Thermal Mass Flow Meters vs Vortex Flow Meters: Pros Cons and Best Applications

Accurate flow measurement is critical in industries where precision, efficiency, and cost-saving matter. 

However, choosing the right flow meter for flow measurement can be tricky, especially when there are so many options.

If you're trying to decide between a vortex and a thermal mass flow meter, you're in the right place. Both are great for measuring flow and suitable for different applications.

Vortex flow meters use the vortex-shedding principle for measuring liquids, gases, and even steam. On the other hand, thermal mass flow meters measure gas flow directly using heat, making them perfect for applications like compressed air and natural gas.

In this blog, we’ll break down how they work, their advantages, and when to use each so you can make the right choice for your industry.

Understanding the Vortex Flow Meter

Vortex flow meters measure the flow of liquid, gases.

Let's understand how;

In a vortex flow meter, you'll find a bluff body placed directly in the flow path. As the fluid flows around the bluff body, it creates alternating low-pressure zones behind it, which form swirling patterns called vortices.

This happens because of the Von Karman principle.

Once the vortices are formed, a sensor detects their frequency and converts it into electrical signals. 

This is how you get an accurate measurement of how much fluid is passing through the pipe.

Vortex flow meter is Best For;

• Liquids, Steam, and Gases
• Medium to High Flow Rates
• Industrial and Harsh Environments

Benefits of the Vortex Flow Meter

Vortex Flow Meter is,

• Suitable for a variety of fluids
• Required low maintanace
• Cost-effective
• Reliable in harsh conditions

Limitations of the Vortex Flow Meter

• Vortex meter requires straight pipes
• May struggle to provide accuracy at low flow rate
• Not ideal for highly viscous fluids

Industrial Application of Vortex Flow Meters:

• Power Generation – Measures steam flow for turbine efficiency and energy management
• Petrochemical – Monitors liquid and steam flow in refining and production processes
• Water Treatment – Measures water flow in filtration and distribution systems
• HVAC – Also measures chilled water and steam flow for system efficiency
• Pulp & Paper – Monitors steam and water flow in paper production processes

Understanding the Thermal Mass Flow Meter

A Thermal mass flow meter measures the mass flow rate of gases 

Let's understand how;

A thermal mass flowmeter measures the gas flow by using heat transfer. Inside the meter, two temperature sensors are placed. One is heated, and one is unheated. When gas flows through the meter, it carries heat away from the heated sensor. The faster the gas flows, the more heat it removes.

The meter constantly monitors the temperature difference between two sensors. Since the rate of heat loss is directly related to the mass flow of the gas, the meter calculates the flow rate based on this temperature difference.

It is based on the Von Karman principle.

Once the meter detects the heat loss, it generates an electrical signal, and this signal is later processed to calculate the mass flow rate of the gas. 

Thermal Mass Flow Meter is Best For;

• Measuring Gases
• Low-Flow Conditions
• Clean and Dry Gas Applications

Key Benefits of Thermal Mass Flow Meters

Thermal mass meter is useful for,

• Mass flow measurement of gases
• Required low maintenance
• Provide high accuracy for low flows

Limitations of Thermal Mass Flow Meters

• Not Suitable for Liquids
• Sensitive to Contamination

Industrial Application of Thermal Mass Flow Meters

• Oil & Gas – To measure natural gas flow for process control and leak detection
• Chemical – Monotors gas flow in chemical reactions and production processes
• Pharmaceutical – Also measures gas flow in drug manufacturing and fermentation processes
• Food & Beverage – Monitors CO₂ and nitrogen flow in carbonation and packaging
• HVAC – Used to measure airflow and improve energy efficiency

Key Differences Between Thermal Mass vs. Vortex Flow Meter

To get better results, Discover other flow meter types

How to Choose the Right Flow Meter for Your Needs

Choose a Thermal Mass Flow Meter if:

• You need to measure gas flow (air, natural gas, nitrogen, etc).
• When your process requires direct mass flow measuremnt
• You have to measure low flow rates
• Need low maintenance
• Your application involves leak detection or gas consumption monitoring.

Choose Vortex Flow Meter If:

• You need to measure liquids, steam, or some gases.
• Your application involves medium to high flow measurement
• You require a cost-effective solution compared to thermal flow meters.
• When your system needs a straight pipe for accurate measurement.
• You need a low-maintenance meter that can handle your industrial conditions.

Conclusion

Choosing between a thermal mass flow meter and a vortex flow meter depends on your specific application needs. By understanding their key differences, benefits, and limitations, you can select the right flow meter for your industry.

Are you ready to take the next step and choose the right flow meter? Let Burak help you find the best thermal mass or vortex flow meter for your needs. Contact us today!