Carbon & Sulfur Analyzer (New) – QualiCSA™ 5
Carbon and sulfur analysis is an essential quality control step when material chemistry affects metal quality, weldability, and specification compliance. The QualiCSA™ 5 Carbon & Sulfur Analyzer is a high-frequency combustion system with infrared (IR) detection, designed to deliver fast, repeatable total carbon and sulfur results for solid inorganic samples. The brochure series includes two configurations: the general-purpose QualiCSA™ 5 and the geology and mineral-focused QualiCSA™ 5M.
The QualiCSA™ 5 combusts samples in an oxygen atmosphere using a high-frequency induction furnace. The resulting CO₂ and SO₂ gases are measured through multi-channel infrared detection cells. Integrated dust and moisture control, catalytic conversion, and stabilized gas-flow management help maintain consistent analytical performance across a wide range of sample matrices.
Designed for efficient laboratory workflows, the analyzer supports rapid testing cycles for production and quality control decisions. Its software provides tools for calibration, analytical method setup, result management, and data security, helping laboratories maintain reliable testing procedures and organized data records.
Optional configurations include a halogen trap, wet-sample handling system, and high-capacity autosampler, allowing laboratories to configure the QualiCSA™ 5 according to sample types, testing requirements, and laboratory throughput.
Carbon & Sulfur Analyzer (New) – QualiCSA™ 5 Applications
Steel, Cast Iron, and Alloy Quality Control
Carbon and sulfur analysis plays an important role in steel, cast iron, and alloy quality control, supporting grade verification, melt control, and final product release testing. Reliable low-level carbon and sulfur measurement is valuable for cleaner steel production, while broader analytical ranges support foundry and alloy manufacturing. Fast analysis helps laboratories make timely production decisions, minimize rework, and maintain consistent process control.
Non-Ferrous Metals and Superalloys
Non-ferrous metals and superalloys can require precise carbon and sulfur control due to their effects on material properties and downstream processing. High-frequency combustion with infrared (IR) detection provides rapid C/S analysis for production monitoring and incoming material inspection. Consistent gas handling helps maintain repeatable measurements during extended laboratory testing and high-volume workflows.
Cemented Carbides and Advanced Materials
Carbon concentration can influence phase balance and performance in cemented carbides and advanced engineered materials. Controlled combustion and consistent gas conditioning help produce comparable carbon and sulfur results across multiple batches. This makes the analyzer suitable for both materials research and development laboratories and production quality control environments using consistent analytical procedures.
Ores, Soil, Sand, Glass, and Mineral Samples
The mineral-focused QualiCSA™ 5M configuration is designed for challenging sample matrices, including powdery, moist, and potentially corrosive materials. Moisture control and corrosion protection help support stable long-term operation when analyzing complex mineral samples. Applications include iron ore, copper ore, bauxite, rare-metal ores, coal, fluorite, sandstone, soil, sand, and glass, as referenced in the brochure materials.
Standards
The QualiCSA™ 5 Carbon & Sulfur Analyzer supports laboratory workflows aligned with recognized international and industry testing standards for carbon and sulfur analysis:
-
ISO 15350: Specifies the determination of total carbon and sulfur in steel and related materials through combustion in an induction furnace followed by infrared absorption measurement.
-
ASTM E1019: Covers analytical methods for determining carbon and sulfur in steel, iron, nickel, cobalt, and related alloys using instrumental techniques.
-
ISO/IEC 17025: Provides a framework for laboratory competence, including validated testing methods, measurement traceability, quality control, and reliable analytical results.
Carbon & Sulfur Analyzer (New) – QualiCSA™ 5 Key Features
Infrared Detection System
-
Dual-Analog High-Order Signal Processing: The QualiCSA™ 5 uses a dual-analog, high-order infrared signal path with filter-based processing. Elliptic analog filtering helps reduce sampling errors associated with purely digital filtering approaches.
-
Three Standard IR Channels: The analyzer includes three independent infrared channels as standard, consisting of two carbon channels and one low-sulfur channel. An optional high-sulfur channel expands the system to four IR channels for broader sulfur measurement capability.
-
Pyroelectric Solid-State Detectors: Infrared detectors feature pyroelectric solid-state sensing elements with a structured optical configuration and analog processing circuitry, supporting stable signal detection during carbon and sulfur analysis.
-
Synchronous Optical Chopper: A synchronous chopper motor with controlled operation maintains consistent optical modulation for continuous infrared measurement and reliable analytical performance.
-
Stable IR Light Sources: The infrared light sources are selected to provide consistent optical output and resistance to oxidation, supporting dependable operation during extended laboratory use.
-
Temperature-Controlled Gas Chamber: The gas chamber uses temperature control to maintain stable analytical gas conditions throughout the measurement process, helping improve measurement consistency.
-
Protective Positive-Pressure Environment: The infrared source and detector area operates under slight positive pressure with purified protective gas. This configuration helps minimize the influence of ambient atmospheric conditions on infrared measurements.
High-Efficiency Extraction System
-
Three-Function Extraction System: The analyzer features an integrated extraction design combining furnace chamber pre-purge, direct ash discharge, and dual-brush automatic cleaning to support efficient sample processing and routine maintenance.
-
Flexible Analytical Methods: Programmable analytical routines allow testing parameters to be configured for different sample types, helping laboratories establish suitable measurement methods for varied carbon and sulfur applications.
-
Optimized Dust Removal: The gas-path design is configured with reduced dead volume to help limit dust accumulation and minimize adsorption and desorption effects that could influence analytical results.
-
Automatic Leak Detection: An integrated leak-check function monitors carrier-gas pressure to identify potential gas-path leaks. This helps improve measurement reliability while making routine maintenance and troubleshooting more straightforward.
-
Corrosion-Resistant Gas Path: Protective materials and design features help reduce corrosion risks caused by aggressive combustion byproducts, supporting long-term gas-path durability.
-
Integrated Hardware Safety: Safety features include an anti-pinch furnace head design, controlled air-pressure operation, and automatic shutdown during power loss, helping protect laboratory personnel and equipment during routine operation and unexpected interruptions.
High-Frequency Combustion Furnace System
-
Efficient Dual-Chamber Furnace Design: The QualiCSA™ 5 features an efficient heat source with a dual-chamber, shielded furnace structure. Air-cooled observation windows and protected furnace tubing help support stable operation during continuous carbon and sulfur analysis.
-
13.56 MHz High-Frequency Power: Operating at 13.56 MHz with adjustable power up to 2.7 kVA, the induction furnace provides the high-temperature combustion conditions required for complete combustion of diverse inorganic solid samples.
-
Stable High-Frequency Power Supply: An integrated power-supply isolation design combined with a feed-through capacitor configuration helps reduce electrical crosstalk and maintain stable high-frequency output during analysis.
-
Waveguide Radiation Shielding: Built-in waveguide shielding helps control high-frequency electromagnetic emissions around the furnace system, supporting safer laboratory operation in accordance with the radiation limits referenced in the brochure.
Flow Control System
-
Micro-Pressure Differential Control: The QualiCSA™ 5 uses micro-pressure differential control combined with high-precision electronic flow regulation to maintain stable analytical gas flow during carbon and sulfur measurement.
-
Fast PID Flow Stabilization: A PID-based control system enables rapid stabilization of gas flow, helping laboratories begin analytical testing quickly after instrument startup.
-
Automatic Gas-Saving Standby Mode: An automatic standby function reduces gas consumption when the analyzer is idle, helping improve operational efficiency during periods without active testing.
-
Optimized Gas-Path Routing: Valve-based gas routing is designed to simplify the analytical gas path, reduce dead volume, and support stable gas movement throughout measurement cycles for consistent carbon and sulfur analysis.
User-Friendly Software
-
Digital-Twin Style User Interface: The software interface provides a visual overview of instrument status, analytical trends, and operational guidance, helping users monitor testing and maintenance activities from a centralized dashboard.
-
Integrated Guidance and Reference Content: Built-in guidance and reference information provides on-demand support for routine instrument operation, analytical procedures, and servicing tasks.
-
Flexible Method Configuration: The software supports multiple analytical routines with streamlined method configuration, making it suitable for routine production quality control and laboratory carbon and sulfur analysis.
-
Two Analytical Operating Modes: The QualiCSA™ 5 provides two operating modes for different testing requirements:
-
Fast Analysis Mode: Combines furnace pre-purge with direct ash discharge to reduce reset and cycle time for faster testing workflows.
-
Standard Analysis Mode: Combines direct ash discharge with dual-brush automatic cleaning to help reduce residual dust between consecutive analyses.
-
Automatic Measurement Range Switching: The analyzer automatically switches between high- and low-range measurement channels, providing expanded analytical range coverage for different carbon and sulfur concentrations.
-
Multiple Calibration Functions: Calibration workflows include single-point, basic, multi-point, and blank calibration, giving laboratories flexibility when establishing and maintaining analytical methods.
-
USB-Key Access Control: USB-key security provides controlled instrument access. Analytical operation is disabled when the designated USB key is removed.
-
Multi-Parameter Compensation: Integrated compensation algorithms help reduce environmental effects on analytical results, including:
-
CO Compensation: Corrects the influence of carbon monoxide on carbon measurement results.
-
Atmospheric Pressure Compensation: Helps reduce measurement variation associated with changes in atmospheric pressure.
Theory and Method
The QualiCSA™ 5 Carbon & Sulfur Analyzer determines carbon and sulfur concentrations through high-frequency induction combustion in an oxygen atmosphere, followed by infrared (IR) detection. During combustion, carbon-containing components are converted into carbon monoxide (CO) and carbon dioxide (CO₂), while sulfur is converted into sulfur dioxide (SO₂).
The combustion gases then pass through integrated dust removal and moisture control stages to condition the gas stream before infrared measurement. Carbon monoxide is subsequently converted into carbon dioxide to support complete carbon measurement. Multi-channel infrared cells measure the absorption signals associated with CO₂ and SO₂, while the analytical software processes these signals against calibrated curves to determine total carbon and sulfur concentrations.
Gas Flow Path and IR Detection
The diagram illustrates the internal gas flow path of the QualiCSA™ 5 Carbon & Sulfur Analyzer during high-frequency combustion and infrared detection. It shows the sequence of oxygen control, sample combustion, combustion-gas purification and drying, and infrared signal measurement.
After combustion, the conditioned gas travels through the analytical gas path to the dedicated CO₂ and SO₂ infrared detection cells. The measured infrared signals are processed by the analyzer software to calculate carbon and sulfur concentrations before the gas is directed to the exhaust system.
Working Principle
QualiCSA™ 5 Gas Flow Path and IR Detection Process
1. Oxygen Supply and Pressure Control
The QualiCSA™ 5 begins the analytical process with controlled oxygen delivery to maintain stable combustion and gas-flow conditions.
-
Total Oxygen Pressure Reducing Valve: Regulates the incoming oxygen pressure to maintain consistent gas flow throughout the analytical process.
-
Carrier Gas Purification: Removes contaminants from the oxygen supply that could interfere with low-ppm carbon and sulfur measurements.
-
Total Oxygen Valve: Provides the primary on/off control for oxygen entering the analyzer.
2. Oxygen Routing to the Furnace
Two controlled oxygen paths direct gas to the combustion zone to support efficient sample combustion and consistent gas transport.
-
Oxygen Lance Valve: Controls the oxygen supply used for combustion support and analytical gas transport.
-
Furnace Lance Valve: Directs oxygen into the furnace chamber to support complete combustion of the sample.
-
Backblow Valve: Provides a brief reverse-flow oxygen function when required, helping clear the gas lines and reduce dust carryover into the analytical gas path.
3. Dust Capture and Moisture Removal
Following combustion, the hot gas passes through dedicated conditioning components before reaching the infrared detection system.
-
Dust Filter: Captures combustion ash and particulate matter to help protect the downstream gas path and optical components.
-
Drying Tube: Removes water vapor from the combustion gas, helping prevent infrared signal drift or saturation during measurement.
Together, these stages help condition the gas stream and support consistent results from one sample to the next.
4. Post-Furnace Switching and Purge Functions
Controlled gas routing after the furnace manages the transition from combustion to measurement and supports rapid system reset between analyses.
-
Post-Furnace Valve: Controls gas routing into the measurement stage.
-
Flushing Valve (Emptying): Purges and resets the analytical gas path between tests, helping prepare the system for the next sample.
-
Carrier Gas Purification: An additional purification stage can further condition the gas stream before infrared measurement.
5. Flow Control and Infrared Detection
The Flow Control system maintains consistent gas movement through the measurement chamber. Stable gas flow is important for repeatable infrared absorption measurements because changes in gas volume and flow conditions can affect the measured signal.
The measurement chamber contains multiple infrared detection channels:
This multi-channel configuration provides a broad analytical range. Low-range channels can be used for trace concentrations, while high-range channels support samples with higher carbon or sulfur concentrations.
6. Purification, Catalytic Conversion, and Exhaust
Before the processed gas exits the analyzer, additional treatment stages help prepare the gas for discharge.
-
Purification Tube: Further conditions the gas stream and helps protect downstream components.
-
Catalytic Furnace: Converts gases as required for accurate carbon measurement and supports cleaner gas handling before exhaust.
-
Discharging Valve: Controls the final release of processed gas from the instrument.
Why the Gas Flow Process Matters
Each stage of the QualiCSA™ 5 gas path contributes to stable and repeatable carbon and sulfur analysis:
-
Clean, dry analytical gas: Purification, dust filtration, and moisture removal help support stable low-ppm measurements.
-
Consistent gas flow: Controlled flow conditions help produce repeatable infrared absorption signals.
-
Wide analytical range: Dedicated low- and high-range carbon and sulfur channels provide expanded concentration coverage without hardware reconfiguration.
-
Efficient cycle reset: Controlled flushing and gas routing help clear the analytical path and prepare the analyzer for subsequent measurements.
Carbon & Sulfur Analyzer (New) – QualiCSA™ 5 Technical Specification
Performance and Measurement
| Specification |
QualiCSA™ 5 |
QualiCSA™ 5M |
| Method |
High-frequency combustion + IR detection |
| Carbon range (1000 mg sample) |
0.6 ppm to 6.0% (0.0006–60 mg absolute mass) |
| Sulfur range (1000 mg sample) |
0.6 ppm to 6.0% (0.0006–60 mg absolute mass) |
| Range expansion |
By changing sample weight, range can extend up to 100% |
| Accuracy |
C: 0.3 ppm or RSD ≤ 0.5% / S: 0.3 ppm or RSD ≤ 0.5% |
| Sensitivity |
0.01 ppm |
| Fastest analysis cycle |
60 seconds |
| Recommended sample mass |
0.1 g to 0.5 g (adjust by content) |
Furnace, Gas, and Electrical
| Specification |
QualiCSA™ 5 |
QualiCSA™ 5M |
| Combustion furnace |
13.56 MHz, 2.7 kVA, adjustable power |
| Carrier gas |
Oxygen purity ≥ 99.5% |
| Power gas |
Nitrogen or other safety gases |
| Voltage |
220 VAC ±10%, 50 ±1 Hz, 16 A (110V is also available) |
Physical
| Specification |
QualiCSA™ 5 |
QualiCSA™ 5M |
| Dimensions (W × D × H) |
620 × 760 × 800 mm |
| Weight |
120 kg |
Capability Differences
| Capability area |
QualiCSA™ 5 |
QualiCSA™ 5M |
| Intended sample focus |
General-purpose inorganic solids, metals, alloys |
Geological/mineral samples and complex matrices |
| Moisture handling emphasis |
Supports direct wet sample introduction via physical dehydration option |
Stronger focus on moisture elimination for wet/powdery mineral-style samples |
| Dust and contamination burden |
High-efficiency dust removal and self-cleaning design |
Enhanced dust removal emphasis for heavy dust loads typical in mineral matrices |
| Corrosive byproducts tolerance |
Corrosion-resistant gas path design |
Corrosion protection emphasis for harsher matrices and longer continuous runs |
| Typical use environment |
Metallurgical QC + mixed lab applications |
Mining, geology, mineral labs, and high-load production testing environments |
