braumSystems

IN-SITU ANALIZA GASOVA

Zirconia OZirconia O22 Goran Radonić

Juni 2011

braumSystems

OO22 Users & Applications Users & ApplicationsWho Measures Combustion Oxygen?Who Measures Combustion Oxygen?

Anyone who needs to monitor and/or Anyone who needs to monitor and/or control their combustion process.control their combustion process.

END USERSEND USERS

Power UtilitiesPulp& Paper Mills

Steel MillsRefineries

Chemical PlantsWaste Incinerators

Hazardous Waste IncineratorsPackage Boiler UsersCement Plants (kilns)

Co-Gen Plants

Power Plants - Utilities Upgrading old systems Installing Low NOx Burners

Sewage Treatment Plants Waste Burners - 40CFR503

Incinerators Trash Burners Hazardous Waste Incinerators

Package Boiler Owners O2 Trim required by EPA

Chemical Plants Process Heaters Boiler Houses

braumSystemsWhat are we Measuring?What are we Measuring?

The most common Application for EXA OXY Analyzers is to measure the oxygen concentration in flue

gas.

Flue Gas is what you get anytime you burn something!

AirFuel

Measure O2 here

GasesBURNINGBURNING

braumSystems

Com

bu

stio

n E

ffic

ien

cyC

omb

ust

ion

Eff

icie

ncy

Optimum Combustion

Zone

Heat loss - dissipated from the stack

Excess Air Ratio (µ)

Insufficient Air

Smokey

Low ExcessAir Ratios

MINIMUMPOLLUTION

High Excess Air Ratios

NOx and SOx increase

Heat Efficiency

Hea

t L

oss

Hea

t L

oss

1.0 1.02 1.10 1.30

Excess Air Fuel RatiosExcess Air Fuel Ratios

Energy loss - due to incomplete combustion

(unburned fuel)

braumSystems OO22 Theory Theory

What is Combustion?What is Combustion?

COMPLETECOMPLETE

INCOMPLETEINCOMPLETE

CombustionCombustion is the is the combinationcombination

of of fuel fuel and and airair with with heat heat producedproduced

and carried by the mass of and carried by the mass of flue gasflue gas

generated.generated.

H2C (carbon)

(hydrogen) OCO 2

H2(water)

(carbon dioxide)++O2

HeatHeat

AirAir FuelFuel

H2C (carbon)

(hydrogen)

++O2

HeatHeat

AirAir FuelFuel

(carbon)

OCO 2

H 2 (water)

(carbon dioxide)

CO(hydrogen)

(carbon monoxide)

Aldehydes

H 2C

FlueFlue GasGas

FlueFlue GasGas

braumSystems

O2CO2

CO2

CO2

CO2

O2

HO

-

H

HO

-

H

HO

-

H

HO

-

H

What Controls the Rate of What Controls the Rate of Combustion?Combustion?TimeTime

OxygenOxygen in contact with the in contact with the Fuel, longer the better.Fuel, longer the better.

TurbulenceTurbulence

Mixes the Oxygen and the Mixes the Oxygen and the Fuel so they are in contact.Fuel so they are in contact.

TemperatureTemperature

The higher the temperature, The higher the temperature, the better the burning.the better the burning.

CO + H OCO + H O22 22

braumSystemsOO22 Concentration vs Millivolts Concentration vs Millivolts

OutputOutput

100

75

50

25

0

0.21.0 10 10020.9

E (

mill

ivol

ts)

Oxygen Concentration and Cell EMF(P = Partial Pressure of O2, Reference)A

E = -50.74 log (P /P )AX

braumSystems

braumSystems

braumSystems

braumSystemsZirconia Oxide - Cell Zirconia Oxide - Cell

TheoryTheory

Platinum ElectrodePlatinum Electrode

Sample GasSample GasOxygen Partial Pressure = POxygen Partial Pressure = P

OO22

xx

OO2-2-

OO2-2-

Reference GasReference GasOxygen Partial Pressure = POxygen Partial Pressure = PAA

Zirconia CeramicZirconia CeramicZirconia CeramicZirconia Ceramic

braumSystems

ZO21D - Internal ZO21D - Internal ViewView

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Process Gas

...

Reference Air vs. Reference Air vs. Sample FlowSample Flow

Process Gas

Cal TubeCal Tube

Zirconia CellZirconia Cell

HeaterHeater

Reference AirReference Air

Ambient AirAmbient Air

Reference Air TubeReference Air TubePiped Reference AirPiped Reference Air

Calibration Gas InletCalibration Gas Inlet

Reference AirReference Air

braumSystems

EXA OXY

MEASMAINTALMFAIL

6.8 %O2

||||||||||||||||||||||||||||||0 10

ZO21ZO21DD

ZA8ZA8CC

Heater Wire (2)

Signal Wire (6)

Auto-Cal Wire (3)

Zero GasInstrument Air

.25” Tubing

Single Point OSingle Point O2 2 - Basic System- Basic System

ZA8FZA8F

braumSystemsSingle Point OSingle Point O2 2 - High Temperature- High Temperature

ZA8FZA8F

ZO21PZO21P

ZA8CZA8C

EXA OXY

MEASMAINTALMFAIL

6.8 %O2

||||||||||||||||||||||||||||||0 10

Heater Wire (2)

Signal Wire (6)

Auto-Cal Wire (3)

Zero Gas

Instrument Air

.25” Tubing

Instrument Air(0-15 psig) ZO21DZO21D

braumSystems

A B

CD E F G

2

H

1

ApplicationApplicationRecovery Recovery

BoilerBoiler

ChemicalChemicalRecoveryRecoveryBoilerBoiler

Oil & GasBurners Salt

CakeSilo

Superheater Header Outlet

Typical O2 ProbeInstallations

Economizer

MixTank

DissolvingTank

O2 O2O2

ZO21DZO21D

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Burners

O2 ProbePlacement

Combustion Zone

Air Preheater

to Stack

Multiple Multiple ZO21DZO21Dprobes!probes!

Probe Protector(ZO21R)

Fly Ash Filter

Application Application Utility BoilerUtility Boiler

Economizer

PrimarySuperheater by Customerby Customer

braumSystems Side by Side Duct - alt.Side by Side Duct - alt.O ProbeO Probe22

““A” DuctA” Duct ““B” DuctB” Duct

O ProbeProbe22

FastFast

SlowSlow

SlowSlow5%5%

4%4%

1%1%

braumSystems Multi Probe System - Multi Probe System - AVERAGINGAVERAGING

5%5%

O Probes - Average “A”O Probes - Average “A”22

SlowSlow

““A” DuctA” Duct ““B” DuctB” Duct

O Probes - Average “B”O Probes - Average “B”22

FastFast

SloSloww

4%4%

1%1%

braumSystems Multi Point OMulti Point O2 2 - 8 Channel System- 8 Channel System

C H

RDYALMERR

CH

RDYALMERR

CH

RDYALMERR

CH

RD YAL MER R

CH

RDYA LMERR

CH

RDYALMERR

CH

RDYALMERR

RS42

R DY

MP20 CPU

RD YAL MER R

R DY

I / O

RDYALMERR

CH

RDYALMERR

PU 40 R S 2 3 2

| || || || | || || | || || || | ||0 1 0

4 6.8Vol %O2

C H N O . D A T AME A S

MA I N TA L M

FA I L

AV8 C ZI R C O N IA O X I D EAV E R A G IN G C O N V E RT E R

Y ES N O HE LP

CAL D ISP EN TER

> >

>

CH AN NE L

YO K OG AWA

- 0 Bar G rap h on L CD- 1 Max O2 /Mi n O 2

- 2 A vera ge O2- 3 Cel l EMF

- 4 Cel l Tem p/ T C E MF- 5 Ou t put / O ut pu t R ang e- 6 Cl ock ( Y / M/ D)

- 0 C al. G as Con c. S pan- 1 C al. G as Con c. Z ero

- 2 C ali brati on Mod e- 3 St abi li zing Ti me

- 4 C ali brati on Tim e- 5 C ali brati on Int erval

- 6 C al. St art Ti m e- 7 Zero/ Span Skip

-0 Out put Range 1-1 Out put Range 2

-2 Out put Hol d-3 Current O ut put

-4 Out put Scale-5 Sign al Dam pin g

-6 Wet/ Dry O2 Select

-7 Avg. G rou ping a-8 Avg. G rou ping b

-0 HH / H Set Poi nt-1 LL/ L Set Poi nt

-2 Cancel A lm C hannel-3 Cont act O utp ut Del ay

-0 Avg. Int . Ent ry-1 Max O 2/Mi n O 2 Int .

-2 deg C = deg F

-0 Cont act O utp ut 1-1 Cont act O utp ut 2

-2 Cont act O utp ut 3

-3 Cont act O utp ut 4-4 Cont act O utp ut 5

-5 Cont act Input 1-6 Cont act Input 2

-0 Com m Mode-1 Baud Rat e

-0 Moist ure cont ent in Exhaust G as

A B C D E

F

G H

J

No. Disp lay Contents No. Entry Contents

DISPLAY Press key. A bar graph appears.DI SP

Press , , or key to select channel and di spl ay.> >

> CHA NN EL

CALIBRATIONPress key. Foll ow t he instruct ions di splayed.C AL

If CAL is cancel led, press key.H EL P

When cel l dat a i s displayed duri ng cal ibrati on, press key.D IS P

CHANGING DATA SET

Press key. Fol low the i nst ruct ions displayed.EN T ER

To cancel dat a set , press key. Display returns to m eas m ode.DIS P

When "Y/N" is displayed, press ei ther key

Di spl ays dat a or st ops ent ry operati on.

Sets CA L mode.Increases or decreases display No. and numeri c data.

Selects di spl ay code No. and numeri c data.

Sets addit ional dat a or s tops calibrati on.

Sets entry m ode and st ores set dat a.

Sets Channel No.

H E L P

C A L

D IS P

E N T E R

>

Y E S N O

>>

CH AN NE L

KEY ENTRY

OPERATION

- 0 Span C orr R ate/ Hi story- 1 Zero C orr Rat e/H i st ory

- 2 Cell R esponse- 3 Cell Int . R esi s tance

- 4 Cell L if e- 5 CJ T em perat ure

- 6 Heat er Dut y- 7 Dry O 2/ H2O

AV8C AV8C

AC 8AC 8

Zero GasZero Gas

Instrument AirInstrument Air

Probe WiringProbe WiringNot ShownNot Shown

““A” DuctA” Duct ““B” DuctB” Duct

Gas LinesGas Lines

AV8EAV8E

braumSystems Product History ofProduct History ofYokogawa Zirconia Oxygen AnalyzerYokogawa Zirconia Oxygen Analyzer

2nd Generation 2nd Generation (1980s)(1980s)Microprocessor-Microprocessor-based (ZO21C)based (ZO21C)

1st Generation 1st Generation (1970s)(1970s)Analog Type (ZO6C)Analog Type (ZO6C)

3rd Generation 3rd Generation (1990s)(1990s)Multifunction (ZA8C)Multifunction (ZA8C)

braumSystems

ZR Series Zirconia Oxygen Analyzer

ZR22, Zirconia detector

ZR402, remote analyzer

ZR202, SMART detector

braumSystemsZR202 /ZR22 Oxygen detectorsZR202 /ZR22 Oxygen detectors

Heater AssemblyHeater Assembly

• Repairable construction • Heavy duty ceramic heater• Max Temperature 700C• Natural convection or forced reference air• Pressure Compensation possible • Superior environmental specifications

braumSystems Detector

Universal Gas-Block

Field replaceable sensorOptional Inconel boltsfor 600< T < 700 C

braumSystemsInstallation Flexibility

reference air: convection, reference air, pressure compensating

Rc1/4 or

NPT1/4 for press.comp

Natural Convection

Pressure compensation

Instrument airas reference

braumSystems

Trending

Information

Diagnostics

Calibration &Maintenance

ZR402 Oxygen Analyzer & ZR22 Oxygen Detector

•Touch Screen matrix LCD• Self diagnostic features•Trend graphing of O2 values• Auto Calibration• Suitable for humidity analysis( indirectly heated dryers )

braumSystems Reduction ofReduction of Maintenance CostsMaintenance Costs

by Digital Communication by Digital Communication

Instrument Gas

• Preventive maintenance by measurement Preventive maintenance by measurement signals and diagnosis informationsignals and diagnosis information

• Reduction of maintenance cost by remote Reduction of maintenance cost by remote maintenancemaintenance

Digital Digital CommunicationCommunication

Zero GasZero Gas

ConverterConverter

120V AC120V ACAuto-Cal UnitAuto-Cal Unit

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