LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Ceramic Gas Sensors for

Optimisation of Combustion

Processes

Dr.-Ing Frank Hammer
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Outline

› Overview of LAMTEC

› Sensor Technology

› Manufacturing Technology

› Combustion Optimisation

› Application

› Summary

› References
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Overview of LAMTEC - Company Profile

› LAMTEC Sensors and Systems for Combustion Engineering (LAMTEC 

Meß- und Regeltechnik für Feuerungen GmbH & Co. KG) 

Wiesenstraße 6, 69190 Walldorf, Germany

› Established: 1st Juli 1995 as MBO from ABB

› Shareholders: Dipl.-Ing. Hans-Jürgen Altendorf, Dipl.-Ing. Bernd Jülg, Dipl.-

Ing. Harald Weber, Olaf Winne

› Subsidaries/ Associated Companies: 

• LAMTEC-Leipzig GmbH & Co. KG, Germany (100%)

• LAMTEC EA Buchon EA Buchon South Korea (80%) Jan. 2006

• LAMTEC Poland

• LAMTEC SEA Ltd. Kuching Malaysia (2010)

• OOO LAMTEC Moscow (2012),

• Escube GmbH & Co. KG Stuttgart, Germany (100%)

› Employees: 100 (2 trainees)

› Turnover 2013: 14.3 Mio. €
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Overview of LAMTEC - Locations

Headquarter Walldorf LAMTEC EAST ASIA Ltd.

Buchon, South Korea

LAMTEC Leipzig

Development of hard- and software

Manufacture of flame scanners

LAMTEC Neu Anspach

Development of electronics
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Overview of LAMTEC - Products/Applications

LAMTEC

Products/Applications

Customers

Electronic burner

control system

Fuel-/air ratio control

IR/UV

Flame monitoring 

system

Process and fault 

indicator system

O2 measurement devices

Option:

Detection of non-burned

CO/H2

Boiler manufacturer

Plant manufacturer

Measurement device 

manufacturer

Burner 

manufacturer Industry

Applications:

Power plant/waste combustion

Chemical industry

Industrial application

Measuring- and control technology

Research facilities and development
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Overview of LAMTEC - Sales Partner
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Overview of LAMTEC - Product Range

Burner Control

Electronic Fuel-/Air Ratio Control

Volume Flow Measurement

Flame Detection

O2 Optimization

O2 Measurement

CO/O2 Monitoring

Process and Fault Indicator System

Product Range
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Sensor Technology – Non-Nernst Principle

Design of a CO measurement cell

Non-Nernst Sensor Voltage

cathode

Ad. phase:

Gas phase: pO2=21%, pCO=1%, (Rest N2)

O2,ad= 90%, COad= 10% O2,ad= 99%, COad= 1%

US

Solid Electrolysis





 



 ⋅ R

=

ad A

ad K

CO

CO

S C

C

F

T U ,

,

ln

2
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Sensor Technology – The Sensor Voltage

› Langmuir adsorption isotherm

• monomolecular adsorption layer

• ads./des. in stationary state condition (SS)

› US is a function the coverage of anode and cathode Θ A, Θ K

• KA=KK :identical reaction kinetics SS-constants through

identical reactions (TE=TK=TS, one measurement

element)

• ∆g ad,A ≈ ∆g ad,K :Comparison of Gibbs enthalpies through similar

adsorbents/adsorbate binding strength (identical basic

materials of electrodes on three phase boundary, alloy of

two phase layer for modification of adsorption on the

anode)

































− Θ ⋅Θ

Θ ⋅ − Θ

+

R

∆ − ∆

+















Κ

Κ ⋅ R

=

K A

ad A ad K K A

K

A

S

S

S

T

g g

F

T

U

(1 )

(1 ) ln ln

2

, ,

R⋅ )

∆

⋅



 





− Θ

Θ

= ⋅ S

ad

ad

T

g

CO e

K

c (

1

1
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Sensor Technology – The CO Sensor

Characteristics of 

Sensor

› planar

› multi-layer

› miniaturised

Functions of Sensor

› Solid electrolyte

› Non-Nernst principle

› electrocatalytic

electrode

Carrier substrate

3,5

2

0

t=0,6

Contact 

point

Zirkonia

Heating coil

Glass cover

Electrode 1 Electrode 2
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Manufacturing Technology – Thick Film Technology

Screen process 

engineering: 

› flexible

› cost-efficient

› reproducible

› mass producible

squegee

Screen

jump

screen

tension

screen

squegee

angle

pressed

thick film

carrier substrate screen printing paste
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Manufacturing Technology – Raw Materials

Sensor materials

› Al2O3-carrier substrate

› YSZ-functional ceramics

› Pt-heating coil

› Pt cathode/Pt-alloy anode

› Special glass cover

Innovative aspects

› laser technology

› hybrid layer technology

› sub-μ and nano-powder

› ceramic printing pastes

Solution

II

Solution

III

Solution

IV

printing

Medium

Solution 

V

paste

HO

destilled 2

Solution

I

stir 400 U/min

25 °C

400 U/min

60 °C, 5 min

400 U/min

25 °C, 2 min

400 U/min

25 °C, 2 min

400 U/min

25 °C, 2 min

400 U/min

25 °C, 2 min

Cool down

500 U/min

65 °C, 45 min

100 Umin

25 °C, 60 min

Solution

V

Binder I

Plasticisers

Disperging

agents

Binder II

Defoamer

Ceramic

powder

Moisturizers

screen

printing

Screen

stir

stir

stir

stir

stir

stir
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Manufacturing Technology – Process Optimisation

Simplification of the

production steps through

› Co-firing which is used in 

the multi-layer process of

the manufactured

sensors

A decrease in 

› Production steps

› Production time

› Tempering processes

› Sintering time

› Energy costs

› Manufacturing costs

Production chains with integrated process controls

co-firing

Printing Electrode 1

Drying

Printing Electrode 2

Check/Testing

Drying

Printing heating oil

Drying

Printing YSZ-Ceramic

Presintering

Paste preparation

Ventilation

Portioning

Positioning

Screen /SMD moulding

Cleaning of substances

Mechanism

Positioning

Carrier substrate

Cleaning of substances

Degreasing

Positioning

Activation Electrode 2

Preliminary test

Hard machining

Final testing

Check/Testing

Check/Testing

Check/Testing

Check/Testing

Check/Testing

Check/Testing

Check/Testing

Check/Testing

Check/Testing

Check/Testing Check/Testing Check/Testing
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Manufacturing Technology – Sensor Optimisation

Thermal analysis

› instationary heating performance

› stationary temperature distribution

› stationary voltage distribution

 optimal sensor geometry

Thermography measurement

› comparison between theory and practice

› calculation of the sensor temperature TS

from the electrical operating data Rh 

 optimal operating temperature

500

600

700

800

900

13 15 17 19 21 23 25

y = 0.7673x

2 +17.139x+ 76.959 

R2

= 0.997

c)

Heating resistor Rn in Ω 

Sensor temperature Ts in K
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Application – The Sensor System

Sensors / Housing

› small (< 3W)

› robust (> 3 Jahre) 

› temperature stability (< 200°C / 500°C)

› cost efficient (< 15€)

› fast (< 1s)

Elektronics (exaple)

› supply unit 14-20 V 

› temperature control

› signal processing

› analogue outputs 0-10 V or 0/4-20mA

› relay outputs
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Application: Combustion Technology

Today: Combustion Systems

› Fossil fuels

• Limited resources

 (coal, gas, oil)

› Pollutant emission

• CO, NOx, CO2 etc.

› Danger: Global warming

Monitoring and Control of

Combustion Systems

Tommorow: Fuel Cells

› Chemical reacting agents

• Unlimited resources

(H2+ atmospheric oxygen)

› Pollutant emission

• No

› Potential for damage: H2

Safety Monitoring of 

fuel cells and hydrogen 

infrastructure
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Application – Combustion Characteristic

Pollutant makers

› Traffic 

› Industry 

› Household and small-sized

burners

Existing sensor systems

› Automobile: λ probe

› Industry: λ / flue-gas probe

› Small-sized burners: 

not available! 

⇒ Development of

miniaturised CO-Sensors 

for combustion optimisation

CO

Ruß CHnm

0.1 0.2 0.4 0.6 0.8 1 2 4 6 8

1.005 1.03 1,30 1,91

Incomplete 

combustion

Flue gas 

heat loss

η

R

u

ß, C

O, C

Hn m

efficiency

Emission edge

Combustion fuels
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Application – Combustion Regulation

Combustion Control 

increases

› The operational range

› reliability of operation

› safety

Combustion Optimisation

› increases the efficiency

› lowers fuel consumption

› Minimises pollution

S2

S1 Processor

Air

Fuel

Burner

Flue gas 

channel

Exhaust air

Probe

Electronic control

Combustion 

chamber
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Sensor element Status: series

Function tested in oil, gas and solid fuel firings since 1999

Production more than 20.000 pieces since 2002 

Reproducibility

 Heater side

 Sensor side

9±1Ω, requirements are fulfilled

requirements are fulfilled for combustion optimisation

Field tests no blackouts of the sensor element since March 2002 

Life time tests tests in oil and gas since Mai 2003, two peripheral blackouts, 

tests go on

Price now: 250€ per piece; goal: 5-10€ per 100.000 piece

Summary – State of the Art
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Housing: Status: „series“

Function around 2000 housings in operation (three different types)

Production

 Integration

 standard

 high temp.

 

experiences with series:

without problems 

up to 200°C, condensing atmospheres

up to 450°C, condensing atmospheres

Life time tests tests in gas and oil since Mai 2003, two blackouts, problems 

solved, tests go on

Price now: 250€ per piece; goal 3-6€ per 100.000 pieces

Summary – State of the Art
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Electronics Status: series 

Function around 1000 units in operation since Mai 2003

Development Feb. 2003: prototype

Mai 2003: pre-series

Oct. 2003: redesign pre-series

March 2004: zero series

Life time tests no blackout since Oct. 2003

Price 500 € per piece 

Summary – State of the Art
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Summary – State of the Art

Field tests (excerpt)

electronics

Status: „ pre-series with demonstrator

Burner Boiler Testing site Testing time

Oil, blue flame Buderus LAMTEC/Odenheim since Sept. 

2002

Oil, blue flame Viessmann VITO/Belgium Jan.-Feb. 2002

Oil, blue flame Rotex HLK/Stuttgart Jan. 2003

Gas, atmospheric Senertec VITO/Belgium Jan.-Feb. 2002

Gas, atmospheric Klöckner LAMTEC/Walldorf since Dec.1999

Gas, condensing Bosch Junkers HLK/Stuttgart Feb. 2003

Gas, condensing Buderus LAMTEC/Reisen since Aug. 2002

Gas, condensing Buderus LAMTEC/Östringen March 2004

Bio mass Hoval CSEM/Switzerland Feb.-March 

2001

Bio mass Brunner FH Karlsruhe/KarlsruheSept. 2003
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

References – Long Term Measurement

Endurance test over 11 months

› identical 

characteristics

› no identifiable 

deterioration 

› sensitivity increases 

slightly
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

References – Sensors in Application (1)

Front view of a dual boiler 50-1.000kW

› 16 CarboSen1000 sensors 

were tested:

• in condensing flue gas

Tmax = 80°C

100% condensation !

• directly in the combustion 

chamber

Tmax = 600° !!

No condensation !

Sturzbrenner
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

References – Sensors in Application (3)

Mounting position in the condensing flue gas channel

› 4 CarboSen1000, plugged in

› 4 CarboSen1000, hanging

› 1 Lambda probe, plugged in
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

References – Sensors in Application (4)

Mounting position in the hot incinerator

› 1 CarboSen1000 

immersion probe
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

CarboSen

27
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

CarboSen

Miniaturised Sensor for Detection of Non-burned (CO/H2) 

in Combustion Exhaust Gas

28
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

CarboSen

29
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Measurement Principal of CarboSen1.000

30
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

CarboSen

Sensor Assembling

› 11 layers incl. carrier

› Measure: 20mm x 3,5mm x 0,7mm

› Material: ceramics, glas, platinum, gold

• Thermally and chemical robust

› Production in thick and thin film process

• Cost-effective, suitable for mass market

31
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

CarboSen

Characteristic

0

20

40

60

80

100

120

140

3000 3010 3020 3030 3040 3050 3060 3070 3080 3090 3100

Zeit in s

Usen in mV

0

50

100

150

200

250

300

350

400

450

500

CO referenz in ppm

U Sen 01 in mV

U Sen 02 in mV

U Sen 03 in mV

CO MRU in ppm

32
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Test Plant of Oil-Blue Burner

Qualification or reference measurement in 

pipe of oil-blue burner

4 CarboSen1.000 in flue gas pipe

Reference 

System (KS1D)

33
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

CarboSen1.000ST

34

Characteristics:

› Measurement of COe directly in humid flue gas up to 150°C, also condensing

› No reference air necessary

› Protection class IP67

Applications:

› Natural gas, fuel oil EL
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

CarboSen1.000

35

Characteristics:

› Measurement of COe directly in humid flue gas up to 400°C

› Elektronic is integrated in sensor head

› No reference air necessary

› Protection class IP67

Applications:

› Natural gas, fuel oil EL, pellet, piece wood
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Thank you for your attention

Questions?
LAMTEC Meß- und Regeltechnik für Feuerungen GmbH & Co. KG

Contact:

Steven Craig – President, Hays Cleveland

Phone: (216) 398-4414 

Fax: (216) 398-8558

E-Mail: scraig@unicontrolinc.com