TechnicalInformation
ZR22G, ZR402GDirect In SituZirconia Oxygen Analyzer(Applications Volume)TI 11M12A01-01E
TI 11M12A01-01E1st Edition, May 2004 (KP)
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
Toc-2
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<Int> <Ind>
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
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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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.
2-2
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<Toc> <Ind>
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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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.
3-2
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<Toc> <Ind>
TI 11M12A01-01E
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)
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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
3-4
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<Toc> <Ind>
TI 11M12A01-01E
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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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
3-6
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<Toc> <Ind>
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
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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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
4-2
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<Toc> <Ind>
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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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
4-4
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<Toc> <Ind>
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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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
4-6
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<Toc> <Ind>
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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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
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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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
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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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
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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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
4-14
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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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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. 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
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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4-194. Applications<Toc> <Ind>
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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i<Toc> <Ind>
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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