Durable Zirconia-Based Oxygen Sensors for Industrial Use
Robust and precise oxygen sensing solutions optimized for emissions monitoring, combustion control, and process efficiency
Overview
Zirconia-based oxygen sensors are renowned for their durability, accuracy, and high-temperature resilience. These electrochemical devices utilize a stabilized zirconium dioxide (ZrO₂) ceramic to measure oxygen concentrations through voltage signals generated from oxygen ion migration. Unlike other technologies, zirconia sensors operate effectively in aggressive and high-heat environments, making them well-suited for combustion control, flue gas analysis, and environmental monitoring.
With long life expectancy and fast response times, they are widely deployed in industries requiring precise oxygen control to meet regulatory standards and improve efficiency. Their solid-state design ensures minimal maintenance and continuous real-time monitoring, essential for today’s demanding industrial processes.Emissions and Stack delivers a wide range of zirconia-based oxygen sensing systems tailored to your unique industrial requirements. Serving B2B clients across North America, we help organizations gain dependable oxygen monitoring solutions backed by technical support, quality engineering, and seamless integration capabilities.
Advanced Components of Zirconia Sensor Technologies
In addition to offering products and systems developed by our team and trusted partners for Zirconia-based oxygen sensors, we are proud to carry top-tier technologies from Global Advanced Operations Tek Inc. (GAO Tek Inc.) and Global Advanced Operations RFID Inc. (GAO RFID Inc.). These reliable, high-quality products and systems enhance our ability to deliver comprehensive technologies, integrations, and services you can trust. Where relevant, we have provided direct links to select products and systems from GAO Tek Inc. and GAO RFID Inc.
Hardware
- Solid-state zirconia sensor element with integrated thermocouple
- High-temperature-resistant probe housing with optional protective sheaths
- Compact mounting modules for in-situ or extractive installation
- Advanced heating elements to maintain optimal sensing temperatures
- Digital and analog signal transmitters for real-time output
Software
- Advanced signal processing algorithms for high-accuracy readings
- Calibration management tools with auto-adjustment features
- User-friendly dashboards for live data monitoring and system control
- Customizable alert and alarm triggers
- Remote access support for diagnostics and troubleshooting
Cloud Services
- Remote access and diagnostics through secure cloud interfaces
- Automated data logging with timestamped oxygen readings
- Integration-ready APIs for seamless connectivity to enterprise platforms
- Alarm notifications via SMS, email, or app push
- User permission control for secure multi-user environments
- High-temperature operation up to 850°C (1562°F)
- Fast response time (<4 seconds) for real-time measurements
- No reference gas required, enabling simplified deployment
- Long service life due to corrosion-resistant construction
- Stable output signal with minimal drift over time
- Direct insertion and extractive sampling options
- Smart calibration and auto-compensation functions
Integrations and Compatibility
Zirconia-based oxygen sensors offered by Emissions and Stack integrate seamlessly into:
- Emission monitoring systems (CEMS)
- Combustion optimization control loops
- Industrial automation platforms (SCADA, PLC, DCS)
- Data historians and cloud-based analytics platforms
We support a range of communication protocols including MODBUS RTU/TCP, 4–20mA, and RS485, ensuring broad compatibility with legacy and modern systems.
Benefits of Using Our Chemiluminescence NOx Analyzers
- Regulatory assurance with consistent, compliant oxygen data
- Minimized operational interruptions via self-monitoring systems
- Lower total cost of ownership with long-life probes and low drift
- Real-time process optimization for combustion control
- Increased safety through continuous O₂ monitoring in critical environments
- Adaptable designs for both fixed and mobile industrial units
Applications
- Combustion control in boilers, furnaces, and kilns
- Flue gas oxygen monitoring in stack emissions systems
- Air-fuel ratio optimization for process efficiency
- Environmental compliance tracking in power and manufacturing plants
- In-situ oxygen measurement in metallurgical and glass industries
- Waste-to-energy plant monitoring
Industries Served
- Power Generation
- Oil & Gas
- Cement and Lime Production
- Pulp and Paper
- Chemicals and Petrochemicals
- Waste Management and Incineration
Relevant U.S. & Canadian Industry Standards
- U.S. EPA 40 CFR Part 60
- U.S. EPA 40 CFR Part 75
- ASTM D6522
- CSA C22.2 No. 61010-1
- Environment Canada EPS 1/PG/7
Case Studies
U.S. Case Study - Steel Manufacturing Facility in Indiana
A large steel plant upgraded its combustion control system by integrating zirconia oxygen sensors from Emissions and Stack. The result was improved fuel efficiency and a 15% reduction in NOx emissions, achieving compliance with EPA regulations and reducing operating costs.
U.S. Case Study 2 - Biomass Power Plant in Georgia
Facing challenges with legacy oxygen measurement technology, a renewable energy plant adopted our zirconia-based sensors. The upgrade enabled precise combustion control, stabilized output levels, and provided automated calibration alerts, significantly improving performance and uptime.
Canadian Case Study - Waste Incineration Plant in British Columbia
A provincial waste-to-energy plant deployed our sensors for stack emissions monitoring. With continuous online measurements and cloud connectivity, plant operators gained valuable insights, streamlined compliance reporting, and ensured real-time safety checks aligned with Canadian emissions regulations.
Want to Upgrade your Emissions Monitoring or Combustion Systems with hHgh-Performance Zirconia Oxygen Sensors?
Contact Emissions and Stack today for expert consultation, custom solutions, technical support.We’re ready to help you integrate dependable, cutting-edge sensor technologies that elevate safety, efficiency,compliance.
