and industrial processes. TIC offers a full line of thermal mass flow meters and flow switches available in either an unobstructed path in-line model, or as an insertion probe model. For more information about Thermal Instrument Company’s flow measurement solutions, please visit our website or contact one of our sales representatives.

https://www.thermalinstrument.com/

Securing the Future of Semiconductor Fabrication

The semiconductor landscape in the United States is undergoing a historic expansion. With Taiwan Semiconductor (TSMC) and Intel breaking ground in Arizona, Intel’s massive investment in Columbus, Ohio, and Texas Instruments’ growth in the South, the demand for “Ultra High Pure” (UHP) infrastructure has never been higher.

Thermal Instrument Company provides the critical flow measurement technology required to support these facilities. Our Model 600-9UHP is specifically engineered to meet the stringent cleanliness and precision standards of modern chip manufacturing, ensuring that the production gases powering the digital revolution remain uncontaminated and accurately metered.

In the semiconductor industry, gases are often as expensive as the silicon they process. Gases like Silane, Argon, Nitrogen, and Ultra-High-Purity (UHP) Hydrogen are critical to the deposition and etching phases of manufacturing. For over 30 years, Thermal Instrument Company has provided the specialized mass flow solutions required to manage these costly resources. With our unique redundant sensor design and UHP-grade surface  finishes, our meters are the standard for accuracy and provide years of service and Return on Investment (ROI) at the world’s leading fabrication facilities.

____________________________________________________________________________________

Trusted by Global Leaders

Our thermal mass flow technology is integrated into the most sophisticated manufacturing environments on the planet. Thermal Instrument meters are currently operational at:

• Top Manufacturers: Texas Instruments, Samsung, GlobalFoundries, and Micron.
• Industry Suppliers: TSMC, Air Liquide, and other critical infrastructure partners.

The Precision Challenge in UHP Gas Delivery

Semiconductor fabrication relies on the delivery of ultra-clean production gases. Any obstruction or roughness in the flow path can lead to particulate buildup, pressure drops, or chemical contamination—all of which are “yield killers.”

Thermal Instrument Model 600-9UHP Solution:

The Model 600-9UHP is designed to address these challenges head-on:

• Unobstructed Flow Path: Our “straight-through” design eliminates internal components that could trap particles or cause turbulence.
• Superior Surface Finish: We provide a 15 Ra surface finish or better on all wetted surfaces, ensuring a smooth, mirror-like path that prevents gas stagnation and contamination.
• Negligible Pressure Drop: Because the meters are sized exactly to your existing lines, there is virtually no loss in pressure, maintaining the integrity of sensitive delivery systems.
• The only mass flow meters in the industry featuring redundant flow and temperature sensors. If a sensor fails, the redundant sensor is there and can take over, preventing costly process interruptions and improving ROI.
• Custom Calibration: Unlike “off-the-shelf” sensors, every Thermal Instrument meter is custom-manufactured and calibrated to the customer’s specific gas mixture and environmental requirements.

Versatility Across the Fab

From micro-dosing to bulk gas delivery, the Model 600-9UHP scales to meet the specific needs of different stages of production:

Beyond the Clean Room: Total Facility Solutions

While UHP gases are the lifeblood of the “front-end” process, Thermal Instrument mass flow meters are utilized throughout the entire facility to optimize operations:

• Compressed Air Management: Accurate monitoring of facility-wide compressed air to reduce energy waste.
• Natural Gas Sub-metering: Precise measurement for power generators and boilers critical to maintaining 24/7 production uptime.
• Cooling Systems: Monitoring water or gas flow in cooling loops to ensure expensive equipment operates within safe thermal margins.

Conclusion: A Trusted Partner in American Innovation

As the U.S. semiconductor industry scales, the need for a reliable, full-service measurement solution provider is paramount.

In alignment with the spirit of the CHIPS Act of 2022, Thermal Instrument remains steadfast in our commitment to revitalizing American manufacturing from our home in Trevose, PA. By sourcing from a network of premier suppliers within a 50-mile radius of the Philadelphia area, we ensure that every flow meter is not only made in the USA but built to support the local economy and small business initiatives. Our localized approach allows us to maintain total oversight of the manufacturing and NIST-traceable calibration processes, providing our partners with the high-precision instruments and domestic reliability necessary to power the next generation of American industry.

About Thermal Instrument Company

Thermal Instrument Company (TIC), established in 1959, headquartered in Trevose, Pennsylvania, provides leading edge instrumentation solutions for measuring the mass flow rate of liquids and gases.  TIC has been providing flow measurement solutions for more than 60 years to a variety of industries across the globe, and has an installed base in excess of 20,000 thermal mass flow measurement devices. TIC has provided flow measurement solutions for: Landfill Gas and Methane from Landfill and Wastewater sites; Natural Gas to boilers, furnaces, and in pipelines; Clean gases used in manufacturing processes; Water for cooling and pharmaceutical applications; and numerous other liquids and gasses used in environmental and industrial processes. TIC offers a full line of thermal mass flow meters and flow switches available in either an unobstructed path in-line model, or as an insertion probe model. For more information about Thermal Instrument Company’s flow measurement solutions, please visit our website or contact one of our sales representatives.

https://www.thermalinstrument.com/

The “Industry Authority” on Thermal Mass Flow Measurement

Heading to the Global Waste Management Symposium in Palm Springs? 🌴

Accurate gas measurement shouldn’t be a guessing game. Whether you’re managing Landfill gas, Bio-Gas, or Digesters, reliability is non-negotiable.
Stop by the Thermal Instrument Company table (Feb 22-25) to meet Ray Young and Kevin Johnson. We’ll be showcasing our working thermal mass flow meters—the same technology we’ve perfected over the last 65 years.

Why stop by?
Local Quality: 100% Made in the USA (Trevose, PA)
Proven Tech: Thousands of successful installations worldwide.
Specialized Focus: Thermal mass flow is the only thing we do.

If you’re looking to measure RNG, hydrocarbons, or CO2, let’s talk shop in the main hall.
See you there.

About Thermal Instrument Company

Thermal Instrument Company (TIC), established in 1959, headquartered in Trevose, Pennsylvania, provides leading edge instrumentation solutions for measuring the mass flow rate of liquids and gases.  TIC has been providing flow measurement solutions for more than 60 years to a variety of industries across the globe, and has an installed base in excess of 20,000 thermal mass flow measurement devices. TIC has provided flow measurement solutions for: Landfill Gas and Methane from Landfill and Wastewater sites; Natural Gas to boilers, furnaces, and in pipelines; Clean gases used in manufacturing processes; Water for cooling and pharmaceutical applications; and numerous other liquids and gasses used in environmental and industrial processes. TIC offers a full line of thermal mass flow meters and flow switches available in either an unobstructed path in-line model, or as an insertion probe model. For more information about Thermal Instrument Company’s flow measurement solutions, please visit our website or contact one of our sales representatives.

https://www.thermalinstrument.com/

In a world increasingly dominated by Zoom calls and virtual handshakes, there is no substitute for being “boots on the ground.” During the week of January 12th, our team—Ray Young and Mike Hesser—headed to Texas to visit some of our most valued partners in the Bio-Gas, Oil & Gas, and Petrochemical sectors.

Texas is the heart of the American energy corridor, with Oil & Gas companies leading the way and generating the materials needed for energy, chemical, and petro-chemical operations and processes. Seeing our equipment operating in these massive complexes was a powerful reminder of how critical precise flow measurement is to the products we use every day.

Solving Measurement Challenges in the Field

During our visits, we saw firsthand how our thermal mass flow meters are being put to work to keep these facilities safe, compliant, and efficient:

• In Oil & Gas Sector: Our units are being utilized for critical flare and vent gas measurement in upstream and midstream applications. These are harsh environments where accuracy is non-negotiable for environmental reporting and safety.
• Small-Scale Precision: One of the most exciting parts of the trip was identifying new opportunities to solve niche measurement challenges. We discussed applications for our unique designs that handle line sizes as small as ¼” —offering precision in tight spaces where traditional meters often struggle.
• Petrochemical Production: We saw our equipment helping to monitor the gases used in the creation of PVC and other plastics. By providing direct mass flow readings without the need for complex pressure/temperature compensation, our meters simplify a very complicated process. Our long time customer, Formosa Plastics, creates the “building blocks” of modern life. They take raw hydrocarbons and, through high-heat cracking and chemical synthesis, transform them into the resins and fibers we rely on. Without these processes, life would be considerably more complicated and messy.

More Than Just Data Points

The highlight of the week wasn’t just seeing the processes behind all the things that are used in everyday life; it was the people. We are incredibly grateful for the time our clients and sales partners spent describing their operations and the unique challenges they face.

Meeting the people who produce the essential materials we all need was a grounding experience. It reinforces our mission: to provide the measurement tools that help these industries run cleaner, safer, and more efficiently.

Contact Thermal Instrument Company to see if we can work together to solve any measurement challenges you may be facing.

About Thermal Instrument Company

Thermal Instrument Company (TIC), established in 1959, headquartered in Trevose, Pennsylvania, provides leading edge instrumentation solutions for measuring the mass flow rate of liquids and gases.  TIC has been providing flow measurement solutions for more than 60 years to a variety of industries across the globe, and has an installed base in excess of 20,000 thermal mass flow measurement devices. TIC has provided flow measurement solutions for: Landfill Gas and Methane from Landfill and Wastewater sites; Natural Gas to boilers, furnaces, and in pipelines; Clean gases used in manufacturing processes; Water for cooling and pharmaceutical applications; and numerous other liquids and gasses used in environmental and industrial processes. TIC offers a full line of thermal mass flow meters and flow switches available in either an unobstructed path in-line model, or as an insertion probe model. For more information about Thermal Instrument Company’s flow measurement solutions, please visit our website or contact one of our sales representatives.

https://www.thermalinstrument.com/