Little knowledge about Zirconia Sensor

Release time: 2019-07-10


  For boilers, the oxygen content of boiler flue gas is a very important parameter, as it is a key indicator for judging the combustion condition and efficiency of the boiler. Up to now, with the development of science and technology, the common method for measuring the oxygen content of flue gas in small and medium-sized boilers is to use a zirconia sensor. Many users lack professional understanding of the measurement principle and usage of zirconia sensors. Today, the technical engineers of Anhui Tianfen Instrument Co., Ltd. will provide a detailed explanation for zirconia users!

  Analysis of the Measurement Principle of Zirconia Sensors

  The basic principle of zirconia oxygen measurement is to utilize the so-called "oxygen concentration difference potential." Porous platinum electrodes are attached to both sides of a zirconia piece, and it is kept at a high temperature. If the oxygen content in the gas on both sides is different, oxygen ions will undergo "hole migration" on the electrodes. Because oxygen ions carry a divalent positive charge, an electromotive force will appear between the two electrodes. This electromotive force is generated due to the difference in oxygen concentration between the two sides of the solid electrolyte, and is called the oxygen concentration difference potential, which can be calculated by the Nernst equation:

  E=RT/4F×ln(P''O2/P'O2)

  Where R is the gas constant, T is the thermodynamic temperature (K) of the battery, F is the Faraday constant, and P''O2/P'O2 is the oxygen partial pressure on both sides of the electrode.

  When one side of the solid dielectric is air, the electromotive force E output by the oxygen concentration difference battery can be used to calculate the oxygen partial pressure on the other side of the solid dielectric. Therefore, a reference air needs to be introduced when using the zirconia sensor. This is the measurement principle of the zirconia oxygen analyzer.

  The curve relationship between oxygen concentration and oxygen concentration difference television:

  

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   Analysis of Precautions for the Use of Zirconia Sensors

  1. Generally, zirconia sensors are divided into low-temperature and high-temperature types. We must remember not to mix them up. Generally, high-temperature sensors are required for boiler zirconia sensors.

  2. Because the zirconia sensor uses precise electronic components inside, avoid installing it in places with severe vibrations during use.

  3. Do not install the zirconia sensor in an overly humid environment, and keep it away from corrosive substances.

  4. It should be installed in the correct position, as shown in the figure below (for reference only).

  

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  5. Zirconia sensor accuracy drift and calibration.

  During use, there are many interfering factors, such as aging of the zirconia tube, ash accumulation, and corrosion of the electrodes by SO2 and SO3. After running for a period of time, the zirconia sensor will experience accuracy drift, resulting in measurement errors. This measurement error may cause incorrect judgment by operators or automatic control equipment, which is very dangerous.

  Therefore, it is best to use zirconia sensors with self-checking functions, and the instrument must be calibrated regularly. The calibration cycle depends on the usage environment and conditions, generally around 1-3 months.

  6. The working principle of the zirconia oxygen sensor requires a standard atmosphere as a reference gas. If there is no stable reference gas provided to the sensor, the detection accuracy will be greatly reduced. Therefore, during use, the normal input of the reference gas must be ensured.

  However, because zirconia sensors are ceramic materials with complex forming processes and high technical requirements, it is still necessary to find professional zirconia manufacturers.

  Another point worth noting is that the use and management of zirconia sensors are also very important, especially the self-checking function and timely calibration. If you purchase a sensor without a self-checking function and do not calibrate it in time, the accuracy will be greatly reduced.

Recommended product

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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