ZOLOSCAN2 COMBUSTION MONITORING SYSTEMZoloSCAN™2 is an innovative, laser-based combustion

monitoring system that utilizes proven TDLAS technology

as recommended by API RP556. The system simultaneously

measures the temperature, O2, CO, CH4 and H2O in real-time,

directly in a reformer, ethylene cracking furnace or process

heater along multiple laser paths. There are no probes to

insert, no sensitive electronics near the furnace, and no

calibration required. ZoloSCAN2 measurements provide a

more accurate and reliable representation of the combustion

gases present in a furnace than traditional, single-point

thermocouples or ZrO2 sensors.

KEY FEATURES• Multiple constituents

- Simultaneously measures temperature,

O2, CO, CH4 and H2O

• Cost-effective installation

- Multiple measurement paths per ZoloSCAN2 system

- Minimal infrastructure requirements

- Install without a heater outage

- Div2/Zone2 Hazardous Location capable

- Nitrogen or air purging not required

• Continuous reporting

- Automatic SensAlign Head alignment maintains

reliable and accurate measurements

- Minimal maintenance required

COMBUSTION OPTIMIZATION

PETROCHEMICAL & REFINING

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IMPROVED SPACIAL RESOLUTIONZoloSCAN2 provides zonal measurements of

key constituents to increase the precision of

combustion control inside the furnace. The data

provided assists for targeted feedback in large

heaters where combustion imbalances can lead

to production constraints, hot spot, reduced

availability, or high emissions.

TEMPERATURE-ENHANCED MEASUREMENT ACCURACYZoloSCAN2’s innovative design takes

temperature readings along the same

path as other species measurement for

more accurate data with no auxiliary

thermocouple-based temperature

feedback uncertainties.

PATENT-PENDING SIGHT-PORT MOUNTZoloSCAN2’s minimal infrastructure requirements (reduced conduit, reflective mirror, sight port retrofit and a locally installed

cabinet) simplify installation and reduce costs. The sight-port retrofit option allows you to swing the ZoloSCAN2 active head

open (like a door) for easy sight-port viewing into your furnace.

Sight Port Retrofitwith ZS2 Active Head

PROVEN TECHNOLOGYZoloSCAN2 utilizes a proven technique known as

Tunable Diode Laser Absorption Spectroscopy (TDLAS).

Zolo’s TDLAS uses multiple lasers, each tuned to unique

absorption constituents to measure multiple species

and temperature at each laser path location.

PROVEN VALUEMultiplexed TDLAS laser systems are the industry benchmark

for reduced maintenance and increased reliability and control of

combustion optimization. Zolo systems have been successfully

installed in over 100 industrial applications around the world and

continue to provide long-term value.

AUTOMATED PATH ALIGNMENTSensAlign™ heads automatically adjust position to maintain continuous alignment and peak laser power. This results in extremely

robust, uninterrupted reporting that accommodates warping furnace or boiler walls.

Traditional Sensors: Other laser-based systems typically defocus their beam to ensure alignment. This practice results in loss of

signal strength leading to reduced measurement performance and residual sensitivity to wall warpage.

BENEFITS• Increase productivity/output

-Optimizeheatfluxprofiles

-Maximizefurnaceavailability

-Increaseprocessyields

•Extendprocesstubelife

-Eliminatelocalizedhotspots

-Increasedecokingintervals

-Increasecatalystlife

•Fuelsavings

-LowerexcessO2

-Optimizeair/fuelratiosacrosstheheater

• Lower emissions

-ReduceNOx,COandCO2

• Safety/sentry

-Real-timevisibilityintostartupandshutdown

-AlarmtohighCOduringheateroperation

-AlarmtohighCH4 during heater start-up

- Detect higher amounts of steam in the furnace

indicatingpossibletuberupture

•Easeofinstallation/use

-Minimalinfrastructureneededforinstallation

-Sight-portmountconvenientlyswings

ZoloSCAN2awayforeasyflameviewing

- Measurement path purging with air or N2

not required

To learn more about our solutions, go to: OnPointSolutions.com© 2021 Koch Engineered Solutions. All rights reserved.

SENSALIGN HEADSFeatures

Active Heads

Automatic Alignment ± 2.5 deg range

Local Indicator Light Green (measuring), Yellow (open), Red (error)

Weight 11 kg (24 lbs)

Dimensions 285 mm D x 215 mm W x 225 mm H (11.3 in. D x 8.7 in. W x 8.9 in. H)

Passive Heads

Hardened Reflecting Mirror Head alignment not required

Weight 9 kg (20 lbs)

Dimensions 110 mm D x 175 mm W x 200 mm H (4.4 in. D x 7.0 in. W x 8.0 in. H)

Measurement Path

Low Maintenance Hinged head, easy to open and clean window

Purge Air/N2 Not required

Cooling Air Not required

Alerts / Health Checks Signal Strength, Temperature, Open Head

Installation ConditionsOperating Temperature -20 to 85 °C R.H. 0-100%, (-4 to +185 F)

Ingress Protection IP54

Sight Tube Installation 75mm Ø (3”) cutout in refractory and furnace for tube penetration

Sight Port Installation Outage not typically required for sight port replacement, Multiple sight port sizes available

Hazardous Classification Class I Division 2 / Zone 2, (NEC / ATEX / IECEx)

Conduit (Active Head to J-Box) Hi-temp flex conduit - electrical and fiber optics

Conduit (J-Box to Rack) 38mm (1.5 in) O.D. typical - electrical and fiber optics

Electrical 48V CAN bus supplied by Control Rack, no local power required

ZOLOSCAN2 CONTROL CABINETFeatures

Data Output OPC UA/DA via Ethernet TCP/IP, Additional protocols available via Kepware converter

User Interface ZoloSCAN BalanceApp for combustion visualization

Species Measurements Path and zone data for all measured species

Alert / Health Checks Laser status, temperature, comm errors

Lock-out Tag-out Available Yes, main power disconnect

Remote Access Available Yes, for remote monitoring and support

Installation ConditionsAmbient Temperature -20 to 55 °C R.H. 0-100%, (-4 to +131 F)

Ingress Protection IP66 (Stainless)

Weight 353kg (780 lbs)

Hazardous Options Class I Division 2 / Zone 2, (NEC / ATEX / IECEx)

Electrical Requirements 230/240 Vac, Single Phase, 50/60Hz , 25A (10A/15A)

Dimensions 1220 mm W x 1525 mm H x 560 mm D (60”W x 60”H x 18”D)

MEASUREMENT SPECIFICATIONSMeasurement Species Combined Temperature, O2, CO, CH4 and H2O on every measurement path

Measurement System Multiplexed Tunable Diode Laser Absorption Spectroscopy (TDLAS)

Available Paths per System 1 to 12

Pressure Range 0.8 to 1.1 atm

Optical Path Length 1 to 30 meters (3 to 98 feet)

Applicable Fired Gasses Natural Gas, LPG, Waste Gas, Naphtha, Hydrogen, and others

Dust Sensitivity Negligible for typical firing conditions

Path Measurement Time 10 seconds Typical per path duration

Complete Furnace Profile Total path count X 10 sec Typical cycle duration (e.g. 12 paths = 2 minutes)

On-site Calibration Not-required Self-calibrated every 24 hours

Constituent Full Scale Range Accuracy Precision Temperature Range

Temperature 260 to 1700° C ± 1.0% fs ± 0.5% fs N/A

O2 % 0 to 30% ± 0.25% abs ± 0.125% abs 260 to 1700° C

CO % (ppm) 0 to 10,000 ± 50 to 200 ± 25 to 100 500 to 1700° C

CH4 % 0 to 10% ± 0.5% abs ± 0.25% abs 25 to 500° C

H2O % 0 to 30% ± 1.0% abs ± 0.50% abs 260 to 1700° C

* fs = full scale abs = absolute Specifications based on nominal installation, actual results will vary based on installation specific criteria.