ABB AZ20/AZ25 Combustion Gas Oxygen Analyzers

ABB Endura AZ20/AZ25 Combustion Gas Oxygen Analyzers Overview

The ABB Endura AZ20 and AZ25 are high-quality, in-situ zirconia oxygen analyzers designed for accurate and rapid measurement of oxygen concentration in combustion gases. These analyzers are crucial for combustion optimization control, emissions monitoring, and process quality control in various industrial applications, particularly in high-temperature furnace and flue gas atmospheres.

Product Detailed Description

• Core Functionality: The primary function of the AZ20 and AZ25 is to provide direct, in-situ (meaning, directly within the process) measurement of oxygen levels. They use a zirconium oxide (zirconia) cell sensor mounted at the tip of a probe that is inserted into the flue duct or furnace. This "in-situ" technique eliminates issues like "equilibrium shift" common in extractive sampling systems where gas samples are cooled before measurement, providing a true and immediate oxygen reading.

• Measurement Principle: Based on the electrochemical properties of a zirconium oxide cell, which generates a voltage proportional to the difference in oxygen partial pressure between the measured gas and a reference air.

• Key Features (Common to both AZ20 and AZ25, with AZ25 optimized for higher temperatures):

• Direct In-situ Measurement: Provides real-time, accurate oxygen readings directly within the process.

• Zirconia Cell Technology: Utilizes ABB's proven zirconia cell design, refined over 50 years of experience, ensuring robust, long-life, and stable measurements. Metallurgically bonded, multi-layer electrode technology enhances resistance to sulphurous and reducing atmospheres.

• Fast Response: Delivers rapid oxygen readings, allowing for quick adjustments in combustion control.

• Unique Integrated Automatic Calibration System: Eliminates the need for expensive external calibration panels and ancillary equipment. The system controls the test gas sequence and detects test gas availability, preventing incorrect calibrations. This simplifies compliance with emissions monitoring regulations and reduces installation/maintenance costs.

• Robust and Durable Probe Design: Engineered for harsh industrial environments, capable of operating at high process temperatures. The AZ20 can handle up to 800 °C (1472 °F), while the AZ25 is designed for even higher temperatures, up to 1400 °C (2552 °F), making it suitable for furnace atmospheres.

• Modular Design with Easy Cell Release: Allows for easy on-site replacement of internal components and the sensor cell with basic hand tools, even after prolonged high-temperature operation, reducing downtime and maintenance costs.

• Advanced Transmitters: Equipped with modern transmitters featuring intuitive HMI for easy setup and monitoring. They typically include HART communication as standard, supported by a full Device Type Manager (DTM) for remote access and configuration. Features also include sensor performance logging and diagnostics.

• Flexible Installation: Available with various probe lengths (e.g., up to 4.0 m / 13.1 ft for AZ20, 600 to 1250 mm / 2 to 4 ft for AZ25) and industry-standard flange configurations to meet diverse application requirements. The transmitter can be probe-mounted or remotely mounted up to 100 m (328 ft).

Product Parameters (Typical, refer to specific model datasheets for exact figures):

• Measurement Principle: Zirconia (Zirconium Oxide) cell

• Measurement Range: 0 to 25% O2 (typical, consult datasheet for specific span options)

• Process Temperature Range:

• AZ20: Up to 800 °C (1472 °F)

• AZ25: Up to 1400 °C (2552 °F)

• Accuracy: Typically better than ±0.5% of full scale (or ±1% of reading, whichever is greater, varies with specific model/range).

• Response Time: Rapid, typically < 3 seconds for 90% step change.

• Output Signal: 4-20 mA DC (isolated, programmable), optionally 0-20 mA.

• Digital Outputs: 2 x User-configurable relay outputs (e.g., for alarms, calibration status).

• Digital Inputs: 2 x User-configurable digital inputs (e.g., for remote calibration initiation).

• Communication: HART protocol standard, RS485 (Modbus RTU) or other fieldbuses may be options depending on transmitter.

• Power Supply: Typically 85 to 265 V AC, 45 to 65 Hz or 24 V DC (varies by transmitter model).

• Reference Air Supply: Required (clean, dry instrument air), flow controlled by internal restrictors (typically 0.3 to 0.5 l/min).

• Test Gases: Required for calibration (zero and span gases).

• Probe Lengths: Various lengths available (e.g., 0.4 to 4.0 m for AZ20; 0.6 to 1.25 m for AZ25).

• Mounting: Flange mounting (various industrial standards available).

• Protection Class: IP65 / NEMA 4X (for transmitter/enclosure).

• Certifications: CE, UL, CSA, ATEX, IECEx for hazardous areas (depending on configuration).

Product Advantages

• Superior Accuracy and Speed: In-situ measurement with zirconia cells provides highly accurate and virtually instantaneous oxygen readings, critical for precise combustion control.

• Enhanced Reliability and Durability: Robust design and high-quality manufacturing ensure long periods of trouble-free operation even in extreme temperature and harsh flue gas conditions.

• Reduced Cost of Ownership: Unique integrated auto-calibration system reduces installation costs (no external calibration panel needed) and maintenance costs. Easy cell replacement further minimizes downtime.

• Optimized Combustion Efficiency: Accurate oxygen measurement allows for precise air/fuel ratio control, leading to improved combustion efficiency, reduced fuel consumption, and lower emissions.

• Compliance with Regulations: Built-in auto-calibration simplifies compliance with environmental emission monitoring regulations.

• Versatile Application: Wide range of probe lengths, mounting options, and high-temperature capabilities suit diverse industrial processes.

• Advanced Diagnostics: Transmitter provides comprehensive diagnostic features and performance logging for proactive maintenance.

Precautions

• Proper Installation: Strictly follow ABB's installation manual. Ensure correct insertion depth of the probe, secure flange mounting, and proper orientation to prevent condensate issues.

• Clean and Dry Air Supply: Crucial for the longevity of the zirconia cell. Always ensure the reference air supply is filtered, dry, and oil-free. Install proper air preparation units (filters, regulators) upstream.

• Electrical Connections: Follow wiring diagrams carefully for power supply, signal output, and digital I/O. Ensure proper grounding.

• Calibration Gases: Use certified and appropriate zero and span calibration gases as specified by ABB. Ensure reliable supply of these gases for automatic calibration.

• Process Conditions: Ensure the process gas temperature and composition are within the specified limits for the particular AZ20 or AZ25 model. Avoid highly corrosive or particulate-laden gases that can foul the sensor without proper filtration/purging.

• Maintenance: Although designed for low maintenance, periodic checks of the probe, air lines, and calibration system are recommended. Refer to the maintenance guide for specific schedules.

• Hazardous Areas: If installed in hazardous areas, ensure the specific model has the required explosion-proof or intrinsically safe certifications and that installation strictly adheres to local and national electrical codes for hazardous locations.

Product Applications

The ABB Endura AZ20/AZ25 analyzers are essential instruments in industries requiring precise control of combustion and emissions.

• Power Generation:

• Boilers (coal-fired, gas-fired, oil-fired) for combustion optimization and NOx/SOx reduction.

• Gas turbines for efficiency and emissions control.

• Oil & Gas / Petrochemicals:

• Furnaces and heaters in refineries and petrochemical plants.

• Flare stacks for combustion efficiency monitoring.

• Cement Production:

• Kilns and preheaters for efficient clinker production.

• Steel Industry:

• Furnaces and soaking pits for optimizing combustion and atmosphere control.

• Waste Incineration:

• Monitoring oxygen levels in incinerators to ensure complete combustion and minimize pollutants.

• Glass and Ceramics:

• Controlling furnace atmospheres for product quality and energy efficiency.

• General Industrial Furnaces/Boilers:

• Any industrial process involving combustion where accurate and reliable oxygen measurement is critical for efficiency, safety, and environmental compliance.

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