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Boiler Efficiency – How to Improve with SST’s Oxygen Gas Sensors

This blog post will show how flue gas sensors can improve boiler efficiency while exploring some of the products available from SST Sensing that are capable of optimizing combustion processes for biomass, coal, natural gas, and oil-burning boiler systems.

All combustion processes require the correct air to fuel ratio of fuel and oxygen. Incomplete combustion creates fuel waste, an increased level of toxic emissions and potential damage, affecting the overall performance and operational costs of the boiler system. Environmental and financial impacts can be significant.

Avoiding Incomplete Combustion with SST’s Oxygen Gas Sensors

The overheads of fuel consumption are high in large scale industrial and commercial boilers and furnaces. In order to see return of investment and keep running costs to a minimum, the operation must be kept at peak efficiency.

Complete combustion requires the ideal ratio of fuel to air. This process is optimised and maintained by measuring the output oxygen level of the exhaust/flue gas by using an oxygen gas sensor in a closed loop feedback system to the boiler controller for regulating the input mix.  This is especially useful when the quality of fuel supplied may vary (i.e. gases from different sources).

Provided the air flow and the temperature is sufficient, the fuel will release high levels of energy while waste carbon molecules are oxidized to form gaseous compounds of low toxicity. This can be assured using flue gas sensors capable of monitoring the levels of oxygen released from the furnace.

Gas sensors used to improve boiler efficiency

Advanced gas sensors like the OXY-Flex Oxygen Analyser from SST Sensing, can eliminate elements of inefficiency from your boiler system by measuring the level of oxygen in flue gases and feeding data back to the boiler controller. This enables in situ monitoring of combustion boiler efficiency and regulation of the fuel and air flow input ratios to optimize combustion in real-time.

The gas sensor uses a zirconium dioxide sensing element that can readily withstand the extreme temperatures of boiler flues up to a maximum operating temperature of 400°C (752°F). It can be configured to three distinct output measuring ranges which can be communicated via 4-20mA,0-10Vdc and RS232 outputs through a closed-loop system. This non-depleting oxygen gas sensor provides peace of mind for boiler operators with a service life of up to 10 years.

OXY-FLEX Datasheet Download

Benefits of Oxygen Gas Sensors from SST Sensing

SST Sensing provides a broad range of gas sensors for combustion processes, helping facilities reduce their carbon output and improve boiler efficiency for critical procedures such as combustion.

Oxygen Gas Sensors from SST have the following unique features and benefits to help optimise your combustion boiler efficiency process:

  • Accurate from 0.1% O2 up to 25%
  • Long operating life technology – non depleting sensor cell
  • Low maintenance and easy to assemble
  • Calibrate in fresh air (20.7%) or other known oxygen concentration
  • Gas temperature up to 400⁰C
  • ISO9001:2015 certified manufacturing company
  • RoHS compliant
  • Fast response time (as low as 4s)
  • Robust stainless steel construction
  • All in one solution – sensor and electronics combined in one housing
  • Industry standard output options: 0-10V, 4-20mA, and RS232/485 RTU

If you would like any more information about using our gas sensors for boiler optimization, please do not hesitate to contact us directly.

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