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Technical Information ZR22G, ZR402G Direct In Situ Zirconia Oxygen Analyzer (Applications Volume) TI 11M12A01-01E TI 11M12A01-01E 1st Edition, May 2004 (KP)

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Page 1: TI 11M12A01-01E 01 - Yokogawa Electriccdn2.us.yokogawa.com/Directinsitu_TI_01.pdfDirect In Situ Zirconia Oxygen ... Ceramic firing furnaces ... K9473XH/K9473XJ *2: E7046EC/E7046EN

TechnicalInformation

ZR22G, ZR402GDirect In SituZirconia Oxygen Analyzer(Applications Volume)TI 11M12A01-01E

TI 11M12A01-01E1st Edition, May 2004 (KP)

Page 2: TI 11M12A01-01E 01 - Yokogawa Electriccdn2.us.yokogawa.com/Directinsitu_TI_01.pdfDirect In Situ Zirconia Oxygen ... Ceramic firing furnaces ... K9473XH/K9473XJ *2: E7046EC/E7046EN

All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

Toc-1<Int> <Ind>

May 31,2004-00

CONTENTS

ZR22G, ZR402GDirect In SituZirconia Oxygen Analyzer(Applications Volume)

1. Overview ................................................................................................. 1-1

2. Installation Guide.................................................................................... 2-12.1 Selecting an Installation Site .......................................................................... 2-1

3. System Configurations........................................................................... 3-13.1 ZR402G Direct In Situ Zirconia Oxygen Analyzer System

Block Diagrams ............................................................................................... 3-1

3.2 Selection According to Use ............................................................................ 3-2

3.3 Examples of System Component Selection Based onSample Gas Conditions .................................................................................. 3-6

4. Applications ............................................................................................ 4-14.1 Boiler ............................................................................................................... 4-1

a) Package boiler .............................................................................................. 4-1

b) Power generation boiler (Heavy oil, Gas) ....................................................... 4-2

c) Pulverized coal boiler .................................................................................... 4-3

d) Black liquor recovery boiler ........................................................................... 4-4

4.2 Iron and Steel Furnaces.................................................................................. 4-5

a) Iron & steel heating furnace........................................................................... 4-5

b) Hot blast stove (blast furnace facility) ............................................................. 4-6

c) Coke oven facility .......................................................................................... 4-7

d) Soaking pit .................................................................................................... 4-8

4.3 Ceramic, Brick, Glass & Cement Furnaces/Kilns) ........................................ 4-9

a) Rotary type lime kiln ...................................................................................... 4-9

b) Cement kiln (cyclone outlet gas).................................................................. 4-10

4.4 Petroleum Refining and Petrochemical Fired Heaters ................................4-11

a) Petroleum refinery process fired heater example ......................................... 4-12

b) Naphtha cracking furnace ........................................................................... 4-13

4.5 Garbage Incinerator ...................................................................................... 4-14

4.6 Non-Combustion Applications ..................................................................... 4-15

a) Oxygen enrichment facility .......................................................................... 4-15

b) Power generation boiler window box ........................................................... 4-16

c) Aeration tank .............................................................................................. 4-17

TI 11M12A01-01E 1st Edition

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TI 11M12A01-01E May 31,2004-00

4.7 Difficult Measurement Applications............................................................. 4-18

a) Glass melting furnace (in-furnace gas) ........................................................ 4-18

b) Calcinating furnace ..................................................................................... 4-19

c) Facilities with reducing gas atmospheres ..................................................... 4-19

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All Rights Reserved. Copyright © 2003, Yokogawa Electric Corporation TI 11M12A01-01E

1-1<Toc> <Ind> 1. Overview

May 31,2004-00

1. OverviewThe EXAxt Zircon Oxygen Analyzer (Model ZR402G) is used to monitor and control the oxygenconcentration in combustion gases, in boilers and industrial furnaces, for wide application inindustries which consume considerable energy—such as steel, electric power, oil and petro-chemical, ceramics, paper and pulp, food, or textiles, as well as incinerators and medium/smallboilers. It can help conserve energy in these industries. The ZR402G also contributes to preserva-tion of the earth’s environment in preventing global warming and air pollution by controllingcomplete combustion to reduce CO2

, SOx and NOx.

ZR22G Detector uses a high-reliability Zirconia sensor, and its heater assembly can be replacedon site. The detector is mounted, for example, on the wall of a flue and can measure the gasesdirectly.

For use in combustion gases at temperatures up to 1400°C, choose the general-use 0.15m longdetector, which is combined with ZO21P-H, the high-temperature probe protector. The converteris equipped with an LCD touch screen which has various setting displays, a calibration display,oxygen concentration trend display, with easier operation and improvement of display functions.The converter is equipped with various standard functions such as measurement and calculationas well as maintenance functions including self-test. Analyzer calibration can also be fully auto-mated— and ZR40H, an automatic calibration unit, is available. Choose the detector versionwhich best suits your needs so that an optimal combustion control system can be obtained.

Use this TI as a system selection guide and application note.

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Blank Page

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2-1<Toc> <Ind> 2. Installation Guide

May 31,2004-00

2. Installation Guide

2.1 Selecting an Installation SiteImproper installation of the detector may cause inaccurate measurement or damage in short-termservice.

(1) Easy access for inspection and maintenance.

(2) Ambient temperature does not exceed 150°C, and the terminal box is not exposed to radiantheat.

(3) A clean environment free from corrosive gases.

(4) Minimum vibration.

Typical good/bad installation examples are shown below for your reference.

Instructions for installation

Duct Gas Flow(Oriented obliquely against the gas flow)

(Installed on a a bend in the duct)

(Mounted above the horizontal)

(Subjected to condensation)

Probe ProtectorDust Guard Protector

Bad Example Good Example

F0201.EPS

Installation Site of the Converter (in case of ZR402G)

1. Allows the operator to easily read the display and operated the keys.

2. Easy access for inspection and maintenance.

3. Ambient temperature does not exceed 55°C, and temperature variations are minimal.

4. Humidity is moderate (40 to 75% RH) and no corrosive gases are present.

5. Minimum vibration.

6. Near to the detector.

7. Not exposed to direct sun light.

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TI 11M12A01-01E

2. Installation Guide

Instrument air is not available

EXA ZR402G

F0202.EPS

ZR22G Zirconia OxygenAnalyzer, Detector

➀Install the stop valve securely so that the gas does not leak.➁Use the standard gas unit.➂Use a shielded cable for the signal line.

ZR402G Converter

Stop valve

Calibration gas

ZO21S Standard gas unit

100 to240 V AC

Contact inputAnalog output, contact output(Digital output HART)

Signal(6-core shield cable)

Heater (2-core)

Instrument air is available

EXA ZR402G

ZR402G Converter

Check valveor Stop Valve

ZA8F flow setting unit

ZR22G Zirconia OxygenAnalyzer, Detector

100 to240 V AC

Air Set

Instrument airCalibration gas

Referencegas

Flowmeter Needlevalve

Zero gascylinder

Span gas

Contact inputAnalog output, contact output(Digital output HART)

Signal(6-core shield cable)

Heater (2-core)

F0203.EPS

➀Install the stop valve or check valve securely so that the gas does not leak.➁Use the flow setting unit and zero gas cylinder.➂Use a shielded cable for the signal line.

Regulator

May 31,2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

3-1<Toc> <Ind> 3. System Configurations

May 31,2004-00

3. System ConfigurationsThis section includes two types of system selection guides for direct in situ zirconiaoxygen analyzers. The reader should refer first the examples of system selection byapplication, and then examine the system block diagram and component device overviews.

3.1 ZR402G Direct In Situ Zirconia Oxygen Analyzer SystemBlock Diagrams

(1) System Selection Examples, by Application

Common

Iron & steel

Non-ferrous metals

Ceramic, brick, glass, & cement manufacture

Petroleum/Petrochemical

Pulp & paper

Other

Boiler (fuel oil, gas)

Boiler (pulverized coal, fluidized bed)

Boiler (bark, wood scrap)

Heating furnaces & soaking pits

Hot blast stove

Coke ovens & annealing furnaces

Sintering furnace

Heating, sintering, & melting furnaces

Coal kilns (rotary & vertical)

Cement kilns (cyclone outlet)

Glass melting furnaces (inside furnace)

Glass melting furnaces (flue)

Ceramic firing furnaces

Fired heaters & cracking furnaces

Black liquor recovery boilers

Electrical generating boilers (window box)

Garbage & sludge incinerators

Oxyten enrichment equipment

L1, L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

L2, L3

D5

D6, (D7)

D5, (D6)

(D5, D6)

D5, (D6)

D5, (D6)

D5, (D6)

D5, (D6)

D5

D7*1

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

H2, H3

D1, (D2)

D4

D3, (D1)

D1

D1, (D2)

D1, (D4)

D1, (D4)

D4, (D3)

D4, (D3)

D1, (D2)

D3, (D4)

D1

D1, D3

System types System typesDetector Detector

General-purpose detector(0 to 700°C)

High-temperature detector(0 to 1400°C)

The meanings of these codes are explained on the pages that follow.

Note 1: Sampling system is required due to the high pressure. T0301.EPS

The symbols such as L1 and D1 used in “the Types of System Configuration and Detector” are only applicable in this Technical Information document for quick reference. They do not appear in other literatures including the bulletin, general specifications, or user’s manual.

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3-2

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3. System Configurations

(2) System Block Diagram Types

Calibration

General typeSimpletype Manual Auto

Specification

Remarks

T0302.EPS

Systemtype No.

Name

L1

L2

L3

H1

H2

H3

General-purpose

General-purpose

General-purpose

High-temperature

High-temperature

High-temperature

using standard gas unit

using instrument air & zero gas cylinder

using instrument air & zero gas cylinder

using standard gas unit

using instrument air & zero gas cylinder

using instrument air & zero gas cylinder

: Yes : None

3.2 Selection According to UseExamples of selection according to use

T0303.EPS

System type No.

For monitoring (package boilers, etc.)

For high precision measurement for control purposes, etc.

For auto calibration options

L1/H1

L2/H2

L3/H3

(1) Type: L1 (simple measurement system)

EXA ZR402G

F0301.EPS

<1> ZR22G Zirconia Oxygen Analyzer, Detector

<2> ZR402G Converter

Stop valve

Calibration gas

<3> ZO21S Standard gas unit

100 to240 V AC

Contact inputAnalog output, contact output(Digital output HART)

Signal*1(6-core shield cable)

Heater (2-core)

May 31,2004-00

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3-3<Toc> <Ind> 3. System Configurations

(2) Type: L2 (no auto calibration)

EXA ZR402G

<2> ZR402G Converter

Check valveor Stop Valve

<3> ZA8F flow setting unit

<1> ZR22G Zirconia Oxygen Analyzer, Detector

100 to240 V AC

Air Set

Instrument airCalibration gas

Referencegas

Flowmeter Needlevalve

Zero gascylinder

Span gas

Contact inputAnalog output, contact output(Digital output HART)

Signal*1(6-core shield cable)

Heater (2-core)

Regulator

No. Check Sketch of shadeName

1

2

3

General-purpose detector (with check valve)

Detector with probe protector (same as above)

Detector with filter (same as above)

Note 1: Detector can be selected from among the following

F0302.EPSSee the detector section for details concerning detectors.

(3) Type: L3 (auto calibration)

F0303.EPS

EXA ZR402G

<1> ZR22G Zirconia Oxygen Analyzer Detector

<2> ZR402G Converter

Signal*1 (6-core shield cable)

Heater (2-core)

Reference gas

Calibration gas

Flowmeter Needlevalve

Zero gas cylinder

100 to 240 V AC

*2

Check valve

<3> ZR40H Auto-Calibration unit

Contact inputAnalog output, contact outputDigital output (HART)

lnstrument air

Regulator

Air Set

Note 1: Shield cable; Use shielded signal cables, and connect the shield to the FG terminal of the converter.

Note 2: When a zirconia oxygen analyzer is used, 100% N2 gas cannot be used as the zero gas. Use approximately 1% of O2 gas (N2-based).

May 31,2004-00

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3. System Configurations

(4) Type: H1 (simple measurement system)

EXA ZR402G

F0304.EPS

<2> ZR402G Converter

<1> High-temperature detector ZR22G-015

Calibration gas

<3> ZO21S Standard gas unit

100 to240 V AC

Contact inputAnalog output, contact output(Digital output HART)

Signal(6-core shield cable)

Air supply(1.5kgf/cm2)

Needlevalve *2

*3

Ejector ASSY

Pressure gauge ASSY

Heater (2-core)

(5) Type: H2 (no auto calibration, no safety purge)

F0305.EPS

Check Vertical downwardmounting

Horizontalmounting

Mountingorientation

Maximumtemperature (°C)

800

1400

SUS310S

SUS310S

SiC

Note 3: Selection of high temperature probe material: Necessary

CheckNeedlevalve*1

EjectorASSY*2

EjectorASSY*3

PressurekPa–0.5

–0.5 to 0.05

0.05 to 0.5

0.5 to 5

*1: K9473XH/K9473XJ*2: E7046EC/E7046EN*3: consult with YOKOGAWA

Note 2: Selection of Needle valve or Ejector

EXA ZR402G

<2> ZR402G Converter

<3> ZA8F flow setting unit

100 to240 V AC

Air Set

Instrument airCalibration gas

Regulator

Referencegas

Flowmeter Needlevalve

Zero gascylinder

Span gas

Contact inputAnalog output, contact output(Digital output HART)

Signal(6-core shield cable)

Heater (2-core)

<1> High-temperature detector ZR22G-015

Air supply(1.5kgf/cm2)

Needlevalve *2

*3

Ejector ASSY

Pressure gauge ASSY

May 31,2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

3-5<Toc> <Ind> 3. System Configurations

(6) Type: H3 (with auto calibration, with safety purge)

F0306.EPS

EXA ZR402G

<1> High-temperature detector ZR22G-015

Air supply(1.5kgf/cm2)

Needlevalve *2

*3

Ejector ASSY

Pressure gauge ASSY <2> ZR402G Converter

Signal*1 (6-core shield cable)

Heater (2-core)

Reference gas

Calibration gas

Flowmeter Needlevalve

Zero gas cylinder

100 to 240 V AC

*2

Check valve

<3> ZR40H Auto-Calibration unit

Contact inputAnalog output, contact outputDigital output (HART)

lnstrument air

Regulator

Air Set

Note 1: Shield cable; Use shielded signal cables, and connect the shield to the FG terminal of the converter.

Note 2: When a zirconia oxygen analyzer is used, 100% N2 gas cannot be used as the zero gas. Use

May 31,2004-00

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3-6

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TI 11M12A01-01E

3. System Configurations

3.3 Examples of System Component Selection Based on SampleGas Conditions

1) Detector and its accessories

F03

07.E

PS

Lo

w (

0.5

g/N

m3

or

less

)D

ust

leve

lP

ress

ure

Tem

pera

ture

(°C

)

Hig

h (

10 g

/Nm

3 o

r le

ss)

Ver

y h

igh

(20

0 g

/Nm

3 o

r le

ss)

Rem

arks

–5 t

o +

250

kPa

(No

te 1

)

Inse

rtio

nle

ngth

Abr

asiv

e

2.5

m~

3 m

No

[D1]

[D2]

[D4]

[D3]

Gen

eral

-pur

pose

dete

ctor

with

prob

e pr

otec

tor

(Not

e 2)

ZR

22G

with

ZO

21R

-L

Gen

eral

-pur

pose

dete

ctor

with

dus

tgu

ard

prot

ecto

ror

with

sic

filte

r

Gen

eral

-pur

pose

det

ecto

r w

ith p

rote

ctor

filte

r

Gen

eral

-pur

pose

det

ecto

r w

ith p

robe

pro

tect

or o

r w

ith s

ic fi

lter

(Not

e 2)

ZR

22G

with

ZO

21R

-Lor

with

K94

71U

A

ZR

22G

with

K94

71U

Cor

with

K94

71U

A

Gen

eral

-pur

pose

dete

ctor

Gen

eral

-pur

pose

dete

ctor

with

prob

e su

ppor

ter

ZR

22G

with

ZO

21R

-Lor

with

K94

71U

A

Yes

Coa

l,pu

lver

ized

coal

boi

ler,

etc.

Gen

eral

-pur

pose

dete

ctor

Less

than

2.5

m

ZR

22G

0 to 700

(Not

e 1)

Whe

n th

e pr

essu

re in

the

furn

ace

exce

eds

3 kP

a, it

is

reco

mm

ende

d th

at y

ou

com

pens

ate

the

pres

sure

. W

hen

the

pres

sure

in th

e fu

rnac

e ex

ceed

s 5

kPa,

you

m

ust p

erfo

rm p

ress

ure

com

pens

atio

n. F

or 0

.15m

pr

obe,

0.5

to 5

kP

a. N

o pr

essu

re fl

uctu

atio

n in

the

furn

ace

shou

ld b

e al

low

ed.

(Not

e 2)

Dow

nwar

d or

ient

ed m

ount

ing

pref

erre

d.

May 31,2004-00

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3-7<Toc> <Ind> 3. System Configurations

F03

08.E

PS

45°

[D5]

[D6]

[D7]

Ove

r 70

0U

p to

140

0

Hig

h-te

mpe

ratu

rede

tect

orH

igh-

tem

pera

ture

prob

e ad

apte

r

Aux

iliar

y ej

ecto

r (o

r ne

edle

val

ve)

Hig

h-te

mpe

ratu

rede

tect

orP

robe

(Not

e 1)

Con

sult

us if

pre

ssur

e is

less

than

–5

kPa

Pre

ssu

rekP

a

Pro

be

mat

eria

l

Max

imu

mte

mp

erat

ure

(°C

)

Co

nd

itio

ns

&sp

ecif

icat

ion

s

Du

st le

vel

Mounting orientation

Tem

per

atu

re (

°C)

Au

xilia

ryej

ecto

rV

alve

No

tre

qu

ired

Req

uir

edN

ot

req

uir

edN

ot

req

uir

edre

qu

ired

No

tre

qu

ired

Val

veV

alve

Au

xilia

ryej

ecto

rA

uxi

liary

ejec

tor

–0.5

to 0

to +

0.05

(Not

e 1)

+0.0

5 to

+0.

5ov

er +

0.5

Lo

w (

1 g

/Nm

2 o

r le

ss ➝

Co

nsu

lt u

s if

hig

her

)R

emar

ks

ZR

22G

-015

ZO

21P

-H-

ZR

22G

-015

ZO

21P

-H-

Nee

dle

valv

e no

tsu

pplie

dZ

R22

G-0

15

ZO

21P

-H-

(E70

46E

C o

r E

7046

EN

)

The

hig

h-te

mpe

ratu

repr

obe

adap

ter

incl

udes

a

stan

dard

mat

eria

lpr

obe.

SU

S31

0S80

0

SU

S31

0S80

0

SiC

1400

Inco

nel 6

00

Not

pos

sibl

e

1000

over

1000

Vertical downward Horizontal

ZR

22G

-015

ZO

21P

-H-

E70

46E

C

or E70

46E

NP

roje

ctio

n: 2

00 m

m m

ax.

Not

sta

ndar

d,pl

ease

cons

ult u

s.

May 31,2004-00

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3-8

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<Toc> <Ind>

TI 11M12A01-01E

3. System Configurations

2) Converter and accessories (flow setting unit, calibration gas, etc.)

F03

09.E

PS

EX

AZ

R40

2G

EX

AZ

R40

2G

EX

AZ

R40

2G

Co

nver

ter

Dev

ice

Use

ZR

402G

Non

e

Sam

e as

abo

ve

General Explosionproof

For monitoring Control/alarming Auto calibration

Without auto calibration

With auto calibration

Not available

ZR

402G

ZR

402G

ZS

8C

Cal

ibra

tio

n g

asF

low

set

tin

g u

nit

Rem

arks

ZO

21S

-�-�

*A

(sta

ndar

d ga

s un

it)

(air

set

not i

nclu

ded)

Min

imum

con

figur

atio

n fo

r

smal

l boi

ler

mon

itorin

g, e

tc.

Mos

t com

mon

con

figur

atio

n.

Sol

enoi

d va

lve

unit

for

hand

ling

unbu

rnt g

as in

ava

ilabl

e as

an

acce

ssor

y sy

stem

for

petr

oleu

m

or p

etro

chem

ical

fire

d he

ater

s.

Thi

s co

nfig

urat

ion

auto

mat

es

the

calib

ratio

n op

erat

ion.

Som

etim

es r

equi

red

for

petr

oleu

m a

nd p

etro

chem

ical

, et

c. B

e su

re to

use

with

ex

plos

ionp

roof

term

ianl

box

ty

pe d

etec

tor.

ZA

8F-

*A

(air

set

not i

nclu

ded)

ZA

8F-

*A

(air

set

not i

nclu

ded)

ZR

40H

Cyl

inde

r:

G70

01Z

CR

egul

ator

: G70

14X

F

G70

13X

FC

ase:

E

7044

KF

Cyl

inde

r:

G70

01Z

CR

egul

ator

: G70

14X

F

G70

13X

FC

ase:

E

7044

KF

May 31,2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4-14. Applications<Toc> <Ind>

May 31,2004-00

4. ApplicationsThis section takes up typical application examples for the zirconia oxygen analyzer. Theseindividual applications are structured as follows.

Application examples: Overview of individual devices, and sample points.

Sample gas condition examples: Examples of sample gas conditions, and block diagrams andtype numbers for zirconia oxygen analyzer systems to be usedunder those conditions.

4.1 Boiler

a) Package boiler

This is the most common application. Although the system is generally used for combustionmonitoring, there are also cases in which it will be used for VVVF or other such combustioncontrol schemes.

Sample point System type

T0401.EPS

ObjectiveDetector

Boiler furnace outlet oreconomizer outlet

L1, (L2) D1, (D2) Combustion monitoring

Package boilerGas temperature: 150 to 300°CGas pressure: �0.5 kPaDust: �1 g/Nm3

Fuel: Fuel oil, kerosene, or gas

Soot Blow Nozzle

Viewport

F0401.EPS

Gas Flow

CombustionChamber

Flame

Top View

Front View Side View

Burner

Burner

Blower

Steam Drum

WaterDrum

Main Tubes

Wall Tubes

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4-2

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TI 11M12A01-01E

4. Applications

b) Power generation boiler (Heavy oil, Gas)

This is a large-scale facility in which use for combustion control is more common than for combus-tion monitoring.

In cogeneration, the majority of cases involve measurement at a single point. In electric powercompanies, measurements are performed at multiple points in a single flue.

Sample point System type

T0402.EPS

ObjectiveDetector

Boiler furnace outlet oreconomizer outlet

L2, L3 D1, (D2) Combustion monitoringO2 control

Heavy Oil

Gas

Forced Draft Fan

Air Preheater

Electric Precipitator

Fuel Pump

Economizer

Reheater

High Pressure Steam

Medium Pressure Steam

F0402.EPS

Power generation boilerTemperature: 250 to 350°CPressure: –0.1 to –0.8 kPaDust: �1 g/Nm3

Fuel: Heavy oil (crude), gas

May 31,2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4-34. Applications<Toc> <Ind>

c) Pulverized coal boiler

These are almost always large facilities such as power generation boilers; the O2 analyzer is used

for combustion monitoring and combustion control. Since the exhaust gas entrains a rather largeamount of ash dust, a detector with dust protector will be used.

Sample point System type

T0403.EPS

ObjectiveDetector

Economizer outlet (economizer, feedwater afterheater)

L2, L3(detector with probe

protector)D4 Combustion monitoring

O2 control

F0403.EPS

Ash

Steam

Boiler MainUnit

ExhaustGas

Drum

Fuel

SuperheaterDust Guard

Horizontal Superheater

Abrasion Due to Dust

Probe Pipe

Probe Protector

Economizer

AirHeater

ElectricPrecipitator

Pulverized coal boilerGas temperature: 300 to 400°CGas pressure: –1.5 to +1.5 kPaDust: Approximately 15 g/Nm3

Fuel: Pulverized coal

AshCentrifugal Force

High Density Dust

Dust Flow Direction: Optimum mounting position

: Second best mounting position

May 31,2004-00

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4-4

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TI 11M12A01-01E

4. Applications

d) Black liquor recovery boiler

The spent liquor in a pulp production process is commonly referred to as “black liquor”. Thesodium carbonate and sulfate components in this black liquor are recovered by burning it andusing the heat to generate steam. The oxygen analyzer is used to monitor or control the combus-tion in the combustion facility (boiler). Since the exhaust gas includes large amounts of dust(hydrated sodium sulfate) and water vapor, a detector with filter is selected.

Sample point System type

T0451.EPS

ObjectiveDetector

Economizer: Outlet (economizer, feedwater preheater)

L2, L3(detector with filter)

D3, (D4) Combustion monitoring

F0451.EPS

Black liquor recovery boilerGas temperature: 170 to 200°CGas pressure: +2 kPaDust: 6 to 15 g/Nm3

Main dust components: Na2SO4�90% Na2CO3�10%

May 31,2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4-54. Applications<Toc> <Ind>

4.2 Iron and Steel Furnaces

a) Iron & steel heating furnace

These furnaces are for the heating of steel slabs, and generally the measured gas is at a hightemperature of 1000°C or above. The oxygen concentration is controlled to a low level to preventoxidation of the slabs. These are also some cases in which there is some amount of CO in thegas, and in which magnetic oxygen analyzers or infrared type CO analyzers are used.

Sample point System type

T0452.EPS

ObjectiveDetector

Preheat zone, heating zone,soaking zone

H2, H3 D5 Combustion monitoring

F0452.EPS

Iron & steel heating furnaceTemperature: 900 to 1400°CPressure: 0.03 to 0.05 kPaDust: MinuteFuel: Gas

May 31,2004-00

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4-6

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TI 11M12A01-01E

4. Applications

b) Hot blast stove (blast furnace facility)

The hot blast stove is a facility used to heat the air used in a blast furnace to provide the high-temperature hot air blast.

The air is heated by combustion of the gas generated from the coke ovens. The O2 analyzer is

used to control or monitor this combustion.

Sample point System type

T0404.EPS

ObjectiveDetector

Duct D1

L2, L3(If pressure is high,

a pressure compensateddetector is selected.)

Combustion monitoringO2 control

F0404.EPS

Purified Gas Bleeder Tube

Furnace Top PressureRecovery Unit

Hot Blast Stove WasteHeat Recovery

C-gas

Combustion Blowers

BlastFurnace

Hot blast stoveTemperature: 20 to 350°CPressure: 3.5 to 10 kPaDust: 50 mg/Nm3

Fuel: Gas

DustPrecipitator

May 31,2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4-74. Applications<Toc> <Ind>

c) Coke oven facility

This facility is used to produce the coke used in the blast furnace.

The O2 analyzer is used to monitor the exhaust gas from the heater combustion used for destruc-

tive distillation of the coal.

Sample point System type

T0405.EPS

ObjectiveDetector

Flue L2, L3 D1, (D2) Combustion monitoring

F0405.EPS

Dust Fuel Coking Chamber

CombustionChamber

Combustion Chamber

Heat Protection Chamber

Flue

Stack

Rich Gas Tube

Lean Gas Tube

Backstay

Coke oven facilityTemperature: 250 to 350°CPressure: 0.1 to 0.3 kPaDust: 100 mg/Nm3

Fuel: Gas

May 31,2004-00

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4-8

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<Toc> <Ind>

TI 11M12A01-01E

4. Applications

d) Soaking pit

The soaking pit is a type of furnace used to maintain the ingots at a constant temperature. Oxygenconcentration is controlled at a low level to suppress ingot surface oxidation.

Sample point System type

T0406.EPS

ObjectiveDetector

Ahead of recuperator H2, (H3) D5 Combustion monitoring

F0406.EPS

Soaking pitTemperature: 1000 to 1200°CPressure: 0.03 to 0.05 kPaDust: 0.5 g/Nm3

Fuel: Gas

Cover Remover

Furnace BedMaterial

Furnace CoverBurner

Preheat Air DuctRecuperator

Damper

Stack

Exhaust Gas Port

Construction of unidirectional top section combustion soaking pit.

Cinder Transport Car

Cinder Removal Device

Furnace Bed Beam

Ingot

Combustion Chamber

May 31,2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4-94. Applications<Toc> <Ind>

4.3 Ceramic, Brick, Glass & Cement Furnaces/Kilns)

a) Rotary type lime kiln

The O2 analyzer is used for combustion monitoring to conserve energy.

Careful attention to detector mounting position and orientation is required due to the presence oflarge amounts of abrasive particulates and intrusion air.

Sample point System type

T0407.EPS

ObjectiveDetector

Kiln endL2, L3

(H2, H3)D4

(D3, D5, D6)Combustion monitoring

Raw Materials

Intrusion Air

Intrusion Air

ExhaustGas

ExhaustGas

Exhaust Gas

F0407.EPS

Rotary type lime kilnTemperature: 250 to 500°C*1

Note 1: Depending on the kiln, there will be cases when the temperature at the measuring point will be 600°C or greater (600 to 750°C). Under these conditions, the high-temperature type should be used.

May 31,2004-00

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4-10

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4. Application<Toc> <Ind>

b) Cement kiln (cyclone outlet gas)

Cement production consumes approximately 100 liters or more of fuel (heavy oil) per ton ofcement. Thus, combustion management by means of O

2 analyzers has become a critical ele-

ment.

There are cases in which O2, CO, and CO

2 measurements are performed using a sampling

system at the kiln outlet.

T0410.EPS

Sample point

Cyclone outlet

System type

L2, L3

Detector

D4, (D3)

Objective

Combustion monitoring

Cement kilnTemperature: 350 to 400°CPressure: –3 to 5 kPaDust: �200 g/Nm3

CO: �0.2%F0410.EPS

May 31, 2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4-114. Applications<Toc> <Ind>

4.4 Petroleum Refining and Petrochemical Fired HeatersIn petroleum refining and petrochemical plants fired heaters are so numerous that you couldalmost say that there is one in almost every process. Also, since a site consists not of just a singlepetroleum refining process but rather of ten or more processes, this means that you have thatmany fired heaters, too (located at the arrows in the diagram above).

In addition to the fired heaters, there will also be a number of boilers. Thus combustion monitoring(or control) is a vital element.

F0411.EPS

May 31, 2004-00

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4-12

All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4. Application<Toc> <Ind>

a) Petroleum refinery process fired heater example

There are two possible locations for the sample point in fired heaters for petroleum refining andpetrochemicals: in the stack, or in the vicinity of the furnace outlet (convection zone).

T0411.EPS

Stack

Furnace outlet(convection zone)

L2, L3

H2, H3

D1, D2

D5, D6Explosion proof type with terminal box may also be selected.

T0412.EPS

Name

StackConvection

Temperature °C

Approx. 300 to 500Approx. 600 to 9002

1

Outlet

Outlet

Outlet

Inlet

Inlet

Inlet

Con

vect

ion

Sec

tion

Rad

iant

Hea

ting

Sec

tion

SteamSuperheaterSection

Process FluidPreheatSection

SteamSuperheaterSection

Petroleum refinery processfired heater

FurnaceWindow BoxAir PreheaterStackDraft BlowerExhaust Blower

F0412.EPS

1

2

1

2

3

4

5

6

1

6

4

2

5

3

May 31, 2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4-134. Applications<Toc> <Ind>

b) Naphtha cracking furnace

This is the first process in a petrochemical facility, in which the Naphtha supplied from the petro-leum refinery is heated and cracked to produce a variety of products. There will be not just onebut rather anywhere from six to twelve fired heaters, each with its own stack.

T0413.EPS

Analyzer installation locations

Sample point System type Detector Objective

Firedheaters

Stack or convection

L2, L3H2, H3

Explosionproof type external terminal box may also be selected

2

1 D1, D2D5, D6

Combustion monitoring

F0413.EPS

Naphtha

Naphtha Heater

Inorganic Oil

Gasoline

Gasoline Propane H

Propylene

Ethylene

MethaneRich Gas

Hydrogen Rich Gas

GasolineFractionater

Ethane Heater

Gas

Pre

ssur

izat

ion

Uni

t

Dem

etha

nize

r

De-

etha

niza

er

Ace

tyle

ne L

ight

ener

Eth

ylen

e Fr

actio

nate

r

Dep

ropa

nize

r

Deb

utan

izer

Pro

pyle

ne F

ract

iona

ter

1

2

Naphtha cracking furnaceTemperature: Stack: 300 to 600°CConvection: 110 to 600°CPressure: –0.2 to 0 kPaDust: 1 g/Nm3max.

May 31, 2004-00

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4-14

All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4. Application<Toc> <Ind>

4.5 Garbage IncineratorThis is a facility to handle by incineration the combustible waste generally contained in municipalgarbage.

The exhaust gas of the incinerator outlet contains large quantities of dust and corrosive gasses,and a large water vapor component.

Yokogawa should be consulted concerning the installation of the unit.

T0414.EPS

Sample point

Scrubber outlet(or stack)

Incinerator outlet(gas cooler outlet)

System type

L2, L3

Detector

D1, (D3)

D5

Objective

Combustion monitoring

Combustion monitoring

H2, H3Note: depending on the conditions at the sample point, a sampling type system may be required.

Sewage Sludge

Measured Feed

Extraction Blower

Air Preheater

CycloneScrubber

Deconsolidator

Dust

Auxiliary Blower

Pressurizing BlowerHot Blast Furnace

Denitration Tower

Electric Precipitator

Control Oil Gun

Wat

er

Wat

er

Heavy Oil

Fluidized Bed Incinerator Plant

Flu

idiz

ed B

ed F

urna

ce

Sta

rtup

Bur

ner

F0414.EPS

Garbage incineratorIncinerator outlet: 700 to 750°CExhaust gas temperature: 700 to 750°CDust: 20 to 30 g/Nm3

Exhaust gas components: SOx Several hundred ppm HCl 100ppm

Scrubber outletExhaust gas temperature: 80 to 120°CDust: 0.1 g/Nm3 maximum

May 31, 2004-00

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All Rights Reserved. Copyright © 2004, Yokogawa Electric Corporation TI 11M12A01-01E

4-154. Applications<Toc> <Ind>

4.6 Non-Combustion Applications

a) Oxygen enrichment facility

Although in most combustion systems air is used as-is, there are cases such as in blast furnacesin steel plants where the air will be enriched with oxygen gas to raise efficiency. When this isdone, oxygen analyzers are used to monitor the oxygen generation unit (air separator, etc.), and/or to check the condition of the mixing with the air in later process stages. In these cases, theoxygen analyzer will be measuring values higher than the concentration of oxygen in the air(approximately 21%).

T0415.EPS

Sample point

Air-oxygen mixing line

Oxygen supply lineOxygen compressor outlet

System type

H3 (Note 1)

H3 (Note 1)

Detector

Note 1

Note 1

Objective

Operational monitoring

Operational monitoring

Note 1: Measurement will be done using a sampling system, since all the points are at high pressure.

F0415.EPS

Air

Blast Furnace

Air Compressor

490 kPa

20 kPa

75 to 100%O2

75 to 100%O2

420 kPa

Regulator Valve

or Needle Valve

Note 1: Due to the high pressure, measurement will be done with a sampling type system.

0 to 50%O2

Air

Blast FurnaceBlowerOxygen

Generation Unit(Air Separation Unit)

Blast Furnace Oxygen Enrichment Example

490 to 780 kPa

Intake Tower

Hot Blast Stove

Oxygen GasCompressor

May 31, 2004-00

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4-16

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4. Application<Toc> <Ind>

b) Power generation boiler window box

In large boilers such as those for power generation, part of the combustion exhaust gas is re-cycled to the combustion intake, and the oxygen concentration in the recycled gas is monitoredso that it does not drop too low.

The analyzer range will be a partial range that includes the atmospheric oxygen concentration,such as 15 to 22% O2

.

T0416.EPS

Sample point

Window box

System type

L2, L3

Detector

D1 (Note)

Objective

O2, control alarm

Note 1: The ZO21DW (terminal box explosionproof type detector; pressure compensated type) or the ZR22G (pressurecompensated type) will be used. These are many cases in which the AV8C averaging converter will be used.

Power generation boiler window boxTemperature: Max. 550°CPressure: –5 to 20 kPa

F0416.EPS

May 31, 2004-00

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4-174. Applications<Toc> <Ind>

c) Aeration tank

In one type of sludge processing, oxygen gas is introduced into the processing tanks to maintainthe dissolved oxygen concentration in the sludge liquid at a proper level. Efficiency is checked bymeasuring the oxygen concentration in the exhaust gas from the processing tank.

T0417.EPS

Sample point

Exhaust line

System type

L2, L3

Detector

D1

Objective

Efficiency monitoring & alarm

F0417.EPS

Activated Sludge Processing Facility(Surface Aeration System Aeration Tank)

Control ValveOxygen

Waste Water

Returned Sludge

AgitatorGas Recycle Compressor

Mixed Liquids

Exhaust

Aeration tankTemperature: Normal temperaturePressure: 0 to 1 kPaConcentration: Approximately 50% O2 (0 to 100% range)

May 31, 2004-00

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4-18

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4. Application<Toc> <Ind>

4.7 Difficult Measurement Applications

a) Glass melting furnace (in-furnace gas)

Oxygen concentration in glass melting furnace stacks can be measured with no problems thesame as in other general combusion exhaust gas applications.

Glass melting furnace (stack): Temperature 0 to 600°C

System block diagram type No: L2, L3

On the other hand when we come to measurement of the gas inside the furnace, continuousmeasurement with a direct in-situ zirconia oxygen analyzer (high-temperature system) is eitherextremely difficult or impossible due to the dust and fumes from the components of the glass.However, since continuous measurements are being performed in some cases by the methodshown in the diagram, we offer this for your reference.

F0418.EPS

Glass melting furnace configuration & with detail of ZR22G installation

Temperature: Norm. 1,200°CMax. 1,300°CFuel: Butane gasO2: �5%Dust level: Normal...LowDuring material charging...High3 to 4 cycles/hour

1

2

3

4

Hot Water

Partial Side View

Pulled by Hood IDF

Sampling PortBurner

Material Charging Inlet

Cover

Probe (alumina, etc.)Of non-reducing material, treated as a consumable item

Note 1: High-temperature detector with probe adapter, with high- temperature probe (pipe) removed.

ExhaustGas

FilterFiber Flux BulkReplace Periodically

(Note 1) ZR22G(with K9471UA)

ZO21P-H

May 31, 2004-00

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b) Calcinating furnace

Exhaust gas oxygen concentration measurement for fluidized-bed calcination roasting furnaces,sulfur combustion furnaces and other such furnaces which burn sulfur-containing materials orelemental sulfur presents sample conditions such as the following, so direct-in-situ type zirconiaoxygen analyzers cannot be used for measurement.

Corrosive gas in exhaust gas: SO2 7 to 18%

Note, however, that the Yokogawa direct in situ type zirconia oxygen analyzers are fully capable ofmeasurement in exhaust gases containing SO2 concentrations up to 5000ppm.

c) Facilities with reducing gas atmospheres

The term “reducing gases” refers to those gases which react with metal oxides to reduce themeither to metal or to oxides of a lower degree of oxidation. These gases are composed of areducing component, of which H2 is the primary example, and an inert gas component such as N2.

These reducing gases are used for purposes such as protecting metal surfaces from oxidation ordacarbonization during heat treatment, or to improve certain properties. If an attempt is made touse a direct in-situ type zirconia oxyen analyzer in such a metal treatment furnace, the combus-tible gas (reducing gas) and oxygen in the sample gas will incite a combustion reaction like thatshown below in the high-temperature cell section (generally above 600°C), causing a negativemeasurement error, so that measurement is generally impossible under these conditions.

2CO+O2➝ 2CO2

2H2+O

2➝ 2H

2O

CH4+2O2➝ CO2+2H2O

Reference

Bulletin 11M12A01-01E

GS 11M12A01-01E

May 31, 2004-00

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May 31, 2004-00

T0418.EPS

Inquiry Sheet for Models ZR22G, and ZR402G Direct In Situ Zirconia Oxygen Analyzer

� vol% O2,

� �C,

� kPa,

� m/sec,

� g/Nm3,

� ppm,

� ppm,

� ppm,

� ppm,

Please place checkmarks in the appropriate boxes and fill in the necessary information in the blanks.

Customer

Destination of delivery

Plant name

Measurement points

2. Process conditions

2.1 Measurement gas components

2.2 Oxygen concentration

2.3 Temperature

2.4 Pressure

2.5 Gas flow

2.6 Dust type, Size

2.7 Corrosive gas

2.8 Combustible gas

2.9 Others

3. Installation site conditions

3.1 Ambient temperature

3.2 Vibration

3.3 1 Probe installation location

3.4 Instrument air supply

3.5 Converter location

3.6 Cable length between probe and converter

3.7 Calibration method

4. Quotation data

Probe Model ZR22G General-use Probe Refer to the GS11M12A01-01E for probe selection.Model ZO21P-H High Temperature Use Probe Adapter

Model ZR402G Separate type Analyzer, Converter

E7046EC /E7046EN Auxiliary Ejector for high temperature use.

Model ZO21R Probe Protector for Oxgen Analyzer

1. General information

Nor. Min. Max.

Nor.

Nor.

Nor.

Nor.

Min.

Min.

Min.

Min.

Max.

Max.

Max.

� No gas � Gas , quantity

�m quantity

� No gas � Gas , quantity

, quantity

, quantity

1. Around Probe temp. from to �C, 2. Around Converter temp. from to �C

� No vibration � Vibration

� Furnace � Stack � Others

2 Probe position � Horizontal � Vertical � Others

� Indoor � Outdoor � Covered

3 Probe insertion length (m) (Note) � 0.4, � 0.7, � 1.0, � 1.5, � 2.0, � 2.5, � 3.0, � 3.6, � 4.2, � 4.8, � 5.4

4 Flange � DIN � ANSI � Others

� Cannot be used. � Can be used. kPa

� Indoor � Outdoor � Covered (under roof)

meters

� Manual � Automatic

Quotation Qantity Description

Options (for general use) K9471UA Filter for Oxgen Analyzer

Model ZO21S Standard Gas Unit Select any one of ZO21S, ZA8F, ZR40H.

Model ZA8F Flow Setting Unit

Model ZR40H Automatic Calibration Unit

Not required if probe options are specified.

L9852CB /G7016XH Stop Valve

K9292DN /K9292DS Check Valve

G7011XF /E7040EL, G7004XF/K9473XG Air Set

G7013XF /G7014XF Pressure Regulator

ZR22A, ZR202A Heater Assembly (Spare Parts)

(Note) 3.6m or more is available only in the U.S.

Object : � indication � record � control � alarm

Fuel : � gas � oil � coal �

Power requirements V AC Hz

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