An oxygen analyzer sensor, or lambda sensor, is an electronic device that measures the proportion of oxygen (O2) in the gas or liquid being analyzed. It was developed by Robert Bosch GmbH during the late 1960s under supervision by Dr. Günter Bauman. The original sensing element is made with a thimble-shaped zirconia ceramic coated on both the exhaust and reference sides with a thin layer of platinum and comes in both heated and unheated forms. The planar-style sensor entered the market in 1998 (also pioneered by Robert Bosch GmbH) and significantly reduced the mass of the ceramic sensing element as well as incorporating the heater within the ceramic structure. This resulted in a sensor that both started operating sooner and responded faster. The most common application is to measure the exhaust gas concentration of oxygen for internal combustion engines in automobiles and other vehicles. Divers also use a similar device to measure the partial pressure of oxygen in their breathing gas.
Scientists use oxygen sensors to measure respiration or production of oxygen and use a different approach. Oxygen sensors are used in oxygen analyzers which find a lot of use in medical applications such as anesthesia monitors, respirators and oxygen concentrators.
There are many different ways of measuring oxygen and these include technologies such as zirconia, electrochemical (also known as Galvanic), infrared, ultrasonic and very recently laser. Each method has its own advantages and disadvantages.
Saturday, December 6, 2008
Oxygen O2 Analyzer - H2S
Friday, December 5, 2008
Oxygen sensor
An oxygen sensor, or lambda sensor, is an electronic device that measures the proportion of oxygen (O2) in the gas or liquid being analyzed. It was developed by Robert Bosch GmbH during the late 1960s under supervision by Dr. Günter Bauman. The original sensing element is made with a thimble-shaped zirconia ceramic coated on both the exhaust and reference sides with a thin layer of platinum and comes in both heated and unheated forms. The planar-style sensor entered the market in 1998 (also pioneered by Robert Bosch GmbH) and significantly reduced the mass of the ceramic sensing element as well as incorporating the heater within the ceramic structure. This resulted in a sensor that both started operating sooner and responded faster. The most common application is to measure the exhaust gas concentration of oxygen for internal combustion engines in automobiles and other vehicles. Divers also use a similar device to measure the partial pressure of oxygen in their breathing gas.
Scientists use oxygen sensors to measure respiration or production of oxygen and use a different approach. Oxygen sensors are used in oxygen analyzers which find a lot of use in medical applications such as anesthesia monitors, respirators and oxygen concentrators.
There are many different ways of measuring oxygen and these include technologies such as zirconia, electrochemical (also known as Galvanic), infrared, ultrasonic and very recently laser. Each method has its own advantages and disadvantages.
Automotive applications
Automotive oxygen sensors, colloquially known as O2 sensors, make modern electronic fuel injection and emission control possible. They determine if the air fuel ratio exiting a gas-combustion engine is rich (with unburnt fuel vapor) or lean (with excess oxygen). Closed-loop feedback-controlled fuel injection varies the fuel injector output according to real-time sensor data rather than operating with a predetermined (open-loop) fuel map. In addition to improving overall engine operation, they reduce the amounts of both unburnt fuel and oxides of nitrogen from entering the atmosphere. Unburnt fuel is pollution in the form of air-borne hydrocarbons, while oxides of nitrogen (NOx gases) are a result of excess air in the fuel mixture and cause smog and acid rain. Volvo was the first automobile manufacturer to employ this technology in the late 70s, along with the 3-way catalyst.
Information on oxygen concentration is sent to the engine management computer or ECU, which adjusts the mixture to give the engine the best possible fuel economy and lowest possible exhaust emissions. Failure of these sensors, either through normal aging, the use of leaded fuels, or fuel contamination with silicones or silicates, for example, can lead to damage of an automobile's catalytic converter and expensive repairs.
Tampering with or modifying the signal that the oxygen sensor sends to the engine computer can be detrimental to emissions control and can even damage the engine. When the engine is under low-load conditions (such as when accelerating very gently, or maintaining a constant speed), it is operating in 'closed-loop mode'. This refers to a feedback loop between the fuel injectors and the oxygen sensor, to maintain stoichiometric ratio. If modifications cause the mixture to run lean, there will be a slight increase in fuel economy, but a possible increase in nitrogen oxide emissions (dependent on excess air and high combustion temperatures although leaner mixtures have lower peak temperatures due to a slower burn), possible misfiring (at ultra-lean mixtures), and slightly higher exhaust gas temperatures. If modifications cause the mixture to run rich, then there will be a slight increase in power, again at the risk of overheating and igniting the catalytic converter, while decreasing fuel economy and increasing hydrocarbon emissions.
When an internal combustion engine is under high load (such as when using wide open throttle), the output of the oxygen sensor is ignored, and the engine automatically enriches the mixture to protect the engine. Any changes in the sensor output will be ignored in this state, as are changes from the air flow meter, which might otherwise lower engine performance due to the mixture being too rich or too lean, and increase the risk of engine damage due to detonation if the mixture is too lean.
Function of a lambda probe
Lambda probes are used to reduce vehicle emissions by ensuring that engines burn their fuel efficiently and cleanly. Robert Bosch GmbH introduced the first automotive lambda probe in 1976, and it was first used by Volvo and Saab in that year. The sensors were introduced in the US from about 1980, and were required on all models of cars in many countries in Europe in 1993.
By measuring the proportion of oxygen in the remaining exhaust gas, and by knowing the volume and temperature of the air entering the cylinders amongst other things, an ECU can use look-up tables to determine the amount of fuel required to burn at the stoichiometric ratio (14.7:1 air:fuel by mass for gasoline) to ensure complete combustion.
The probe
The sensor element is a ceramic cylinder plated inside and out with porous platinum electrodes; the whole assembly is protected by a metal gauze. It operates by measuring the difference in oxygen between the exhaust gas and the external air, and generates a voltage or changes its resistance depending on the difference between the two. The sensors only work effectively when heated to approximately 800°C (1,472F), so most newer lambda probes have heating elements encased in the ceramic to bring the ceramic tip up to temperature quickly when the exhaust is cold. The probe typically has four wires attached to it: two for the lambda output, and two for the heater power, although some automakers use a common ground for the sensor element and heaters, resulting in three wires. Earlier non-electrically-heated sensors had one or two wires.
The probe
The sensor element is a ceramic cylinder plated inside and out with porous platinum electrodes; the whole assembly is protected by a metal gauze. It operates by measuring the difference in oxygen between the exhaust gas and the external air, and generates a voltage or changes its resistance depending on the difference between the two. The sensors only work effectively when heated to approximately 800°C (1,472F), so most newer lambda probes have heating elements encased in the ceramic to bring the ceramic tip up to temperature quickly when the exhaust is cold. The probe typically has four wires attached to it: two for the lambda output, and two for the heater power, although some automakers use a common ground for the sensor element and heaters, resulting in three wires. Earlier non-electrically-heated sensors had one or two wires.
Operation of the probe
The zirconium dioxide, or zirconia, lambda sensor is based on a solid-state electrochemical fuel cell called the Nernst cell. Its two electrodes provide an output voltage corresponding to the quantity of oxygen in the exhaust relative to that in the atmosphere. An output voltage of 0.2 V (200 mV) DC represents a lean mixture. That is one where the amount of oxygen entering the cylinder is sufficient to fully oxidize the carbon monoxide (CO), produced in burning the air and fuel, into carbon dioxide (CO2). A reading of 0.8 V (800 mV) DC represents a rich mixture, one which is high in unburned fuel and low in remaining oxygen. The ideal point is 0.45 V (450 mV) DC; this is where the quantities of air and fuel are in the optimum ratio, called the stoichiometric point, and the exhaust output mainly consists of fully oxidized CO2.
The voltage produced by the sensor is so nonlinear with respect to oxygen concentration that it is impractical for the engine control unit (ECU) to measure intermediate values - it merely registers "lean" or "rich", and periodically adjusts the fuel/air mixture to keep the output of the sensor alternating between these two states. The time period chosen by the ECU to monitor the sensor and adjust the fuel/air mixture creates an inevitable delay, which makes this system less responsive than one using a linear sensor (see below). The shorter the time period, the higher the so-called "cross count"and the more responsive the system.
The zirconia sensor is of the 'narrow band' type, referring to the narrow range of fuel/air ratios to which it responds.
Oxygen Sensor Types
Today’s oxygen analyzers use one of a several types of oxygen sensors. As industrial process applications call for improved measurement accuracy and repeatability, users are also demanding analyzers that require a minimum of maintenance and calibration. To this end, users of oxygen analyzers are encouraged to evaluate the merits of a particular oxygen sensor type in context to the application for which it is intended. There is no one universal oxygen sensor type.
The synoptic review of the various gas phase oxygen sensors provided below should be used in conjunction with information gathered from manufacturers of oxygen analyzers. This combination will help to ensure the selection of the right sensor type for the application under consideration.
* Ambient Temperature Electrochemical Oxygen Senors
* Paramagnetic Oxygen Sensors
* Polarographic Oxygen Sensors
* Zirconium Oxide Oxygen Sensors
Ambient Temperature Electrochemical Oxygen Sensors
The ambient temperature electrochemical sensor, often referred to as a galvanic sensor, is typically a small, partially sealed, cylindrical device (1-1/4” diameter by 0.75” height) that contains two dissimilar electrodes immersed in an aqueous electrolyte, commonly potassium hydroxide. As oxygen molecules diffuse through a semi-permeable membrane installed on one side of the sensor, the oxygen molecules are reduced at the cathode to form a positively charge hydroxyl ion. The hydroxyl ion migrates to the sensor anode where an oxidation reaction takes place. The resultant reduction/oxidation reaction generates an electrical current proportional to the oxygen concentration in the sample gas. The current generated is both measured and conditioned with external electronics and displayed on a digital panel meter either in percent or parts per million concentrations. With the advance in mechanical designs, refinements in electrode materials, and enhanced electrolyte formulations, the galvanic oxygen sensor provides extended life over earlier versions, and are recognized for their accuracy in both the percent and traces oxygen ranges. Response times have also been improved. A major limitation of ambient temperature electrochemical sensors is their susceptibility to damage when used with samples containing acid gas species such as hydrogen sulfide, hydrogen chloride, sulfur dioxide, etc. Unless the offending gas constituent is scrubbed prior to analysis, their presence will greatly shorten the life of the sensor. The galvanic sensor is also susceptible to over pressurization. For applications where the sample pressure is > 5 psig, a pressure regulator or control valve is normally recommended.
Polarographic Oxygen Sensors
The polarographic oxygen sensor is often referred to as a Clark Cell [J. L. Clark (1822- 1898)]. In this type of sensor, both the anode (typically silver) and cathode (typically gold) are immersed in an aqueous electrolyte of potassium chloride. The electrodes are separated from the sample by a semi-permeable membrane that provides the mechanism to diffuse oxygen into the sensor. The silver anode is typically held at a potential of 0.8V (polarizing voltage) with respect to the gold cathode. Molecular oxygen is consumed electrochemically with an accompanying flow of electrical current directly proportional to the oxygen concentration based on Faraday’s law. The current output generated from the sensor is measured and amplified electronically to provide a percent oxygen measurement. One of the advantages of the polarographic oxygen sensor is that while inoperative, there is no consumption of the electrode (anode). Storage times are almost indefinite. Similar to the galvanic oxygen sensor, they are not position sensitive. Because of the unique design of the polarographic oxygen sensor, it is the sensor of choice for dissolved oxygen measurements in liquids. For gas phase oxygen measurements, the polarographic oxygen sensor is suitable for percent level oxygen measurements only. The relatively high sensor replacement frequency is another potential drawback, as is the issue of maintaining the sensor membrane and electrolyte.
A variant to the polarographic Oxygen Sensor is what some manufacturers refer to as a non-depleting coulometric sensor where two similar electrodes are immersed in an electrolyte consisting of potassium hydroxide. Typically, an external EMF of 1.3 VDC is applied across both electrodes which acts as the driving mechanism for reduction/oxidation reaction. The electrical current resulting from this reaction is directly proportional to the oxygen concentration in the sample gas. As is the case with other sensor types, the signal derived from the sensor is amplified and conditioned prior to displaying. Unlike the conventional polarographic oxygen sensor, this type of sensor can be used for both percent and trace oxygen measurements. However, unlike the zirconium oxide, one sensor cannot be used to measure both high percentage levels as well as trace concentrations of oxygen. One major advantage of this sensor type is its ability to measure parts per billion levels of oxygen. The sensors are position sensitive and replacement costs are quite expensive, in some cases, paralleling that of an entire analyzer of another sensor type. They are not recommended for applications where oxygen concentrations exceed 25%.
Zirconium Oxide Oxygen Sensors
This type of sensor is occasionally referred to as the “high temperature” electrochemical sensor and is based on the Nernst principle [W. H. Nernst (1864-1941)]. Zirconium oxide sensors use a solid state electrolyte typically fabricated from zirconium oxide stabilized with yttrium oxide. The zirconium oxide probe is plated on opposing sides with platinum which serves as the sensor electrodes. For a zirconium oxide sensor to operate properly, it must be heated to approximately 650 degrees Centigrade. At this temperature, on a molecular basis, the zirconium lattice becomes porous, allowing the movement of oxygen ions from a higher concentration of oxygen to a lower one, based on the partial pressure of oxygen. To create this partial pressure differential, one electrode is usually exposed to air (20.9% oxygen) while the other electrode is exposed to the sample gas. The movement of oxygen ions across the zirconium oxide produces a voltage between the two electrodes, the magnitude of which is based on the oxygen partial pressure differential created by the reference gas and sample gas. The zirconium oxide oxygen sensor exhibits excellent response time characteristics. Another virtue is that the same sensor can be used to measure 100% oxygen, as well as parts per billion concentrations. Due to the high temperatures of operation, the life of the sensor can be shortened by on/off operation. The coefficients of expansions associated with the materials of construction are such that the constant heating and cooling often causes “sensor fatigue”. A major limitation of zirconium oxide oxygen sensors is their unsuitability for trace oxygen measurements when reducing gases (hydrocarbons of any species, hydrogen, and carbon monoxide) are present in the sample gas. At operating temperatures of 650 degrees Centigrade, the reducing gases will react with the oxygen, consuming it prior to measurement thus producing a lower than actual oxygen reading. The magnitude of the error is proportional to the concentration of reducing gas. Zirconium oxide oxygen sensors are the “defacto standard” for in-situ combustion control applications.
Other types of oxygen measuring techniques are under development and in some cases being used for specific applications. They include, but are not limited to, luminescence polarization, opto-chemical sensors, laser gas sensors, et al. As these techniques are further developed and improved, they may represent viable alternatives to the major oxygen sensor types currently in use.