1. IN-SITU ANALIZA GASOVA
Zirconia O2
Goran Radonić
Juni 2011

2. O2 Users & Applications Who Measures Combustion Oxygen?
Anyone who needs to monitor and/or
control their combustion process.
END USERS
Power Plants - Utilities
Upgrading old systems
Installing Low NOx Burners
Sewage Treatment Plants
Waste Burners CFR503
Incinerators
Trash Burners
Hazardous Waste Incinerators
Package Boiler Owners
O2 Trim required by EPA
Chemical Plants
Process Heaters
Boiler Houses
Power Utilities
Pulp& Paper Mills
Steel Mills
Refineries
Chemical Plants
Waste Incinerators
Hazardous Waste Incinerators
Package Boiler Users
Cement Plants (kilns)
Co-Gen Plants
The above slide shows typical markets that use combustion O2 sensors. Name 1 large market that is in your area.
IMPORTANT NOTE: All Power Utilities use steam, and thus use boilers to produce the steam. Whose O2 equipment is your Power Company using?

3. The most common Application Flue Gas is what you get anytime
What are we Measuring?
The most common Application
for EXA OXY Analyzers is to measure the oxygen concentration in flue gas.
Air
Fuel
Measure O2 here
Gases
BURNING
Flue gas is the gas produced after the combustion process. The probe is placed in the flue gas, and not the fire box, which is where the fuel is burned.
Flue Gas is what you get anytime
you burn something!

4. Combustion Efficiency
Excess Air Fuel Ratios
Heat Efficiency
Optimum Combustion Zone
Heat Loss
Energy loss - due to
incomplete combustion
(unburned fuel)
Heat loss - dissipated
from the stack
1.0
1.02
1.10
1.30
Excess Air Ratio (µ)
Incentives for controlling O2:
1. Save money ($) with Lower fuel consumption.
2. Minimize pollution from Nox and Sox emissions. (EPA fines and additional equipment)
3. Efficient Heat Energy.
An easy household example of combusion control is a Bar-B-Que cookout with a charcoal grill!
Combustion Efficiency
MINIMUM
POLLUTION
Smokey
NOx and SOx increase
Low Excess
Air Ratios
Insufficient Air
High Excess Air Ratios

5. O2 Theory COMPLETE INCOMPLETE What is Combustion?
Heat
Air
Flue Gas
Fuel H O H
(water)
(hydrogen) 2 O + 2
Combustion is the combination
of fuel and air with heat produced
and carried by the mass of flue gas
generated. 2 C CO
(carbon dioxide)
(carbon) 2
COMPLETE
Heat
Flue Gas
The above slide shows the chemical response when fuel combines with air. Our measurement of O2 is used to help the customer to have a complete combustion reaction.
Air
Fuel
(carbon) O CO 2 H
(water)
(carbon dioxide)
(hydrogen)
(carbon monoxide)
Aldehydes C H
(hydrogen) O + 2 2 C
(carbon)
INCOMPLETE

6. What Controls the Rate of Combustion?
Time
Oxygen in contact with the Fuel, longer the better.
Turbulence
Mixes the Oxygen and the Fuel so they are in contact.
Temperature
The higher the temperature, the better the burning.
CO + H O 2

7. O2 Concentration vs Millivolts Output
Oxygen Concentration and Cell EMF
(P = Partial Pressure of O2, Reference) A
100 75
E = log (P /P ) A X
E (millivolts) 50
The Nerst equation graph of millivolts versus % O2 gives a straght line. This means our O2 measurement is linear.
Here’s what you need to know about this slide:
1. For ambient air, the millivolts generated is 0 millivolts. As shown on the graph, 20.9% is the % O2 in dry ambient air.
2. We use instrument air as our reference gas. Also, it is used as our span gas. This means that during calibration, our span gas will give us a perfect zero millivolts. We need another gas to give us the slope of the line (or angle of the line).
3. Our customers purchase 1 calibration gas from a gas supplier. This is a savings($$) to the customer for maintenance cost!
4. JYC does not supply test gases. You must use a local supplier of test gases. 25
100
1.0 10
20.9
0.2

11. Zirconia Oxide - Cell Theory
Platinum Electrode
Zirconia Ceramic
Sample Gas
Oxygen Partial Pressure = P x
The millivolts value is produced by platinum electrodes on 2 sides of the zirconia cell. The mV value represents the % of Oxygen present in the flue gas. There are two sides to a cell, which are called Reference Side and Sample Side. Your customer’s process is on the sample side. Instrument air is always on the reference side. O 2 O 2- O 2-
Reference Gas
Oxygen Partial Pressure = P A

12. ZO21D - Internal View
The only part of the probe that does a lot of work is the very tip. Its functions is to heat the zirconia cell to 750 deg C and maintain it at that temperature. Although the probe comes up to temperature in minutes, it usually takes about 3 hours before the cell is fully heated to the correct temperature.
Also, the slide shows the importance of the calibration port on the probe, as it brings the cal gas to the sample side of the cell. No special equipment is used to do this.
A 3 year manufacture warranty is given on the heater and thermocouple against manufacture defects. See Demo Tips handout!

13. Reference Air vs. Sample Flow
Process Gas
Process Gas
Ambient Air
Reference Air
Cal Tube
Zirconia Cell
Reference Air
The reference side is welded and sealed inside of the probe and never comes in contact with the process flue gas. JYC’s unique design of the probe saves customers $ on cal gas. Competitors use 4 times more gas than JYC. See Demo Tips.
Why is it important to plug the calibration gas inlet port and not leave open to ambient air?
Heater
Calibration Gas Inlet
Reference Air Tube
Piped Reference Air

14. Single Point O2 - Basic System
ZA8C
ZA8F
Auto-Cal Wire (3)
Signal Wire (6)
Heater Wire (2)
ZO21D
Typical Low Temperature O2 Systems (less than deg F) have an analyzer, probe, and calibration unit. See Price Sheets.
Notice the options, and product notes.
Customers sometimes want to cut conners and choose to not purchase the calibration. Why is calibration important?
Sales advantages:
Low maintenance and Installation Labor
3 year Warranty on probe’s heater and thermocouple.
Fewer probe spare parts.
Instrument Air
Zero Gas
.25” Tubing

15. Single Point O2 - High Temperature
ZA8C
Auto-Cal Wire (3)
ZA8F
Signal Wire (6)
Heater Wire (2)
Instrument Air
(0-15 psig)
Typical High Temperature System with Analyzer, Calibration Unit, Probe, and ADAPTER TEE.
We use the same analyzer and calibration unit. We use a shorter probe that is atttached to an adapter, which lowers the temperature of the sample gas.
1. What part of the high temp system is exposed to the extreme temperature?
Sales Point:
Zirconia cell has platinum molecularly bonded to the zirconia. Hence, no probe failure because of separation of zirconia from platinum due to high temperatures.
ZO21D
Instrument Air
ZO21P
Zero Gas
.25” Tubing

16. Superheater Header Outlet
Typical O2 Probe
Installations
Application
Recovery Boiler
Superheater Header Outlet O2 O2 O2
Economizer
ZO21D
Chemical
Recovery
Boiler
Oil & Gas
Burners
Salt
Cake
Silo
See application data sheet.
Mix
Tank
Dissolving
Tank

17. Application Utility Boiler
Multiple
ZO21D
probes!
Primary
Superheater
by Customer
Economizer
Probe Protector
(ZO21R)
Burners
to Stack
O2 Probe
Placement
See application data sheet. Large utility boilers normally use multiple probes. What is a stratification, and what is the solution to this problem? By being aware of this problem, and providing the solution, you can not only save your customer $ by saving on fuel consumption, but also you gain an AV8C system sale!
Fly Ash Filter
Air Preheater
Combustion Zone

18. Side by Side Duct - alt. “A” Duct “B” Duct O Probe O Probe 2 Slow 5%4% 1%
Slow
Fast
Most ducts have varyying O2 values that make single point measurements questionable when it comes to accuracy. For a utility boiler, the duct size can be as large as 75 feet. Multipoint measurements are better representations of the process in utility boilers.
Slow
“A” Duct
“B” Duct

19. “A” Duct “B” Duct Multi Probe System - AVERAGING
O Probes - Average “A” 2
O Probes - Average “B” 2 5%
Fast
Slow 1% 4%
Slow
Multipoint measurements give a mor accurate representation of the process. JYC has a uniqu, cost effective system with 1 analyzer, 1 calibration unit, and up to 8 probes.
“A” Duct
“B” Duct

20. Multi Point O2 - 8 Channel System
AV8C
AC 8
Zero Gas
Instrument Air
AV8E
Probe Wiring
Not Shown
Gas Lines
AV8C has individual mA outputs for each probe. Each probe is independent from other probes for ture system redundancy. If a probe fails, it is dropped out of the average, but the remaining probes remain on line! Modular design makes probe expansion easy.
We are using the same probes as the ZA8C systems. However, we use a different calibration unit, and a differenct converters.
What are the 2 basic AV8C systems? Where do we start saving by using the AV8C instead of the ZA8C system?
“A” Duct
“B” Duct

21. Product History of Yokogawa Zirconia Oxygen Analyzer
1st Generation (1970s)
Analog Type (ZO6C)
3rd Generation (1990s)
Multifunction (ZA8C)
2nd Generation (1980s)
Microprocessor-based (ZO21C)

22. ZR Series Zirconia Oxygen Analyzer ZR402, remote analyzer
ZR22, Zirconia detector
ZR202, SMART detector

23. ZR202 /ZR22 Oxygen detectors
Repairable construction
Heavy duty ceramic heater
Max Temperature 700C
Natural convection or forced reference air
Pressure Compensation possible
Superior environmental specifications
Heater Assembly

24. Detector Field replaceable sensor Optional Inconel bolts
for 600< T < 700 C
Universal Gas-Block

25. Installation Flexibility reference air: convection, reference air, pressure compensating
Pressure compensation
Rc1/4 or
NPT1/4 for
press.comp
Instrument air
as reference
Natural Convection

26. ZR402 Oxygen Analyzer & ZR22 Oxygen Detector
Trending
Information
Diagnostics
Calibration &
Maintenance
Touch Screen matrix LCD
Self diagnostic features
Trend graphing of O2 values
Auto Calibration
Suitable for humidity analysis
( indirectly heated dryers )

27. Reduction of Maintenance Costs by Digital Communication
Preventive maintenance by measurement signals and diagnosis information
Reduction of maintenance cost by remote maintenance　　
Digital Communication
Zero Gas
Converter
120V AC
Auto-Cal Unit
Instrument Gas

28. HVALA NA PAŽNJI !
Pitanja?