Product Overview
In-Situ Zirconia Oxygen Analyzer
- Direct insertion installation inside flue ducts, no sampling or pre-treatment needed
- Stable operation under severe high-temperature and dusty flue gas conditions
- Widely applicable to boilers, kilns, incinerators in power, metallurgy, cement, petrochemical and waste-to-energy industries
- Optional module supports combined gas detection to optimize combustion management and meet emission standards
- Delivers fast response to boost energy efficiency and cut emissions
- Compact installation space, low operating cost with no consumables
Technical Specifications
| Parameter | Specification |
| Measured Parameter | O₂ (standard); NOₓ (optional add-on module) |
| Measurement Range | 0–25% vol |
| Basic Accuracy | ±2% F.S. (Class 1 precision) |
| Repeatability | ±1.5% |
| Zero Drift | ≤ ±2% F.S. / 7 days |
| Span Drift | ≤ ±2% F.S. / 7 days |
| Response Time (T₉₀) | ≤ 5 seconds |
| Background Correction | –20 mV to +20 mV |
| Flue Gas Temperature | • <350°C: use heated probe • 350–800°C: standard in-situ probe • 800–1300°C: high-temp/explosion-proof probe |
| Output Signals | 0–10 mA DC or 4–20 mA DC (user-configurable) |
| Load Capacity | • 0–1.2 kΩ (at 0–10 mA) • 0–600 Ω (at 4–20 mA) |
| Ambient Conditions | 0–50°C, ≤90% RH |
| Power Supply | 220 V AC ±10%, 50 Hz ±5% |
| Power Consumption | Transmitter: ～8 W; Heater: ～50 W (average) |
| Probe Length Options | 0.4 m / 0.6 m / 0.8 m / 1.0 m / 1.2 m / 1.5 m (custom lengths available) |
Key Features
✅ True In-Situ Installation – No Sample Conditioning Needed
Flange-mounted direct insertion into the flue duct eliminates the need for filters, coolers, pumps, or condensate traps-reducing system cost by up to 60% and removing major failure points.
✅ Built for Extreme Conditions – 1300°C & High Dust
Sensor constructed with specialized high-temperature, corrosion-resistant ceramics and alloys. Explosion-proof versions available for hazardous zones in chemical or refining plants.
✅ Self-Ventilating Reference Air – No External Pump Required
Patented design enables natural convection of ambient air into the reference chamber-no external air supply or pump needed, simplifying installation and cutting maintenance costs.
✅ On-the-Fly Calibration – No Shutdown Required
Integrated calibration gas port allows online zero/span verification while the process is running-zero production interruption.
✅ Smart Integration – Ready for Industry 4.0
Standard 4–20 mA output + optional RS-485 with MODBUS RTU protocol ensures seamless connectivity to PLC, DCS, SCADA, or cloud-based energy management platforms.
✅ Ultra-Fast Response – Real-Time Combustion Control
T₉₀ ≤ 5 seconds with Class 1 accuracy (±2% F.S.)-fast enough for closed-loop combustion optimization, reducing fuel use and NOₓ formation instantly.
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Applications
Power & Energy
O₂ monitoring in coal-fired boilers and waste incinerators at up to 1300°C-optimizing combustion efficiency, minimizing CO/NOₓ, and supporting carbon accounting.
Metallurgy & Steel
Real-time O₂ tracking in blast furnaces, converters, and reheating furnaces-withstanding extreme dust and corrosive gases to improve yield and reduce energy consumption.
Petrochemicals & Chemicals
Fast-response O₂ control in crackers, reformers, and heaters-ensuring safe operation and compliance, with optional PLC Cooperation for automated air-fuel ratio tuning.
Cement, Glass & Ceramics
Continuous monitoring in rotary kilns and melting furnaces (>800°C)-24/7 operation without shutdowns, enabling green production and thermal efficiency gains.
Waste Treatment
Reliable performance in municipal, medical, and hazardous waste incinerators-handling wet, dirty, variable-composition flue gas for stable combustion and effective after-treatment control.
Other High-Temp Industries
Adaptable to non-ferrous smelters, asphalt plants, and more-with probe lengths from 0.4 m to 1.5 m to fit any duct depth.
Why Choose This In-Situ Zirconia Analyzer?
Unmatched Durability
Operates from 350°C to 1300°C in high-dust, corrosive flue gas-with optional explosion-proof certification for petrochemical safety.
Speed + Precision = Better Control
T₉₀ ≤ 5 s and ±2% F.S. accuracy provide the real-time data needed to cut fuel costs by 3–8% and reduce emissions.
Lower TCO – No Sampling, No Pumps, No Consumables
True in-situ design avoids condensation, adsorption, and plugging errors inherent in extractive systems-delivering higher reliability at lower lifetime cost.
Future-Ready Connectivity
4–20 mA + MODBUS RTU ensures plug-and-play integration with Siemens, Rockwell, Mitsubishi PLCs and modern digital twin platforms.
Compliance & Carbon Management
Accurate O₂ is the foundation for SCR/SNCR control and CO₂ emission calculation. Add NOₓ module for full compliance with ultra-low emission standards.
Minimal Maintenance – Ideal for Remote Sites
Self-ventilating reference air + online calibration = annual maintenance visits reduced by 50%. Perfect for unmanned or hard-to-access facilities.
FAQ
Q1: Can it really work in a 1000°C+ blast furnace? Do I need an air pump?
A1: Yes. Use the high-temperature probe (800–1300°C)-built with corrosion-resistant materials for metallurgical dust. No air pump needed: reference air flows in naturally via convection.
Q2: Is the 5-second response fast enough for automatic combustion control?
A2: Absolutely. With T₉₀ ≤ 5 s and Class 1 accuracy, it's ideal for closed-loop air-fuel ratio control in boilers and kilns-proven to improve thermal efficiency and cut fuel bills.
Q3: How do I calibrate it? Does the process need to stop?
A3: No shutdown required. Simply connect a calibration gas cylinder to the built-in port and perform online zero/span checks during normal operation.
Q4: Can it connect to our existing Siemens/Allen-Bradley PLC?
A4: Yes. Standard 4–20 mA output works out of the box. With the RS-485 + MODBUS RTU option, it integrates directly with all major PLC brands for real-time data access.
Q5: Can it measure NOₓ, or just oxygen?
A5: Base model delivers high-precision O₂ only. For O₂ + NOₓ co-monitoring, add the optional NOₓ sensor module-ideal for ultra-low NOₓ compliance or carbon-nitrogen control strategies.
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