Zirconium oxide sensors for measuring of O2 value in waste gas
Highest measuring precision. Best sensor life cycles. Only with the Original from STG.
The more accurate and reliable the measurement of the residual oxygen in the flue gas, the closer the furnace can be operated to the low stochiometric optimum without safety excess air, which consumes energy and produces NOx.
Due to the harsh operating conditions in the hot end zone, it was originally thought that oxygen sensors in particular would only last a few months in the hot and aggressive flue gas atmosphere. The idea of using their signal as the basis for automatic control was unthinkable at the time. As a result of more than 30 years of persistent and systematic development and the many years of experience of our practical service personnel, STG can now guarantee a minimum sensor life of one year, but with an expected life of 2 to 4 years, with the best results reaching up to 9 years.
More than just displaying the O2% value, STG can derive monitoring of CO, lambda process value and XF air ingress number from the sensor mV signals. This is called "Advanced Sensor Signal Processing". Available with a stand-alone PLC / HMI or (even better) for direct implementation into your furnace control system if it is based on Siemens or Rockwell / Allen-Bradley platforms.
Going one step further, STG has developed a pioneering solution for energy efficiency and pollution reduction called "STG Lambda Control": a patented software function for automatic control of combustion air flow, compensating for any ingress of parasitic air into the melting process. The Original from STG: Essential for the efficient operation of your furnace.
Standard length: 1000 mm
Diameter: 25 mm protection tube
Probe voltage: -10 ... 1000 mV
Thermo voltage: thermocouple type B
Measuring range: 0,0 ... 80,0 % O2
Operation temperature: 700 °C ... 1.500 °C
Measuring place: regenerator crown or waste gas channel, vertical position
Economical use of energy by controlled low excess air: approx. 1,5 % energy saving potential, depending on conditions (in a combination with STG Lambda Control)
Controlled reliable near stoichiometric operation with O2 residue concentrations below 1 %, as requirement to reduce the NOx emission
Monitoring and control of air infiltration, e.g. reversal leakages, ingressed air
Monitoring and compensation of CO Peaks after reversal
Important: About 2 … 10% of combustion air results form uncontrolled air ingress, which is not detected by combustion air flow measurement!
Zirconium oxide Oxygen probes , type standard
- For typical endport furnace design: 2 sensors (each 1 left and right regenerator side)
- For typical crossfired furnace designs: depending on number of ports, from 10 (5 ports) to 14 (7 ports)
- For other designs: depending on specific melter characteristics (recuperative furnace or OxyFuel unit melter: typically 1 sensor)
Protection funnels, to use as heat protection and sensor rack
Signal cable connectors and coupling for reference air copper pipe
High temperature signal cable and reference air copper pipe
Reference air control boxes with:
- Pump for ambient air or
- Pressure regulator for compressed air
- Air filter, microflowmeter and valves
Signal Processing: Different options, see below
Installation and Start Up / Regular services (see maintenance concepts below)
STG oxygen probes are renowned for their reliability and durability. However, they are also subject to operational wear and tear in the harsh environment of the glass melting process.
In order to provide our customers with the required probe signals at all times, we offer a unique rental and service system that includes both regular service calls and the replacement of any defective probes by experienced technicians.
Our "all-inclusive" service package.
Available on a rental basis or with a post-warranty service contract.
Renting Contract:
to be disclosed before the initial installation
- Providing / installation of an oxygen measurement system on a rental basis
- incl. regular service with maintenance of the measurement, comparative measurements and replacement of all probes - at no additional cost
- incl. service hotline
- STG remains the owner of the equipment
Annual Maintenance contract:
to be disclosed at the end of the warranty period
- One-off purchase of the equipment / installation costs for an Oxygen measurement
- After disclosure of the contract at the end of the warranty: including regular service with maintenance of the measurement, comparative measurements and replacement of all probes - at no additional cost
- incl. service hotline
The customer remains the owner of the equipment
With such a contract, the customer gets exactly what he really needs - the stable and continuous O2% reading. The installation, maintenance and replacement of worn out or defective probes, on the other hand, is left to those who have learnt to do it better than anyone else under the harsh conditions of the furnace: the specialists at STG.
(Of course, we also offer individual service visits on request).
Advanced Sensor Signal Processing & Lambda Control
More than just displaying the O2% value, STG provides monitoring of CO, Lambda process value and XF air ingress number from the sensor mV signals. This is called "Advanced Sensor Signal Processing". Available with a stand-alone PLC / HMI or (even better) for direct implementation into your furnace control system if it is based on Siemens or Rockwell / Allen-Bradley platforms.
Going one step further, STG has developed a pioneering solution for energy efficiency and emissions reduction called "STG Lambda Control": a patented software function for automatic control of combustion air flow, compensating for any ingress of parasitic air into the melting process.
Compatible with all types of Furnace Control Systems
Advanced Signal processing function with:
- online monitoring of O2%
- online monitoring of CO ppm value
- online monitoring of Lambda Process value
- online monitoring of Air ingress number XF
Standalone signal processing unit (either Siemens Simatic or Rockwell / ControlLogix platform) mounted in local control box
Ready for signals implementation into existing Furnace Control System by Ethernet / Profibus / analogue 4...20mA connection
Coming with module for temporary remote access during start-up and later support
Provides necessary data for future upgrade to Lambda Control functionality
Installation and Start Up / Optimisation / Support by remote access
Available for Siemens / Rockwell (Allen-Bradley) Furnace Control Systems
Advanced Signal processing function with:
- online monitoring of O2%
- online monitoring of CO ppm value
- online monitoring of Lambda Process value
- online monitoring of Air ingress number XF
Full integration into visualisation (S7/WinCC; PCS7; iFIX; FactoryTalk)
By modification / extension of existing Furnace PLC and visualisation program (e.g. additional faceplates)
STG requires temporary access to Engineering Station with valid license and currently running program
Provides necessary data for future upgrade to Lambda Control functionality
Installation and Start Up by STG programmer(s) / Optimisation / Support by remote access
Available for Siemens and Rockwell / Allen- Bradley based Furnace Control
- either by extension of an existing Control System
- or as an integral part of a complex Furnace Control System package by STG
Available for Siemens / Rockwell (Allen-Bradley) Furnace Control Systems
Patented automatical "Lambda Control" feature for optimisation of combustion
- Detection of uncontrolled air ingress and identify its sources from oxygen sensors signals and temperatures
- Compensate typical air ingress (combustion air flow misreadings, incompletely closed reversal damper, ingress into regenerator bottom) by providing new combustion air flow setpoint
- Any air ingress into furnace chamber has to be answered by modification of furnace pressure, without affecting the overall thermal balance of the regenerators, using "temperature footprint of air ingress XF"
Full integration into visualisation (S7/WinCC; PCS7; iFIX; FactoryTalk)
By modification / extension of existing Furnace PLC and visualisation program (e.g. additional faceplates)
STG requires temporary access to Engineering Station with valid license and currently running program
Installation and Start Up by STG programmer(s) / Optimisation / Support by remote access
Available for Siemens and Rockwell / Allen- Bradley based Furnace Control
- either by extension of an existing Control System
- or as an integral part of a complex Furnace Control System package by STG
For Oxygen sensors get in touch with
Helmut Heelemann
