Zirconia Oxygen Sensors are renowned for their exceptional precision and durability in high-temperature applications. This technology exploits the ionic conductivity properties of zirconium dioxide (ZrO₂) when exposed to varying levels of oxygen.
Principle of Operation
Zirconia sensors work based on the principle that zirconium dioxide becomes ionically conductive at high temperatures. When heated above 600°C, ZrO₂ can conduct oxygen ions from a high oxygen partial pressure area to a low one. A zirconia sensor incorporates a zirconia ceramic coated with thin platinum electrodes on both sides. The difference in oxygen concentration between the two sides generates a voltage across the ceramic, which is directly proportional to the oxygen concentration. This electromotive force (EMF) measurement provides the oxygen level.
Design and Components
1. Zirconia Element: A solid electrolyte made from zirconium dioxide that conducts oxygen ions at high temperatures.
2. Electrodes: Platinum electrodes are applied on both sides of the zirconia element to facilitate the transfer of ions and the measurement of EMF.
3. Heater: An integral heating element is necessary to maintain the zirconia at the required temperature for ionic conduction.
4. MSRS Sensor Cells: These feature a metal-supported structure enhancing the mechanical stability and thermal shock resistance, particularly beneficial in fluctuating temperature environments.
5. MIPS Sensor Cells: Utilizing a metal-insulated planar structure, these cells offer improved insulation and durability, optimizing performance in harsh operational conditions.
Advantages
- High Temperature Operation: Zirconia sensors excel in high-temperature environments, making them ideal for industrial processes that involve combustion.
- Longevity and Stability: Known for their long operational life and stability, even under harsh conditions.
- Accuracy: Provide highly accurate oxygen measurements, crucial for optimizing combustion processes and reducing emissions.
- Enhanced Durability: MSRS and MIPS designs contribute to enhanced durability and reliability in variable and extreme conditions.
Applications
- Industrial Combustion: Monitoring and controlling oxygen levels in furnaces, boilers, and industrial heaters to ensure efficient fuel usage and minimize emissions.
- Gas Generation: Used to measure gas quality in a N2 or Ar gas generator.
- Additive Manufacturing: Used to measure N2 purge of print chamber to ensure inert printing environment.
Zirconia oxygen sensors are especially useful in settings that demand precise control and measurement of oxygen levels at high temperatures:
Zirconia oxygen sensing technology, especially with the integration of MSRS and MIPS sensor cells, offers unmatched performance in high-temperature applications, providing critical data for optimizing industrial processes. Its ability to withstand extreme environments and deliver precise measurements makes it an invaluable tool in industries where efficiency and emission control are a priority.