As the exclusive representative for Germany, EKOMAT provides you with direct access to the products of Fluid Components International (FCI).
FCI manufactures innovative flow and level measurement devices and is the global leader in dispersion technology. System or custom solutions from FCI are versatile and applicable for air, gas (including variable mixtures and flare gas compositions), liquids (e.g., water, oils, hydrocarbons), and slurries.
When harsh conditions come with strict requirements for process control, FCI's thermal dispersion RTD sensor elements offer unmatched product performance.
Advantages of Thermal Dispersion:
- No moving parts, openings, bearings, or seals that can become contaminated or fail
- Accuracy for precise flow measurements, especially in low-flow applications
- Repeatability for consistent measurements in complex process environments
- Wide flow range and large control ranges for a variety of applications
- High reliability and safety in harsh process environments
- Easy installation with low maintenance requirements
Products
Flow Switches
FCI's electronic flow switches reliably monitor whether a set flow value is being exceeded or not met. In case of deviations, they send a signal - either for process control, as a warning, or for automatic shutdown.
Highlights:
- Usable at temperatures up to 454 °C and pipe sizes ranging from 3 to 1500 mm
- Worldwide approvals, e.g., Div.1/Zone 1, SIL 1/2
- Robust outputs: Relay, transistor, 4–20 mA
- Protection classes IP65 to IP67
- Flexible configuration: Alarm and switching points for flow, temperature, time delay, and much more.
Level Switches
FCI's electronic level switches reliably detect when liquid levels are too high or too low. They automatically control pumps, valves, or report alarms to your control system—enhancing safety and efficiency in process control.
Highlights:
- Suitable for tanks, containers, and pipelines
- Worldwide approvals, e.g., SIL 2
- Powerful outputs: DPDT relays, hermetically sealed relays
- Flexible configuration: Alarm and switching points for level, temperature, time delay, and much more.
Flow Meters
FCI's electronic flow meters accurately measure the mass flow of air and gases. They provide precise data for process monitoring, consumption control, and regulation.
Highlights:
- Suitable for small lines starting from 6 mm to large ducts and stacks
- Robust, durable electronics (RoHS compliant)
- Diverse communication options: 4–20 mA, pulse, HART, Foundation Fieldbus, PROFIBUS, Modbus, and more
- Worldwide approvals: FM, ATEX, IECEx, SIL, QAL1, CEMS, and others
Flow Conditioners
In applications with unfavorable flow conditions, FCI VORTAB Flow Conditioners ensure stable and uniform flows. This secures the performance of thermal mass flow meters, keeping measurements precise and repeatable, even with short inlet and outlet runs.
Highlights:
- Eliminates flow turbulence and distortions
- Improves measurement accuracy and repeatability
- Minimal pressure loss in the process
- Ideal for optimizing flow meters in demanding installation situations
Anwendungsgebiete
Hydrogen
Hydrogen is rapidly emerging as a key gas across multiple industries – from chemical processing and refining to power generation, metallurgy, and advanced energy applications such as fuel cells and Power-to-Gas projects.
Accurate measurement and monitoring of hydrogen flows are essential for process efficiency, safety, and compliance. FCI’s thermal dispersion flow meters provide proven solutions for hydrogen applications by combining precise mass flow measurement, rugged design and tailored calibration.
Challenges of Hydrogen Measurement
- Extremely low molecular weight and density
- High diffusivity and tendency to leak through small gaps
- Potentially explosive atmospheres (requiring ATEX/IECEx certification)
- High flow velocities in pipelines
- Wide pressure and temperature variations
- Critical need for accuracy in safety and process control
Advantages of FCI Technology in Hydrogen Applications
- Direct mass flow measurement – no separate temperature or pressure sensors needed
- ATEX, FM, and IECEx approvals for safe use in hazardous areas
- Non-clogging, no moving parts design for long-term reliability
- Wide turndown ratio to handle variable flow conditions
- Flexible single-point and multi-point installation options
- Custom calibration for pure hydrogen or hydrogen mixtures
Exhaust Air Monitoring
Exhaust air is generated in a wide range of industrial processes including metals production, chemical plants, food processing, pharmaceutical manufacturing, refineries, pulp and paper mills, power generation, and boiler operations.
FCI’s thermal dispersion flow meters – available as single-point sensors (ST Series) or multi-point systems (ST102A, MT100 Series) – or the flow switches FLT93 and FS10i - provide accurate and cost-effective solutions for exhaust air monitoring.
Challenges of Exhaust Air Measurement
Exhaust air typically consists of mixed gas compositions that vary depending on the fuel and the process. Typical components include nitrogen, carbon dioxide, oxygen, water vapor, and pollutants such as sulfur oxides, nitrogen oxides, carbon monoxide, and particulates. These factors create unique measurement challenges:
- Mixed and variable gas compositions
- Wet or dirty gas conditions
- Large pipe diameters with limited accessibility
- Distorted, swirling, or uneven flow profiles
Advantages of FCI Technology in Exhaust Air Applications
- Calibrated for mixed gas compositions
- Low-cost installation in large pipe sizes
- Single-point and multi-point configurations
- Direct mass flow measurement
- No moving parts for low maintenance and high reliability
- Wide turndown ratio to handle broad flow ranges
- Remote mountable electronics
- Temperature compensation for accurate results
FCI thermal dispersion flow meters are designed to overcome these challenges and meet all critical requirements. For pipe sizes up to 30 inches [760 mm], single-point insertion meters are commonly applied. For larger ducts and stacks, FCI multi-point systems with up to 16 sensors provide flow averaging across large cross-sectional areas. Since these instruments measure mass flow directly, there is no need for additional temperature or pressure sensors as required by volumetric techniques.
Biogas
Organic industrial waste from food processing and slaughterhouses, food waste from restaurants and homes, manure collected from livestock, as well as energy crops can be digested in anerobic conditions in reactor tanks, also called fermentation towers. The output from this biomass digestion process is biogas, a mixture of methane (CH4), carbon dioxide (CO2), water and trace hydrogen sulfide (H2S). The entire process involves gas creation, cleansing, storage (tank or bag-type accumulator), and ultimately the use of biogas, also known as renewable natural gas or RNG, as a fuel source for heating or generating electricity. A ground flare is an integral part of the safety system for the process. Installation of biogas flow meters and RNG flow meters at several points in the system provides operators with critical information for optimal gas production, control, safety and reporting.
Challenges of Biogas Measurement
- Low flow sensitivity during start-up and for seasonal changes which produce lower flow rates
- Temperature compensation for correct readings in varying temperatures
- Calibration for mixed gas composition of CH4 + CO2 + trace gases
- Wet, dirty gas with corrosive H2S content
- Potentially flammable or explosive gas installation environment
- Easy, low cost installation and low maintenance
Advantages of FCI Technology in Biogas Applications
- Mass flow measuring of both rate and totalized flow
- No moving parts or small holes to clog or foul in dirty or wet gas environments
- Biogas-specific calibration
- Low flow sensitivity, at least 0.6 FPS [0,2 m/s] and wide turn-down of 100:1
- Pressure drop over flow element should be limited to 0.01Psi [1 mBar]
- All wetted parts resistant to H2S corrosion; minimum of 316L stainless steel
- Easy and safe removal under line pressure with simple ball valve
- System agency approvals for safe installation in Division 2 [Zone 2] or Division 1 [Zone 1]
Flare Gas
FCI ist der weltweit führende Hersteller von Fackelgas-Durchflussmessern, die die Wärmeleitungs-Technologie nutzen. FCI verfügt über die größte installierte Basis und unmatched Erfahrung in einer Vielzahl von Fackelanwendungen und Installationsbedingungen. Von einzelnen Bodenfackeln bis hin zu komplexen Mehrlinien-, Mehranlagen-Systemen, von der Prozessbetriebskontrolle bis zur regulatorischen Berichterstattung, von einheitlichen Gasen bis hin zu komplexen, gemischten Kohlenwasserstoffgasen und von landgestützten bis zu Offshore-Plattformen gibt es eine FCI-Lösung zur Messung Ihres Fackelgasflusses. Neben Fackelgas-Durchflussmessern bietet FCI auch Durchflussmesslösungen für Abluftspüleitungen und Hilfsgaszufuhrleitungen an.
Die Wärmeleitungs-Fackel-Durchflussmesser von FCI haben keine beweglichen Teile, keine Glasfenster oder Optiken im Strömungsbereich, die verstopfen, verrußen oder gereinigt werden müssen. Sie messen den direkten Massendurchfluss und werden an einem einzelnen Entnahmepunkt installiert, was die Lösung mit den niedrigsten Gesamtinstallationskosten ergibt. Breite Drosselverhältnisse, mehrere analoge Ausgänge, Buskommunikation wie HART, Foundation Fieldbus und Modbus, Präzision, tatsächliche Gas-Kalibrierungen, umweltgerechte Genauigkeit, weltweite Zulassungen für Ex-Installationen, VeriCal-In-situ-Kalibrierungsüberprüfung, SIL-Zertifizierungen und mehr sind nur einige der Funktionen und Merkmale, die in den FCI-Fackel-Durchflussmesslösungen verfügbar sind.
Flue Gas
Flue gases are exhausted from many processes including metals operations, chemical, food processing, petroleum processing, pharmaceutical productions, paper plants, power plants and boilers.
FCI's single-point (ST Series) or multi-point (ST102A, MT100 Series) flow meters offer accurate and cost effective solutions to flue gas flow measurement.
Companies utilizing FCI flow meters for flue gas applications include US Steel, Kraft Foods, Georgia-Pacific, Dupont, Rohm & Haas, Shijiazhuang Refinery, ELF Atochem, Kemirea Pigments, Fundia Wire, Noranda Mining, and Foster-Wheeler Energy, among others.
Flue gases are the general name given to the mixed composition gases that are the by-product of a combustion process. A flue is typically a large pipe, duct, stack, chimney or other venting attached to a process system such as a boiler, furnace, steam generator, oven, etc. through which waste flue gases are exhausted from the combustion process.
Depending on the process, the fuel used and efficiency, flue gases can consist of nitrogen, carbon dioxide, trace amounts of oxygen and water vapor, and environmentally sensitive pollutants such as sulfur oxides, nitrogen oxide, carbon monoxide and particulates. In addition to measuring the flow of flue gases for process control data, reporting is often mandated by Federal, Regional, and/or Local environmental air quality regulations.
Challenges for Flue Gas Measurement
- Mixed composition gases
- Wet and/or dirty gas
- Large and difficult to access pipes
- Wide flow range and distorted, swirling flow profiles
Advantages of FCI Technology in Biogas Applications
- Accurate and calibrated for mixed composition gases
- Low cost installation in large diameter pipes
- Single-point and multi-point solutions
- Mass flow measurement
- Non-clogging, no moving parts design for low maintenance
- Wide turndown for wide range flow measurement
- Remote mountable transmitter/electronics
- Temperature compensation
Greenhouse Gas
Around the world, regulations increasingly require the monitoring and reporting of greenhouse gas (GHG) emissions.
FCI supports organizations in meeting these demands with accurate and reliable gas flow measurement solutions. Whether compliance is mandatory or part of broader sustainability initiatives, FCI provides the right tools and expertise to ensure long-term, trustworthy reporting.
FCI’s thermal dispersion technology flow meters deliver direct mass flow measurement with simple installation—often requiring just a single insertion point into a pipe or stack. They are available for line sizes from ¼” to more than 100” and provide accuracies of ±1% of reading, ±0.5% of full scale, exceeding the performance levels expected by regulatory and industry standards worldwide.
Each device measures mass flow rate, totalized flow, and temperature, with flexible outputs such as a built-in digital display, 4–20 mA signals, and digital communications including HART and Profibus. All instruments are precision-calibrated for the specific gas, installation, and operating conditions.
With extensive experience measuring methane (CH₄), nitrous oxide (N₂O), sulfur hexafluoride (SF₆), HFCs, PFCs, and carbon dioxide (CO₂), FCI delivers high-accuracy, repeatable flow meters that help facilities worldwide achieve compliance and sustainability goals.
