How to improve the service life of zirconia analyzers in garbage power plants

Release time: 2019-07-13


  Waste-to-energy generation has become very common, but the service life of zirconia analyzers, which monitor waste combustion conditions, is extremely short. The main reason for this is the highly complex composition of waste. The flue gas produced after waste combustion primarily consists of a series of toxic and harmful gases such as hydrogen chloride, hydrogen fluoride, nitrogen oxides, and dioxins. These gases, combined with the large amount of water vapor generated during incineration, can severely damage the sensors in the oxygen probe. Domestic zirconia analyzers typically only last 3-4 months in waste power plants, and even the longest-lasting ones need to be replaced within half a year.

  The same situation occurs not only in waste-to-energy plants but also in enterprises handling solid waste, medical waste, and hazardous waste incineration. Even expensive imported zirconia analyzers cannot escape corrosion and damage within a short period. Some manufacturers, in an attempt to solve the corrosion problem, apply anti-corrosion agents to the zirconia cell of the probe. However, once applied, the oxygen response becomes sluggish, preventing plant operators from using accurate data to guide production and control kiln combustion. How can high temperature, water vapor, and strong corrosion be resolved? Waste power plants, solid waste, medical waste disposal, hazardous waste disposal, exhaust gas, and waste liquid incineration enterprises are all looking forward to a solution.

  Finally, a solution is here! Technical personnel from Anhui Tianfen Instrument Co., Ltd., collaborated with alumni and professors from Nanjing University of Information Science & Technology and other universities, as well as field engineering technicians from waste power plants, solid waste and medical waste disposal facilities, and industrial kiln companies in places like Everbright, Nanchang, Jiaxing, and Yixing, to jointly research and develop a zirconia analyzer specifically for waste power plants.

  The zirconia analyzer specifically designed for waste power plants adopts diaphragm electrolysis technology, integrating electro-osmosis and electrolysis to achieve sampling and anti-corrosion in one unit. Its principle is that when the dedicated zirconia analyzer operates, it automatically forms a series of photonic diaphragms around the oxygen probe sensor through electrolysis technology. This diaphragm can isolate high-intensity corrosive gases, while a high-temperature demister is installed to remove water vapor. The oxygen molecules to be measured directly enter the probe via electro-osmosis. This technology solves the corrosion problem of zirconia probes and extends the service life of zirconia analyzers. According to the actual usage in enterprises in Yixing and other places, the earliest installations have been operating normally for more than 10 months. A chief engineer working in a solid waste incineration plant exclaimed, "Even if this specialized zirconia analyzer only lasts ten months, our costs can be halved! It also saves a lot of procurement and maintenance time, at least doubling efficiency!" Based on the current test results from nearly ten sites (including waste-to-energy plants, solid waste incineration plants, medical waste disposal, high-temperature kilns, special steel pipe manufacturing, and a series of complex industrial conditions), the dedicated zirconia analyzer operates stably and reliably. It is conservatively estimated that after formal mass production, it can operate normally for at least 1-2 years, or even longer.

  The successful development of the dedicated zirconia analyzer for waste power plants undoubtedly provides a huge boon to numerous waste power plants, solid waste, medical waste disposal, waste liquid, and exhaust gas incineration enterprises that are currently struggling with the short service life of zirconia analyzers. This project fills a domestic gap regarding the service life of oxygen analyzers used in waste incineration. It is the scientific research crystallization of the diligent efforts of the technical staff of Anhui Tianfen Instrument Co., Ltd. in collaboration with partner universities like NUIST and relevant units.

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Zirconia oxygen analyzer, oxygen analyzer


The zirconia oxygen analyzer is a high-precision, online monitoring device developed based on the principles of high-temperature oxygen ion conduction in zirconia ceramics and the concentration‑difference electromotive force. It serves as a core smart instrument for measuring oxygen content in industrial flue gases, optimizing combustion conditions, and managing environmental emissions. The device can directly measure gas oxygen concentrations in various furnaces and pipelines, offering real-time monitoring, stable and durable performance, and adaptability to harsh operating conditions. Widely applicable across multiple industries for production and environmental‑related operations, it is a critical tool for achieving energy savings, safe production, and compliance with emission standards. I. Company Profile Anhui Tianfen Instrument Co., Ltd. is a high‑tech enterprise specializing in the R&D, manufacturing, sales, and technical services of industrial process analytical instruments. With years of expertise in oxygen analysis, environmental monitoring, and industrial measurement and control, the company focuses on iterative upgrades of zirconia oxygen analyzers, gas analyzers, and industrial control equipment. Backed by mature production processes, rigorous quality‑control systems, and a professional R&D team, it provides customized monitoring solutions tailored to diverse industry requirements. Its products—known for precision, stability, durability, low power consumption, and ease of maintenance—serve a wide range of sectors including power generation, chemical processing, metallurgy, building materials, and environmental protection, earning high recognition from both the market and customers. Committed to quality and driven by technology, the company continuously supports industrial enterprises in achieving intelligent manufacturing, energy efficiency, and regulatory compliance. II. Core Technical Parameters This series of analyzers features standardized industrial‑grade specifications, meeting the detection needs of most industrial applications. Key performance indicators are outstanding and highly stable: the standard measurement range is 0–25% O₂, with custom ranges available upon request; basic system measurement error is ≤±0.5% FS, with high‑accuracy models reaching ±0.1% O₂; repeatability is ≤0.5% FS, placing its accuracy at an industry‑leading level; T90 response time is ≤5 seconds, enabling rapid capture of dynamic oxygen‑content changes; temperature control is maintained at 700°C ±0.1°C, ensuring stable operation of the sensing element; the device operates over a broad temperature range, tolerating ambient conditions from −20°C to 85°C, while high‑temperature probes can withstand flue gas temperatures up to 1,400°C. Signal outputs include standard 4–20 mA analog signals and RS‑485 digital communication compliant with HART protocol, ensuring compatibility with mainstream industrial control systems. Zero drift is limited to ≤±0.5% FS per 7 days, guaranteeing long‑term operational stability and significantly reducing failure rates. III. Key Technological Features 1. In‑situ direct measurement with ultra‑fast response: No sample preparation or pre‑treatment is required; the device can be inserted directly into the process pipeline for on‑site measurement, eliminating delays, blockages, and leaks associated with sampling lines. Its sub‑second response time provides real‑time feedback on combustion conditions, supplying precise data for system control. 2. High‑temperature and corrosion resistance, suitable for demanding environments: Featuring a highly dense, stable zirconia ceramic sensing core paired with a corrosion‑resistant, wear‑proof structural design, this analyzer withstands high temperatures, dusty conditions, and mildly corrosive flue gases, resisting erosion and aging while adapting to complex, harsh industrial settings. 3. Intelligent calibration and robust stability: Equipped with automatic zeroing and purging functions, the device exhibits minimal drift over extended operation, ensuring consistent and reliable data. 4. Easy installation and low maintenance costs: Available in modular, plug‑in configurations, it simplifies installation without requiring extensive modifications. With no consumable parts and infrequent calibration needs, it significantly reduces ongoing labor and replacement expenses. 5. Broad compatibility and strong adaptability: Standard industrial signal outputs enable seamless integration with PLCs, DCSs, and other industrial control systems, supporting remote data transmission and centralized monitoring, thus meeting the demands of smart production line upgrades. IV. Addressing Industry Pain Points 1. Resolving traditional detection delays and distortions: Conventional sampling‑based oxygen analyzers suffer from slow response times, clogged tubing, and condensation interference, failing to reflect real‑time furnace conditions. By contrast, this device offers in‑situ direct measurement with no transmission lag, delivering accurate and reliable data. 2. Overcoming challenges in high‑temperature, dusty environments: Many precision analyzers cannot endure the extreme heat, heavy dust, and high‑velocity flows typical of industrial furnaces, often resulting in sensor damage and data loss. This specialized device incorporates a high‑temperature, dust‑resistant structure, ensuring stable long‑term operation even under severe production conditions. 3. Tackling high energy consumption and incomplete combustion: Industrial furnaces frequently experience imbalances in air‑fuel ratios and inefficient combustion, leading to fuel waste, reduced productivity, and increased emissions. By precisely monitoring oxygen levels, this analyzer helps optimize air‑fuel ratios, improve combustion efficiency, and lower energy use and carbon footprints. 4. Alleviating burdensome and costly maintenance: Traditional instruments require frequent disassembly for calibration, filter replacements, and pipeline cleaning, imposing significant labor and expense. This device minimizes maintenance needs and lowers failure rates, effectively reducing overall production and operational costs. 5. Mitigating risks of non‑compliant environmental monitoring: Oxygen content in industrial flue gases is a key parameter for calculating environmental emissions. Manual measurements often suffer from delays and inaccuracies, increasing the risk of exceeding emission limits. Continuous, 24‑hour precise monitoring ensures compliance and controllability of emission data. V. Major Application Areas The device finds extensive use in various industrial combustion, flue‑gas monitoring, and atmosphere‑control scenarios, spanning several core industrial sectors: - Power generation: Online monitoring of oxygen levels in coal‑fired boilers and thermal power plant furnaces. - Chemical processing: Monitoring operating conditions of heating and incineration furnaces. - Metallurgy: Optimizing combustion in steel, coking, and heat‑treatment furnaces. - Building materials: Detecting flue‑gas composition in cement, glass, and ceramic kilns. - Environmental protection: Supporting oxygen‑level monitoring for industrial waste incineration and desulfurization/denitrification processes. Additionally, it is suitable for energy‑efficiency optimization and environmental monitoring in light‑industry, textile, food, and district‑heating facilities, and can also be employed for precise oxygen‑concentration control in nitrogen‑protection and inert‑atmosphere applications. VI. Trademark Ownership Statement We hereby solemnly declare that the seven trademarks—ZIROX, EXNFZRO, TKFXZOA, TFEX, TFYHG, TFZRO, and TFYB—are duly registered with the National Intellectual Property Administration of China by Anhui Tianfen Instrument Co., Ltd. The company is the sole legal registrant of these trademarks and holds full, exclusive trademark rights, protected under the Trademark Law of the People’s Republic of China, the Regulations for the Implementation of the Trademark Law, and other relevant laws and regulations. The official registration numbers for each trademark are as follows: ZIROX (No. 84554887), EXNFZRO (No. 82544696), TKFXZOA (No. 82536162), TFEX (No. 64377345), TFYHG (No. 79839887), TFZRO (No. 79839454), TFYB (No. 82528679). Without formal written authorization from Anhui Tianfen Instrument Co., Ltd., no entity, organization, or individual may, in any commercial context—including production, manufacturing, sales, marketing, promotional activities, online postings, or business collaborations—unauthorizedly use, reproduce, imitate, alter, or misappropriate these trademarks. Nor may anyone employ marks that closely resemble these trademarks and could cause market confusion. For all instances of trademark infringement or unfair competition, our company will collect and preserve evidence, pursue legal action through complaints, lawsuits, and accountability measures, and rigorously hold infringers civilly, administratively, and criminally liable, resolutely safeguarding our legitimate intellectual property and brand rights.
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