In the operation of gas boilers, accurate monitoring and control of oxygen content in flue gas is the key to ensuring combustion efficiency, reducing energy consumption and reducing pollutant emissions. As the core sensor to achieve this goal, zirconia probes have become the standard of modern industrial boiler systems with their advantages of high precision, fast response and long life. This article will discuss the application scope and technical characteristics of the probe and analyze its important role in gas boilers.
Ⅰ.Core functions of zirconia probes
The zirconia probes for gas boilers work based on the oxygen ion conductivity of solid electrolyte zirconia. By measuring the potential difference (oxygen concentration difference potential) generated by the oxygen concentration difference on both sides, the oxygen content in the flue gas is calculated in real time. Its core advantages are:
1. Wide range adaptability: It can detect oxygen concentrations of 0.1%~25%, covering the typical operating range of oil/gas boilers.
2. High temperature tolerance: The working temperature is stable at 600~850℃ and can be directly installed in high-temperature flues.
3. Strong anti-interference ability: It is immune to chemical components such as carbon monoxide and sulfide to avoid misjudgment.
Ⅱ. Application scenarios and technical adaptation
1. Gas boiler combustion optimization
In small and medium-sized gas boilers, the zirconia probe guides the burner to automatically adjust the air-fuel ratio by monitoring the flue gas oxygen content in real time. For example:
① When the oxygen content is greater than 3%, it indicates that there is too much excess air, resulting in heat loss;
② When the oxygen content is less than 1%, incomplete combustion may occur, generating carbon monoxide (CO) pollutant gas.
2. Energy saving of industrial furnaces and incinerators
In high-temperature industrial environments such as glass kilns and waste incinerators, it can monitor the oxygen content to optimize the combustion process and reduce energy waste. For example:
① When incinerating waste, dioxin (DIOX) emissions are reduced by controlling oxygen-enriched combustion;
② In glass furnaces, accurate oxygen content monitoring can improve glass purity.
3. Environmental compliance and emission control
In recent years, nitrogen oxide (NOx) emission standards have become increasingly stringent. Zirconia probes combined with low-nitrogen combustion technology can optimize the performance of denitrification systems. For example:
① In the SCR (selective catalytic reduction) system, dynamically adjust the urea injection amount according to the oxygen content to improve the denitrification efficiency;
② Meet the limit value requirement of NOx≤150 mg/m3 in the “Boiler Air Pollutant Emission Standard” (GB 13271-2014).
III. Technical Challenges and Solutions
1. Probe aging and poisoning problems: Long-term exposure to sulfide or lead vapor may cause the performance of the probe to deteriorate. Regular calibration (recommended once a quarter) or anti-poisoning probes are required.
2. Installation location optimization: The probe should be installed in a straight flue with stable flue gas flow rate and uniform temperature to avoid eddy current interference measurement.
3. Digital integration: Modern probes support 4-20mA signal output and Modbus protocol communication, and can be seamlessly connected to DCS (distributed control system) to achieve remote monitoring and data recording.
IV. Future development: intelligence and multi-parameter integration
In the future, the probe will be upgraded in the following directions:
1. Intelligent diagnostic function: built-in AI algorithm predicts probe loss and prompts maintenance cycle;
2. Multi-parameter integration: combined with temperature and pressure sensors, it provides more comprehensive combustion analysis data;
3. Miniaturized design: adapt to the needs of compact industrial equipment.
As the “eyes” of the gas boiler combustion control system, the zirconia probe not only improves energy utilization efficiency, but also provides technical support for green and low-carbon transformation. From heating boilers to industrial furnaces, its application potential continues to expand. With the advancement of the intelligent trend, this core sensor will play a more important role in the field of industrial energy conservation and environmental protection. Choosing a high-performance probe is choosing an efficient, safe and sustainable production future.
Post time: Jul-14-2025
