Unitary gas sensors

Abstract: A gas sensor (10) contains a body of solid electrolyte (14) in contact with a monitor electrode (12) exposed to a monitored gas environment (13) containing selected gas components to be measured, and in contact with a reference electrode (15) which is isolated from the monitored gas environment, where the solid electrolyte at the operating temperature of the gas sensor is effective to dissociate to provide at the reference electrode (15) the sole source of a self-generated gas corresponding to the selected gas component to be measured.

Description: This invention relates to unitary gas sensors. The requirements for monitoring and controlling stack gas pollutants have resulted in the development of solid electrolyte gas sensors having electrolyte compositions uniquely responsive to gases such as SO₂, CO₂ and NO₂. These sensors are electrochemical concentration cells which sense the equilibrium of a gas species of interest and generate an EMF signal corresponding to the difference in partial pressure of the gas species across the solid electrolyte sensor. Typically, the solid state sensor includes an ion conductive solid electrolyte with electrodes disposed on its opposite surfaces. The stack gas, or monitored gas stream, contacts a sensing electrode, while the opposite electrode serves as a reference electrode which is contacted with a reference gas stream. Conventional solid electrolyte compositions require operating temperatures of between 200°C and 900°C to exhibit the desired ion conductivity to generate a suitable EMF signal. In the past, a major problem with these devices was isolation of the monitored gas from the reference gas, to prevent unpredictable drift in the measurement signal. U.S. Patent Specification No. 4,377,460 (Hirayama et al.) discloses solving this sealing problem by using a closed end, gas impermeable, mullite (3Al₂O₃ 2SiO₂) tube which acts as an alkali ion conductive membrane at high temperatures. The mullite tube, like most ceramics, incorporates some alkali oxide impurities, such as K₂O, making it a K⁺ ionic conductor at high temperatures. This tube was used to separate the two gas streams and provide two identical alkali ion conductive half cells secured to opposite sides of the mullite. The two, alkali ion conductive solid electrolyte discs used in each half cell of the Hirayama et al. design, to monitor SO₂, CO₂ or NO₂, were made of K₂SO₄, Na₂CO₃, or NaNO₃, respectively. A platinum electrode was attached to one side of each half cell electrode. In the case of a SO₂ + O₂ reference gas stream, this provided the cell assembly: SO₂ + O₂ Reference Gas, Pt|K₂SO₄|Mullite|K₂SO₄|Pt,SO₂ + O₂ Flue Gas U.S. Patent Specification No. 4,427,525 (Lin et al.) discloses a somewhat similar system using calcia stabilized zirconia as the solid electrolyte. These sensor designs, however, are complicated to make and operate. Also, this use of a SO₂ + O₂ reference gas stream is inconvenient and expensive, since a constant supply of certified tank gas is required. Several instances of simplified, unitary gas sensors have been disclosed in the art. U.S. Patent Specification No. 3,915,830 (Isenberg), relating to O₂ sensors, discloses hermetically encapsulating a metal/metal oxide reference medium, such as nickel/nickel oxide, exhibiting a stable oxygen activity, within a small, stabilized zirconia solid electrolyte disc. A metal electrode is attached to the outside of the solid electrolyte and is in electronic communication with the encapsulated reference medium. Sealing other reference media, such as oxygen gas or air within the solid electrolyte is also mentioned. U.S. Patent Specification No. 4,399,017 (Inoue et al.) discloses the encapsulation of an electrode within a microporous, stabilized zirconia solid electrolyte. A second electrode is attached to the outside of the solid electrolyte, and the whole covered with porous ceramic. Upon application of a D.C. current, migration of oxygen ions, and diffusion of oxygen gas through the microporous solid electrolyte, can establish a reference partial pressure of oxygen at the interface between the microporous solid electrolyte and the encapsulated electrode, to enable measurement of oxygen gas content in flue gas. U.S. Patent Specification No. 4,394,240 (Pebler) discloses triangular, combination electrochemical cells, which form an internal cavity which contains a common internal gas forming reference. In the triangular configuration, two sides are made of stabilized zirconia, oxygen ion conductive solid electrolyte, and the third side can be made of K₂SO₄ when SO₃ or SO₂ gases are to be measured. Reference electrodes are disposed on the inside electrolyte walls of the triangular configuration and sensing electrode are disposed on the outside electrolyte walls. The measuring concept utilizes heating a central, enclosed, MgSO₄, MnSO₄ or Ag₂SO₄ reference material, which provides SO₃ on decomposition. This reference material must be kept sealed from K₂SO₄ electrolyte, because of the possible reaction of these twocomponents at high temperatures. None of these designs provide a simple, inexpensive construction effective to measure SO₂, CO₂ or NO₂ content of flue gases. However, a gas sensor corresponding to the preamble of claim 1 is known from US-A-4388155. Accordingly, the present invention resides in a unitary gas sensor for measuring selected component gases of a monitored gas environment with the additional features disclosed in the characterizing portion of claim 1. Conveniently, the electrodes are of metal and are attached to a circuit means effective to generate an electrical signal measurement of the selected component gases in the monitored gas environment. When the selected gas component to be monitored is SO₂, the solid electrolyte will be selected from K₂SO₄ and Na₂SO₄. When the selected gas component to be monitored is CO₂ or the like gases, the solid electrolyte will be selected from K₂CO₃ and Na₂CO₃. When the selected gas component to be monitored is NO₂ or the like gases, the solid electrolyte will be selected from KNO₃ and NaNO₃. Thus, there is no need to supply any reference gas in the reference system. Additionally, this single-cell sensor can be miniaturized and its manufacture and operation can provide substantial cost savings. The preferred electrodes are platinum, and the portion of the unitary sensor not to be contacted by the monitored gas environment can be enclosed in a gas impermeable, high temperature stable, ceramic, sealing material. This sensor is effective within the temperature range of 200°C to 900°C. In order that the invention can be more clearly understood, convenient embodiments thereof will now be described, by way of example, with reference to the accompanying drawings in which: Figure 1 is a cross-sectional view of one embodiment of a unitary, single cell, self-generating reference gas sensor of this invention; Figure 2 is a cross-sectional view of another embodiment of the sensor of this invention, where each electrode physically contacts electrolyte but the electrolyte is split into two sections separated by a potassium or sodium ion conductive material; Figure 3 are calibration curves in SO₂ + air, of EMF vs. ppm SO₂, for the self-generating reference gas sensor of the invention, A and B, and a standard SO₂ gas sensor, C and D, both at controlled temperatures; and Figure 4 are calibration curves in SO₂ + air, of EMF vs. ppm SO₂ for the self-generating reference gas sensor of this invention, A and B, and a standard SO₂ gas sensor, C, D and E, both at widely varied temperatures. Referring now to Figure 1, solid electrolyte, unitary, gas sensor electrochemical cell 10 is shown. This single sensor cell is contained within a non-porous, high temperature stable, gas impermeable vessel 11, usually a dense ceramic cylindrical cup or bored out tube made of, for example, alumina, mullite (Al₂O₃ 2SiO₂), magnesia, zirconia, and the like, preferably of at least 90% purity. These materials would be isostatically pressed at high temperatures, to provide a sintered, high density (at least 90% dense) cup or tube. A first, metal, monitor electrode 12, contacts both the monitored gas environment 13, containing the gas component to be measured, and the single body of solid oxide electrolyte 14 contained in the sensor cell. A second, metal, reference electrode 15, may be completely encapsulated, surrounded, and contacted by electrolyte 14, or may be disposed against an inner wall of the containment vessel, as at point 16, and contacted by electrolyte. The solid electrolyte 14, in either case, will preferably be at least 95% dense, and will be of at least 95% purity. The solid electrolyte will be made from sintered, submicron particles, preferably in a range from approximately 0.1 micron to 0.9 micron, and will be effective to prevent monitored gas 13 contact with the reference electrode 15. The preferred material for electrodes 12 and 15 as well as electrical leads 18 is platinum. A porous, gas dispersing ceramic spacer 17 may be used to assure uniform contact of the monitored gas environment 13 with the monitor electrode 12. Measuring circuit means, comprising electrical lead wires 18 connected to the electrodes 12 and 15, as well as voltmeter 19 are shown. This circuit responds to electrical signals generated, and provides an indication of both the partial pressure of selected gas component in the monitored gas environment and the partial pressure of the corresponding similar gas generated by decomposition of the electrolyte. A high temperature stable ceramic oxide sealant 20, such as, for example a mixture of 49 wt.% CaO, 49 wt.% Al₂O₃ and 2 wt.% SiO₂, having a melting point of approximately 1430°C, is used to ensure isolation of monitor electrode 12. The main body of this gas sensor cell can be inserted or assembled into a probe structure, having a heating element and temperature control, to provide a gas sensing apparatus. The EMF (electromotive force) signal generated by the solid electrolyte gas sensor cell, is developed in accordance with the well-known Nernst equation, where the variables include the cell temperature, and the variation of partial pressure of the gas component of interest in the monitored gas environment at the monitor electrode 12, and the partial pressure of the same reference gas at the reference electrode 15. The solid electrolyte itself, upon the application of heat, is effective to dissociate to provide the sole source of reference gas. In the case where the monitored gas environment contains SO₂ and O₂, and where the solid electrolyte is K₂SO₄, upon operation of the gas sensor cell at from 600°C to 900°C, the solid electrolyte will be in equilibrium dissociation to provide a SO₂+O₂ reference gas, according to the chemical reaction: K₂SO₄ ⇄ 2K⁺ + SO₂ + O₂. In this case, the EMF would be calculated from the equation: where R = the universal gas constant, T = temperature °K, F = Faraday Constant (23,061 cal./volt), P = partial pressure of reference SO₂ and O₂, and P′ = partial pressure of monitored SO₂ and O₂, where R, T, F, and P are known. From this equation, a direct measurement of SO₂ plus O₂ component gases in the monitored gas environment can be made by the measurement of the EMF of the censor cell. This design would measure SO₂+O₂, CO₂+O₂, or NO₂+O₂, so that a separate O₂ sensor would be installed, and the O₂ concentration, interims of voltage output, would be compensated for electronically. When the selected gas component to be monitored is SO₂, the solid electrolyte will be selected from K₂SO₄ and Na₂SO₄. At 600°C to 900°C sensor operation, solid K₂SO₄ will be in equilibrium dissociation with 2K⁺+SO₂+O₂. At 600°C to 880°C sensor operation, solid Na₂SO₄ will be in equilibrium dissociation with 2Na⁺+SO₂+O₂. When the selected gas component to be monitored is CO₂, the solid electrolyte will be selected from K₂CO₃ and NaCO₃. At 600°C to 800°C sensor operation solid K₂CO₃ will be in equilibrium dissociation with 2K⁺+CO₂+½O₂ and solid Na₂CO₃ will be in equilibrium dissociation with 2Na⁺+CO₂+½O₂. When the selected gas component to be monitored is NO₂ or NO, the solid electrolyte will be selected from KNO₃ and NaNO₃. At 200°C to 300°C sensor operation, solid KNO₃ will be in equilibrium dissociation with K⁺+NO₂+½O₂ and solid NaNO₃ will be in equilibrium dissociation with Na⁺+NO₂+½O₂. This last sensor can be operated only at low or cooled flue gas temperatures. In all instances, at the operating temperature of the sensor cell, the solid electrolyte itself is effective to prevent monitored gas from reaching the reference electrode, provides alkali ion conductivity, and provides the sole source SO₂, CO₂ or NO₂ reference gas, depending on the solid electrolyte used. The amount of SO₂, CO₂ or NO₂ generated by equilibrium dissociation of the solid electrolyte will be on the order of 0.5 ppm (parts per million) to 100 ppm, whereas the amount of SO₂, CO₂ or NO₂ in the monitored gas environment may be from 500 ppm to 2500 ppm, in most cases. There is no separate, exterior reference gas stream associated with this sensor apparatus. The only useful cations are K⁺ and Na⁺, as they provide the best combination of low electrolyte resistance and highest decomposition temperature for the anions used. Ideally, the partial pressure of SO₂ and O₂ or other dissociation gas species at the reference electrode 15, would be equivalent to the true dissociation pressure of K₂SO₄, or the other useful solid electrolytes described hereinbefore, at a controlled temperature, if the reference electrode is perfectly sealed in the solid electrolyte without formation of any minute voids. Presence of minute voids in the solid electrolyte could trap a variety of gas species during the electrolyte fabrication process, and could also accumulate SO₂ and O₂ gases from the dissociation reaction of the solid electrolyte during sensor cell operation. An essentially void free solid electrolyte is strived for in this invention. The preferred solid electrolyte in this invention will be substantially free of minute voids. It will preferably be at least from 95% to 98% dense. Since any voids present in the solid electrolyte would be minute under presently used powder sintering techniques, and they would be either hermetically sealed or confined in a small space, these trapped gas species would tend to be in equilibrium with the solid electrolyte at a controlled temperature. Therefore, a stable and constant partial pressure of SO₂+O₂, or CO₂+O₂, or NO₂+O₂ is expected to be maintained at the reference electrode, which would result in a stable and reproducible EMF measurement. What is essential is to establish a constant partial pressure of SO₂+O₂, or CO₂+O₂, or NO₂+O₂ at the reference electrode during sensor cell operation. Another embodiment of this invention is shown in Figure 2, where each electrode 12 and 15 physically contact electrolyte 14, but where the electrolyte is split into two portions separated by an extension 22 of the gas impermeable vessel 11. In this instance, the gas impermeable vessel 11 and its extension 22 will be made of a potassium or sodium ion conductive material, such as a mullite (3Al₂O₃ 2SiO₂) material which contains alkali oxide impurities, such as Na₂O, K₂O and the like, making it a K⁺ and/or Na⁺ conductive membrane. The self-generating reference gas function of solid electrolyte in contact with the reference electrode 15 remains the same as in the device of Figure 1. This embodiment can be in the form of a long tube, end 23 of which can be far removed from the monitored gas environment 13. This embodiment could be substituted for the long tubular inner reference cell in sensors described in U.S. Patent Specifications Nos. 4,377,460 and 4,427,525. The gas sensor cell can be made by providing a high density cylindrical cup of high purity gas impermeable alumina. A small hole can be drilled at the closed end, a platinum reference electrode disc positioned inside the cup near the closed end, and a platinum lead wire inserted through the hole and soldered to the electrode. High temperature ceramic sealant can be used over the drilled hole on the outside of the alumina cup. Then, a fine powder of potassium or sodium sulfate, potassium or sodium carbonate or potassium or sodium nitrate can be packed into the alumina cup and around the reference electrode. This alkali salt would then be press sintered at a temperature about 100°C below its melting point. Melting points are 1072°C for potassium sulfate, 891°C for potassium carbonate, and 337°C for potassium nitrate. This will provide an essentially void free, gas impermeable, solid electrolyte, preferably with no cracking upon cooling. A platinum monitor electrode can then be placed on top of the solid electrolyte across the opened end top of the enclosing cup, and platinum lead wire soldered in place. Finally, a porous, ceramic gas dispersing grid can be sealed on top of the monitor electrode. The leads can then be connected to gas monitoring circuitry, usually including a voltmeter, and the gas sensor cell placed in a monitoring gas environment, usually in an encasing probe means with a heater and heater controls, and operated at an operating temperature effective to cause equilibrium dissociation of the solid electrolyte. The sensor must be operated at a temperature substantially below the melting point of the solid electrolyte. The invention will now be illustrated by the following EXAMPLE: EXAMPLE A single cell, self-generating reference gas sensor, similar to that shown in Figure 1, was made. A high purity (99⁺%) alumina, closed end tube, approximately 1 cm long, 1 cm in outside diameter, and 0.2 cm thick, isostatically pressed to 98% density, was drilled at the middle of the closed end to provide a small hole about 1 mm. in diameter. Platinum wire was inserted through the hole, wound as a support, and soldered to a platinum electrode screen having a diameter of approximately 0.8 cm, held in place within the tube, Powdered, 99% pure K₂SO₄, having a submicron particle size, was poured into the bottom of the tube, around the electrode, and on top of the electrode to the top of the tube and tamped in place. The K₂SO₄ filled tube was then hot pressed with a plunger at approximately 980°C. This caused the K₂SO₄ particles to come into very intimate contact, and to heat-sinter together, to form an essentially void free, 98% dense, solid electrolyte structure. An exterior, platinum monitor electrode screen was then pressed and bonded to the top of the solid electrolyte. Platinum wire was then attached to the monitor electrode. Both wire leads from the monitor electrode and encapsulated interior sensing electrode were connected to a Keithley digital voltmeter. The whole sensor was assembled into a probe structure having a heating element and temperature control to provide a gas sensor apparatus. As a control apparatus, a standard SO₂+O₂ sensor, as substantially described in U.S. Patent Specification No. 4,377,460, utilizing two K₂SO₄ solid electrolyte cells separated by a mullite tube, and being fed a reference gas stream of 100 ppm. of SO₂ in air from certified gas tanks was used. Both sensor apparatus were placed in a gas environment containing varying amounts of SO₂, at a controlled temperature, and EMF values were measured. It appeared that the partial pressure of SO₂ and O₂ at the platinum reference electrode of the self-generating reference gas sensor was higher than that of the true dissociative pressure of K₂SO₄. Both apparatus were calibrated as follows in TABLE 1, where the reference electrode was the positive electrode: The slopes of the calibrations are shown in Figure 3, EMF in mV vs PSO₂ in ppm in air, where slopes A and B are of the self-generating reference gas sensor of this invention at day 1 and day 28, respectively. Slopes C and D are of the standard, control, SO₂ gas sensor at day 1 and day 28, respectively. As can be seen, the slopes are almost exactly the same, with only minor drifting over the 28 day period. For about 8 months of life testing in the laboratory, both sensors behaved similarly. The slopes of the calibration curves of both sensors approximate the theoretically predicted curve. The same two sensors were used to study the effect of temperature on the behavior of both sensors during the life testing period. Figure 4, a graph of EMF in mV vs PSO₂ in ppm in air, shows the effect of cell temperature on the SO₂ calibration curves of both sensors. A large temperature effect was observed for the calibration curves of sensor using the self-generating reference gas, while the effect of temperature on the calibration curves on the standard sensor, using 100 ppm SO₂ in air as a reference gas, was relatively small. Curves A and B in Figure 4 show the calibration curves for the self-generating reference gas sensor at 854°C and 901°C, respectively. Curves C, D, and E show the calibration curves for the standard, control, SO₂ gas sensor at 765°C, 820°C and 867°C, respectively. The large temperature effect on the cell EMF when using the self-reference electrode is due to the large effect of temperature on the equilibrium of the existing gases and the solid K₂SO₄ at the reference electrode, which results in a large partial pressure of SO₂ and O₂ change at the electrode when the cell temperature varied. However, when the cell temperature is controlled at a fairly constant level, both sensors behaved reliably. This effect should have no effect on performance or reliability as long as the temperature is kept relatively constant.

Claims: A gas sensor for measuring a selected component gas of a monitored gas environment by generating an electrical signal on the basis of a difference in the partial pressure between the selected component gas of the monitored gas environment at a monitor electrode, in contact with the monitored gas environment and a solid electrolyte, and a corresponding component gas of a reference gas environment at a reference electrode, in contact with the reference gas environment and said solid electrolyte; characterized in that the reference electrode (15) comprises platinum and is fluidically isolated from the monitored gas environment and in direct contact with the solid electrolyte (14), and the solid electrolyte (14) has a single component composition and dissociates at the operating temperature of said sensor to provide at the reference electrode (15) the sole source of the corresponding component gas of the reference gas environment. A gas sensor according to claim 1, characterized in that the reference electrode is embedded in the solid electrolyte, the solid electrolyte being effective to prevent contact of the monitored gas environment with the reference electrode. A gas sensor according to claim 1 or 2, characterized in that the electrodes are of metal and are attached to a circuit means effective to generate an electrical signal measurement of the selective component gases in the monitored gas environment. A gas sensor according to claim 1, 2 or 3, characterized in that the solid electrolyte is K₂SO₄, Na₂SO₄, K₂CO₃, Na₂CO₃ or NaNO₃ A gas sensor according to any of claims 1 to 4, characterized in that the portion of the sensor not to be contacted by the monitored gas environment is enclosed in a gas impermeable, high temperature stable, ceramic sealing material. A gas sensor according to any of claims 1 to 5, characterized in that a stable and constant partial pressure of the self-generated gases is maintained at the reference electrode. A gas sensor according to any of claims 1 to 6, characterized in that such sensor is operable at a temperature below the melting point of the solid electrolyte. A gas sensor according to any of claims 1 to 7, characterized in that the solid electrolyte is K₂SO₄ or Na₂SO₄, and a gas component present in the monitored gas environment is SO₂. A gas sensor according to any of claims 1 to 8, characterized in that both electrodes physically contact the same body of electrolyte. A gas sensor according to any of claims 1 to 9, characterized in that each electrode physically contacts electrolyte and where the electrolyte is split into two portions separated by a potassium or sodium ion conductive material, with each electrode being disposed on opposite sides of the ion conductive material.

Inventors: HIRAYAMA CHIKARA, LIN CHING-YU, HIRAYAMA, CHIKARA, LIN, CHING-YU
Applicants: ROSEMOUNT ANALYTICAL INC, ROSEMOUNT ANALYTICAL INC.
Application year: 1989
Main classification: G01N27
IPC codes: G01N27