Zirconia Analyzer

Zirconia Oxygen
Analyzer
| Document Number| October 22, 2019 |

© Yokogawa Electric Corporation
‹#›
Introduction – Typical Combustion
FUEL RICH （Flue gas condition in the firebox） AIR RICH
(Insufficient Air) Efficiency Extended Life (Excess Air)

• Reduce fuel • Reduce coking
consumption • Prevent formation
- Explosion risk
CO • Increase
throughput
of hotspots - Energy loss
• Tube life - Affect heater life cycle
- Unburned fuel
Emissions Safety
• Reduce Pollutants: • API-556
NOx, CO • Prevent risk of unstable
combustion
• Reduce greenhouse
gases: CO2 • Prevent unnecessary trips
• Detect leakage of fuel
shut-off valve
O2
Stoichiometric air demand
Optimal Excess Oxygen level

% EXCESS AIR
‹#›
1. Yokogawa O2 Analyzer Line-up
OX400
Zirconia
Yokogawa
Para-
O2 magnetic
Analyzer
Laser
TDLS8000
‹#›
2. Selection Flow Chart (1)
Oxygen Analyzer
Application
Semiconductor etc. Combustion control

“ppm” measurement or Process control etc.
OX400

‹#›
Combustion control or Process control etc.
Flammable gas NO
Next page
included?
No ignition source YES
Direct in-situ Sampling
Explosion-proof YES
Required? MG8E
NO
TDLS8000
MG8G
‹#›
ZR Series
Averaging
Measurement? NO
YES
Line averaging Multi point averaging
TDLS8000
AV550G+ZR22
‹#›
AGENDA
1. Zirconia Products Outline

Yokogawa Zirconia O2 analyzer
ZR22G/S
ZR202G/S
ZR402G
AV550G
2. Zirconia Sensor Principle & Structure

3. MS Code
4. Other Equipment
5. Summary

‹#›
Yokogawa Zirconia O2 Analyzer

Long history, since 1970’s
Reliable zirconia sensor
Application; Power plant, steel, chemical, etc.
ZR22G
ZR202G
ZR402G AV550G

‹#›
Yokogawa Zirconia O2 Analyzer

Long history, since 1970’s
Reliable zirconia sensor
Current
3rd Generation models(2000s)
(1990s) (ZR series)
Multifunction (ZA8C)
2nd Generation
(1980s)
1st Generation Microprocessor-based
(1970s) (ZO21C)
Analog Type (ZO6C)
Same design sensor
‹#›
ZR22G/S Detector (1)

Proven zirconia sensor
Long Life, Fast response
Field replaceable design
Sensor, Heater
Ex-proof available (ATEX, FM, CSA, IEC)
Zone1, Div.1

‹#›
ZR22G/S Detector (2)

ZR22G/S Specification Description
Measurement range 0-5~0-100 %O2
Repeatability ±1%FS 0-5%O2～0-25%O2 range
Linearity ±0.5%FS 0-5%O2～0-25%O2 range
Response time <5 sec 90% response
Sample gas temp. 0~700℃ (1400℃) (ZO21P-H is required)

Pressure compensation type
Sample gas pressure -5～+250kPa ZR22S; -5～5kPa
(No press. Comp.)
Ambient temp. -20～+150℃

Enclosure NEMA4X or Ex-proof type

‹#›
ZR402G Converter (1)

LCD touch screen operation
HART communication & configuration
Auto calibration
Sensor diagnostics with cell life
Just as “Guide”
NEMA4X enclosure
No Explosion-proof model

‹#›
ZR402G Converter (2)

ZR402G Specification Description
Display range 0.00～100%O2
Display size 320 by 240 dot With touchscreen
Analog output 4-20mA 2-points

Relay output 3+1 (for fail-safe)
Contact input 2 For calibration etc.
Digital communication HART

Ambient temp. -20～55℃
Enclosure NEMA4X
Safety EN, CSA, UL

‹#›
ZR202G/S Integral type (1)

Local display, Infra-red “push-button” operation
HART communication & configuration
Automatic calibration unit can be attached
Reduces wiring costs
Ex-proof available (ATEX, FM, CSA, IEC).
Zone1, Div.1

‹#›
ZR202G/S Integral type (1)

ZR202G/S Specification Description
Analog output 4-20mA 1-point
Relay output 1+1 (for fail-safe)
Digital communication HART

Enclosure NEMA4X or Ex-proof type
Safety EN, CSA, UL

‹#›
AV550G Averaging Converter

Multi channel oxygen analyzer
8 individual detector outputs and 3 average
outputs
Large, Color display
Automatic calibration
Foundation Fieldbus available

‹#›
AV550G Detector Features (2)

AV550G Specification Description
Display range 0.00～100%O2
Display size 5.7”, 320 by 240 dot With touchscreen
3-average
Analog output 4-20mA 8-individual
Relay output 4+1 (for fail-safe) + 8-individual output
Digital communication Foundation Fieldbus

Enclosure Indoor type
Safety EN, CSA, UL

‹#›
AGENDA

Principle of Zirconia O2 Analyzer
Principle of Humidity Analyzer
Detector Structure
3. MS Code
4. Other Equipment
5. Summary

‹#›
Principle of Zirconia O2 Analyzer (1)

Sensor structure and principle
E Electromotive force
－＋ 750℃
℃
Ｏ２
Ｏ2--
Reference air
Ｏ2--
Ｏ２
Sample gas
Zirconia Cell Molecularly Bonded Platinum

‹#›
PX
PA
E; Electromotive force [V]
R; Gas Constant (8.31 J/mol ºK)
T; Absolute Temperature [ºK] ( ºK = 273.15 + ºC )
n; Electrons (= 4)
F; Faraday’s Constant ( 9.64 × 104 coulomb/mol )
Px ; Partial Pressure of O2 on Sample Side of Cell
PA; Partial Pressure of O2 on Reference Side of Cell

‹#›
Principle of Zirconia O2 Analyzer (2)
100
67mV
75
EMF [mV]
50
25
20.95%
0
0.2 1.0 10 100
O2 [%]
‹#›
Principle of Humidity Analyzers
H 2O X
Water 79%
H2O Air
100 % N2
100 %
Nitrogen
O2 21%
Y Oxygen

‹#›
Detector Structure
Contact spring Heater TC (type-K)
Cell output
Cell
Terminal
U-shape pipe
Calibration gas pipe Reference gas pipe Gas connection port

‹#›
AGENDA

3. MS Code
Probe length
Wetted Material
Reference Air
Option
4. Other Equipment
5. Summary

‹#›
3. MS-code
ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description
① Probe Length Insertion probe length
② Wetted Material Cal gas pipe material can be selected
③ Flange ANSI, DIN, JIS, 14 type available
④ Reference Air 3 types, which is appropriate?
⑤ Gas Thread Gas port thread, NPT(ANSI) or R(ISO)
⑥ Connection box Thread Cable entry thread, NPT or G or M or Pg
⑦ Instruction Manual English or Japanese
⑧ Spare (Always “-A”)
⑨ Options Valve, Filter, Tag etc.

‹#›
3. MS-code
ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description

‹#›
3. MS-code
① Probe length
MS code Length Note
for high temp. (with ZO21P)
-015 0.15m
Flange “-Q” is required
-040 0.4m
・・・
・・・
-200 2.0m
-250 2.5m
-300 3.0m
-360 3.6m
In horizontal installation,
ZO21R Probe protector is
-420 4.2m
required
-480 4.8m
-540 5.4m
‹#›
3. MS-code
ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description

‹#›
3. MS-code
② Wetted Material
Description
MS-code
Main Material Calibration gas pipe
-S Stainless steel Stainless steel
Inconel
-C Stainless steel
(Prevent corrosion, e.g. HCL)
Calibration gas pipe
Condensation
.

Cal gas inlet
‹#›
3. MS-code
ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description

‹#›
3. MS-code
④ Reference air type
“-C” Natural convection “-E” Instrument Air “-P” Pressure Comp.
Wide gap Small hole Sealing enclosure

Enclosure; IP44 Enclosure; IP44 Enclosure;IP66/NEMA4X
‹#›
3. MS-code
Natural convection type “-C”

Instrument air is not required
Measurement is not stable due to humidity
Instrument air can be connected
Replacement of ZO21D (Recommend)
Gap
Plug
‹#›
3. MS-code
Instrument air type “-E”
“Rain proof type”
Better enclosure protection than natural
convection type
Can not use as natural convection type
Small hole (Outlet)
Reference air inlet

‹#›
3. MS-code
Pressure compensation type “-P”
Sample gas pressure; MAX.250 kPa
IP66/NEMA4X enclosure
No fluctuation by sample gas pressure
Ref. air pressure setting; Inside probe >
Furnace
Return pipe Sealing wall
To furnace
Reference air inlet

‹#›
3. MS-code
ZR22G-①-②-③-④-⑤-⑥-⑦-⑧/⑨
ZR22G Description

‹#›
3. MS-code
⑨ Option
Option code Description
/C Inconel bolt and U-shape pipe
/CV Check valve
/SV Stop valve (Needle valve)
/F1 Dust filter
/F2 Dust guard filter
/PT Printed tag plate (Label)
/SCT Stainless steel tag plate

‹#›
3. MS-code
⑨ Option (1)
Option code Description
/C Inconel bolts and U-shape pipe
Sample gas temperature ≧ 600℃
Prevent bolts and U-shape pipe seizing
Bolts for fixing

U-shape pipe
the cell (4 pics)

‹#›
3. MS-code
⑨ Option (2) “/SV” or “/CV”
Option Description
code Part name Usage
/SV Stop valve Manual calibration
/CV Check valve Automatic calibration
Stop valve Check valve

‹#›
3. MS-code
Check valve “/CV”
Enable to conduct Automatic-calibration
Body; Stainless steel, Piston; FPM
Supply pressure range; 150〜350kPa
Setting; Sample gas pressure + 150kPa
Max. Sample gas pressure; 200kPa
Piston Body
IN OUT
Check valve

‹#›
3. MS-code
⑨ Option (3) “/F1” or “/F2”

Option Description
code Part name Application
Concrete kiln
/F1 Dust filter Recovery boiler etc.
General purpose
/F2 Dust guard protector Dust; 1g/Nm3～
SiC filter Flow
Dust filter Dust guard protector

‹#›
3. MS-code
⑨ Option (3) “/F1” or “/F2”
Option code
Advantage Disadvantage
Name
/F1 - Corrosive dust -Slow response

- Flammable dust -Clogged
Dust filter (ZO21R prevent it from being clogged)
/F2 - Fast response - Corrosive dust

Dust guard - Unlikely to be clogged - Flammable dust
protector
F1; Needs careful selection

F2; Recommend
Fly Ash filter – coal & Biomass fuel
‹#›
3. MS-code
ZR402G-①-②-③-④/⑤
ZR402G Description
① Converter thread Cable entry thread
② Display Display language
English, German, French, Chinese, Japanese
③ Instruction Manual English, Chinese, Japanese
④ Spare (Always “-A”)
⑤ Option Humidity setting, Hood, Tag, Namur* NE43
* Namur ;
German standard for actuator components
Hood

‹#›
3. MS-code
ZR202G-①-②-③-④-⑤-⑥-⑦-⑧-⑨/⑩
ZR202G Description
④ Auto calibration Back pack type Auto calibration unit
⑤ Reference Air 3 types, which is appropriate?
⑥ Gas Thread Gas port thread, NPT(ANSI) or R(ISO)
⑦ Connection box Thread Cable entry thread, NPT or G or M or Pg
⑧ Instruction Manual English or Japanese
⑨ Spare (Always “-A”)
Options Valve, Filter, Tag, Namur NE43 etc.
‹#›
AGENDA

3. MS Code
4. Other Equipment
Calibration Equipment (ZO21S, ZA8F, ZR40H)
Detector Equipment (ZO21P-H, ZO21R-L)
5. Summary

‹#›
4. Other Equipment
1. Calibration equipment
Description
Model
Product name Usage
ZO21S Standard gas unit Manual calibration
ZA8F Flow setting unit Manual calibration
ZR40H Auto calibration unit Automatic calibration

‹#›
4. Other Equipment
Description
Model
Product name Usage
Manual calibration
ZO21S Standard gas unit
(with ambient air & zero gas)
Air pump
Flow-
supplying
checker
ambient air
Valve Zero gas

cylinder
(6-pack)
‹#›
4. Other Equipment
System configuration using ZO21S
Exception; Pressure compensation type
ZO21S

‹#›
4. Other Equipment
Description
Model
Product name Usage
Manual calibration
ZA8F Flow setting unit
(with instrument air & zero-gas)
Poll mount or wall mount

Rainproof
Max. pressure; 300kPa
Sample gas pressure; MAX.250kPa
With check valve; MAX.150kPa

‹#›
4. Other Equipment
System configuration using ZA8F
ZA8F

‹#›
4. Other Equipment
Description
Model
Product name Usage
Automatic calibration
ZR40H Auto calibration unit
(with instrument air & zero-gas)
Available only ZR402G

Poll mount or wall mount
IP67/NEMA4X (except flow meter)
Max. pressure; 690kPa
Sample gas pressure; MAX.250kPa
With check valve; MAX.200kPa

‹#›
4. Other Equipment
System configuration using ZR40H

‹#›
4. Other Equipment
1. Detector equipment
Description
Model
Product name Usage
High temperature sample gas
ZO21P-H Probe adapter
(700～1400℃)
- Brace for long probe
ZO21R-L Probe protector - Protector from abrasion of heavy dust
- Protect dust filter from clogging

‹#›
4. Other Equipment
Description
Model
Product name Usage
High temperature sample gas
ZO21P-H Probe adapter
700～1400℃
Ejector ZR22G
(Option) Length; -015
Flange; -Q
Probe
ZO21P-H
Sample gas Flow

‹#›
4. Other Equipment
ZO21P-H-①-②-③-④/⑤
Description
ZO21P-H
code Specification usage
① Probe material -A Stainless steel (SUS310S) ～800℃
～1400℃
-B SiC
(Vertical only)
② Probe length - 0.5～1.0, 1.5m －
③ Flange - ANSI, DIN, JIS, JPI －
④ style code *B －－
⑤ Option Ejector /EJ1 Rc1/4 (ISO) Negative
Pressure
⑤ Option Ejector /EJ2 1/4NPT (ANSI) (-0.5～0 kPa)
Tag plate /SCT Stainless steel tag plate －
‹#›
4. Other Equipment
Ejector or valve
Sample gas pressure
～+0.05 kPa
-0.5～～+5 kPa
+0.05～ 5 kPa ～
Ejector P.G Valve
Reducer/Connector
Air
Valve
e.g.) + L9852CB (Rc1/4) or

Option; “EJ1 or EJ2”
Option; None G7016XH (1/4NPT)
(including P.G, valve)
+ Reducer
‹#›
4. Other Equipment
Probe materials
Sample gas temperature
～800 ℃ ～1000 ℃ ～1400 ℃
Vertical SUS310S SUS310S SiC

installation ZO21P-H-B-… ZO21P-H-B-… ZO21P-H-A-…
Inconel600
Horizontal SUS310S
installation
ZO21P-H-Z-… N/A
ZO21P-H-B-…
Z; Tokuchu
Probe
Probe
Vertical Horizontal

‹#›
4. Other Equipment
Description
Model Product
Usage
name
- Brace for long probe (>2.0m)
- Protector from abrasion of heavy dust
ZO21R-L Probe protector
(Flow rate >10m/s2)
- Protect dust filter from clogging
Dust Flow
Gravity
Brace Protect
‹#›
AGENDA

3. MS Code
4. Other Equipment
5. Summary

‹#›
5. Summary
Calibration equipment selection

～5
-5～～ 150 ～200 ～250
Sample gas pressure
kPa kPa kPa kPa
Needle valve N/A N/A N/A
ZO21S
Manual-cal Check valve N/A N/A N/A N/A
Needle valve N/A

ZA8F
Manual-cal Check valve N/A
ZR40H Needle valve

Auto-cal unit
(For ZR402G) Check valve N/A
ZR20H
Auto-cal unit －
(for ZR202G)

‹#›
Thank you

‹#›

Zirconia Analyzer

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Zirconia Analyzer

Uploaded by

Copyright:

Available Formats

Zirconia Oxygen

| Document Number| October 22, 2019 |

(Insufficient Air) Efficiency Extended Life (Excess Air)

Stoichiometric air demand

Optimal Excess Oxygen level

Semiconductor etc. Combustion control

| Document Number| October 22, 2019 |

Combustion control or Process control etc.

No ignition source YES

Direct in-situ Sampling

Line averaging Multi point averaging

1. Zirconia Products Outline

2. Zirconia Sensor Principle & Structure

| Document Number| October 22, 2019 |

Yokogawa Zirconia O2 Analyzer

| Document Number| October 22, 2019 |

Yokogawa Zirconia O2 Analyzer

ZR22G/S Detector (1)

| Document Number| October 22, 2019 |

ZR22G/S Detector (2)

Linearity ±0.5%FS 0-5%O2～0-25%O2 range

Response time <5 sec 90% response

Sample gas temp. 0~700℃ (1400℃) (ZO21P-H is required)

Ambient temp. -20～+150℃

| Document Number| October 22, 2019 |

ZR402G Converter (1)

| Document Number| October 22, 2019 |

ZR402G Converter (2)

Analog output 4-20mA 2-points

Digital communication HART

| Document Number| October 22, 2019 |

ZR202G/S Integral type (1)

| Document Number| October 22, 2019 |

ZR202G/S Integral type (1)

Digital communication HART

Safety EN, CSA, UL

| Document Number| October 22, 2019 |

AV550G Averaging Converter

| Document Number| October 22, 2019 |

AV550G Detector Features (2)

Relay output 4+1 (for fail-safe) + 8-individual output

Contact input 2 For calibration etc.

Digital communication Foundation Fieldbus

| Document Number| October 22, 2019 |

1. Zirconia Products Outline

| Document Number| October 22, 2019 |

Principle of Zirconia O2 Analyzer (1)

Zirconia Cell Molecularly Bonded Platinum

| Document Number| October 22, 2019 |

| Document Number| October 22, 2019 |

| Document Number| October 22, 2019 |

Calibration gas pipe Reference gas pipe Gas connection port

| Document Number| October 22, 2019 |

1. Zirconia Products Outline

| Document Number| October 22, 2019 |

| Document Number| October 22, 2019 |

| Document Number| October 22, 2019 |

| Document Number| October 22, 2019 |

Calibration gas pipe

| Document Number| October 22, 2019 |

| Document Number| October 22, 2019 |

Wide gap Small hole Sealing enclosure

Natural convection type “-C”

Small hole (Outlet)