Xinjiang Huadong Group successfully applied a new type of zirconia oxygen analyzer: helping the thermal power industry set a new benchmark for energy conservation and emission reduction

Release time: 2025-04-22


Xinjiang Huadong Group Successfully Applies a New Type of Zirconia Oxygen Analyzer: Helping to Set a New Benchmark for Energy Conservation and Emission Reduction in the Thermal Power Industry

Customer Profile
Xinjiang Huadong Group is a major thermal power generation enterprise in Xinjiang, undertaking the core task of regional power supply. As a practitioner of the national "dual carbon" strategy, the Group has always been committed to improving the efficiency of coal-fired units and reducing pollutant emissions through technological innovation. However, in the boiler combustion optimization process, the instability and frequent maintenance of the original oxygen monitoring equipment have become bottlenecks restricting efficiency improvements.


Challenges: Pain Points of Traditional Equipment
In thermal power generation, the oxygen concentration monitoring of boiler combustion is directly related to combustion efficiency and environmental protection indicators. The original oxygen analyzer of a power plant in Xinjiang Huadong had the following problems:

Large Data Fluctuations Affected by flue gas dust and high-temperature environments, the measured values frequently drift, leading to lagging adjustment of the automatic control system;

High Maintenance Costs Monthly shutdown calibration is required, the sensor life is short, and the annual cost of spare parts replacement exceeds 200,000 yuan;

Energy Efficiency Loss Oxygen control deviations caused the boiler thermal efficiency to decrease by about 0.8%, and the annual coal consumption increased by thousands of tons.

"The original equipment cannot meet the needs of refined management, and a high-stability, low-maintenance solution is urgently needed." said the technical person in charge of Xinjiang Huadong.


Solution: High-Performance Zirconia Oxygen Analyzer
In response to customer pain points, our company customized the TFYHG® 5100 series zirconia oxygen analyzer ,the core technical advantages include:

Triple Anti-Interference Design Using self-developed high-temperature filtering modules and reference gas compensation technology, effectively coping with flue gas fluctuations, and achieving measurement accuracy of ±0.5%;

Ultra-Long Life Sensor The corrosion resistance of the new composite ceramic zirconium tube is increased by 3 times, and the calibration cycle is extended to 6 months;

Intelligent Diagnosis System Built-in AI algorithm for real-time monitoring of probe status, early warning of faults, and reduction of unplanned downtime risk.

During project implementation, the technical team was on-site throughout the process, completing the replacement of old equipment and system debugging within 72 hours, and conducting special training for maintenance personnel to ensure seamless connection.


Results: Breakthrough in Economic and Environmental Benefits
Since the equipment was put into operation, significant results have been achieved:

Improved Combustion Efficiency The oxygen control error has been reduced to within 0.3%, the boiler thermal efficiency has increased by 1.2%, and the annual saving of standard coal exceeds 5,000 tons;

Reduced Maintenance Costs Annual maintenance frequency reduced by 80%, spare parts expenditure reduced by 65%;

Emission Reduction Compliance The concentration of nitrogen oxides emissions is stably below 50 mg/Nm³, helping the power plant pass environmental protection assessment.

"This is one of our most successful technical transformation cases in recent years." feedback from the Xinjiang Huadong project team, "The new equipment not only provides accurate data, but its self-diagnosis function greatly reduces the maintenance pressure and provides reliable support for the construction of a smart power plant."


Industry Demonstration Significance
The successful implementation of this project has provided a benchmark solution for oxygen monitoring in high-dust and high-humidity environments. Currently, Xinjiang Huadong has promoted this product to three other units and plans to include it in the Group's green technical transformation recommendation list. In the future, the two parties will carry out in-depth cooperation in the field of combustion optimization big data analysis, jointly exploring the path of low-carbon transformation of thermal power.


Conclusion
Empowering the upgrading of traditional energy with technological innovation is the only way under the "dual carbon" goal. We look forward to working with more partners to promote the greening of industry with precise measurement technology and contribute to global sustainable development.


【About Us】
Anhui Tianfen Instrument Co., Ltd. has focused on the field of gas analysis for 20 years. Its products are widely used in the power, metallurgy, petrochemical and other industries, and has served more than 3,000 customers worldwide. If you need a customized solution, please contact: 18225808093 (WeChat same number)

 

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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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