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TR-9200 Calorific Value Analysis System

The TR-9200 calorific value analysis system is a specialized online analysis system used for gas calorific value analysis in coke oven gas projects. The system has advanced technology, accurate measurement, fast reaction speed, and can continuously analyze the measured gas for a long time. It adopts PLC for automatic control and has the characteristics of reasonable structure, safe and reliable operation, high degree of automation, less maintenance, and strong self diagnostic protection function.

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Detailed description

Summary

This system is professionally designed based on the gas calorific value analysis working conditions of the coke oven gas project, and modular and targeted design is carried out on the basis of mature pretreatment technology and analysis control technology from Xi'an Juneng Instrument Co., Ltd.

The complete gas analysis system for this process (hereinafter referred to as the system) is an online monitoring system for the gas calorific value of the coke oven gas project, including analysis instruments (calorific value) for CO, H2, and CH4, as well as the application guarantee part (standard gas) for the pre-treatment device and its accessories; By targeting the on-site application conditions. The system design of process gas sample conditions, the correct matching and reasonable combination achieved, enables CO, H2, and CH4 analytical instruments (calorific value) to adapt well to the special process conditions of gas calorific value analysis in coke oven gas projects. The system can automatically, continuously, accurately, and reliably analyze the content of CO, H2, and CH4 in coal gas. The calorific value is displayed using * * Kcal/Nm3, and the system can provide four standard output signals of 4-20mA for CO, H2, CH4, and calorific value simultaneously during normal operation; And output an over limit alarm status signal based on the content value of the measured components. The analytical instrument of this system is the sensor core, which is imported from the original equipment. The system has advanced technical solutions, concise structure, reliable component performance, high degree of automation, simple operation, and low maintenance, making it an ideal equipment for monitoring the calorific value of coke oven gas.

This system mainly consists of sampling unit (gas source purification unit), gas transmission unit, pretreatment unit, analysis unit, control unit, and calibration unit. Can be applied to monitor the calorific value of coke oven gas. The system has many characteristics such as safety and reliability, real sampling, fast response, high analysis accuracy, and optimal configuration and selection. The system not only considers adapting to hazardous environments, but also avoids the generation of unsafe factors within the system.

Calorific value calculation method

Coke oven gas is a gas generated by the reaction of refining coke in a closed coke oven. It is a high calorific value gas fuel, mainly composed of CO, H2, CH4, etc. After being pressurized, it is transported to various heating furnaces to improve comprehensive utilization efficiency.

The analysis system for calculating the calorific value of coke oven gas (as shown in Figure 1) is composed of a sampling probe (sampling unit), a blowing unit, a sampling pretreatment unit, a flow control unit, a gas path switching unit, a gas analysis instrument, a PLC program control unit, an analog input and output unit, a display unit, a standard gas unit, and other parts. It can continuously measure the volume percentage concentration of the measured gas components and calculate the calorific value of coke oven gas.

The analysis system extracts coke oven gas from the process pipeline through a sampling probe, and obtains a dry and clean sample gas that meets the requirements of the gas analysis instrument through three-stage filtration, pre-treatment, pressurization, dilution, stabilization, condensation dehumidification, and fine filtration of the probe. The gas enters the calorific value gas analysis instrument through flow regulation to measure the volume ratio (percentage content) of CO, H2, and CH4 components in the coke oven gas. The entire working process of the system is automatically controlled through a programmable controller (PLC), and the 4-20mA current signal corresponding to the volume ratio (percentage content) of each component is connected to the PLC analog input and output module. Due to CO The various components of H2 and CH4 have different calorific values. Based on the relationship between the volume ratio (percentage content) of the components and the corresponding calorific value of a single component, a mathematical model can be constructed and the calorific value of coke oven gas can be obtained through mathematical formula calculation. The calculation process of calorific value is achieved through programmable logic controller (PLC) software programming. The current signals corresponding to the volume ratio (percentage content) of each component are continuously read from the PLC analog input and output module through a programmable controller (PLC), and the heating value of the online coke oven gas is calculated. The simulated 4-20mA current signal corresponding to the heating value is transmitted to the CCR system through the PLC analog input and output module. At the same time, the volume ratio (percentage content) value and heating value (Kcal/NM3) of each component can be intuitively monitored through the LCD display screen. Practice has shown that the results obtained by calculating the calorific value using the gas component volume ratio (percentage content) have a similar trend to the results measured by the direct combustion calorimeter. However, the response of the calculated calorific value to process changes is much faster than the measured output of the calorimeter. The lag time of the output value of the calorimeter is about 6 minutes, and there is almost no lag time for calculating the calorific value.

 

Composition diagram of gas analysis complete system

 

Steps to achieve system calorific value calculation

Building a mathematical model for calculating the calorific value of coke oven gas.

The analysis system can measure the volume ratio (percentage concentration) of each component in coke oven gas through infrared and thermal conductivity gas analysis instruments. Based on the relationship between the volume ratio (percentage concentration) of each component and the corresponding calorific value of a single component, a mathematical model is first built to obtain the mathematical formula, and then the calorific value of coke oven gas can be obtained through mathematical formula operation.

Using a Programmable Logic Controller (PLC) to calculate calorific value and output.

The mathematical formula for calorific value is programmed through programmable logic controller (PLC) software to achieve calculation functions.

(1) The 4-20mA current corresponding to the component content is converted to the actual value. After the PLC programmable controller analog-to-digital conversion, the low 3 bits and the high 0 bits of the digital value are 0. After shifting to the right 3 bits, the 0-20mA current corresponds to the digits 0-4096. Therefore, 4-20mA corresponds to 819-4096. Assuming the zero point of the actual value is ZERO, the range point is SPAN, and the actual analog-to-digital conversion value is COUNT.

Actual value=(SPAN-ZERO) x (COUNT-819)/4096-819

(2) The actual value is converted to 4-20mA current, and the digital quantity required for the analog-to-digital conversion of the PLC programmable controller is in the 4th to 14th digits of the number, with other digits being 0. Therefore, the resolution is 11 bits, and the analog output range is 0-32000, which is a binary 0-0000 01111101 0000. After shifting 4 bits to the right, it is 0-2000, so it can be considered that the current output of 0-20mA corresponds to 0-2000, and 4-20mA corresponds to 400-2000. Assuming the zero point of the actual value is ZERO, the range point is SPAN, and the actual value is Value. Expanding the value by 100 times in the formula is because the calculation in PLC is an integer calculation, in order to improve calculation accuracy!

{(2000 − 400) x (Value x 100)/(SPAN − ZERO) x 100}+400

The display of the volume ratio (percentage concentration) and calorific value (Kcal/NM3) of coke oven gas components is achieved through programming with a programmable logic controller (PLC). The volume percentage concentration and calorific value of coke oven gas components are displayed on a text display, allowing users to more intuitively monitor the volume percentage transition value and calorific value of each component in coke oven coal gas, and better control the combustion status of coke oven gas.

The analysis system for calculating the calorific value of coke oven gas has been put into use in many large metallurgical enterprises. Practice has proven that this system has short response time, convenient operation, intuitive, accurate data, and is widely used.

 

System technical indicators and parameters

Main characteristics of the system

• Innovative filtering principles fundamentally solve the problem of tar blockage.

• Adopting independent innovative patented technology sampling probe, reverse blowing for cleaning dust, tar, etc., to solve the problem of impurity agglomeration.

• The system has online sampling and analysis function, with fast response speed, ensuring continuous online analysis.

• The system adopts full dry filtration, with undistorted sampling and accurate analysis.

• A fully automated system that is truly completely unmanned.

• Visual display of calorific value, constantly observing changes in calorific value.

• Using a touch screen interface program control, various parameters within the PLC program can be modified at any time through the touch screen.

Technical requirements for system installation

• To ensure that the system can reflect working conditions in real time, reduce lag, and ensure safety, the distance between the sampling point and the analysis cabinet should be as short as possible, generally not exceeding 20 meters.

• The analysis cabinet adopts external dimensions: single point 2000 × 800 × 600. Open the front and back doors, and the inlet and outlet pipelines are behind and below the analysis cabinet. Please leave space.

• Analysis room requirements: It is recommended that the area of the analysis room be greater than 3500 × 4000mm2, and the temperature inside the room should be within the range of+5~45 ℃.

• When the outdoor temperature is below 0 ℃, the outdoor drainage pipe should have insulation and anti freezing measures.

 

System composition and function

The TR-9200 complete set of calorific value analysis system is a specialized online analysis system used for gas calorific value analysis in coke oven gas projects, and has been awarded the title of "National New Product". The system has advanced technology, accurate measurement, fast reaction speed, and can continuously analyze the measured gas for a long time. It adopts PLC for automatic control and has the characteristics of reasonable structure, safe and reliable operation, high degree of automation, less maintenance, and strong self diagnostic protection function.

Analytical instruments

The analytical instrument used in the TR-9200 complete system is a gas analyzer manufactured by Xi'an Juneng Instrument Co., Ltd. with imported sensor technology. The instrument has accurate measurement, reliable performance, and high cost-effectiveness.

The analytical instrument unit adopts the JNYQ series analyzer from Xi'an Juneng Instrument Co., Ltd. to complete online continuous analysis of sample gases CH4, CO, and H2. The sensors of the analyzer are manufactured using advanced technology from foreign companies, with stable and reliable performance, fast response time, and high level of intelligence.

Analysis parameters: carbon monoxide, methane, hydrogen (calorific value).

The JNYQ-I-91 multi-component (including infrared) analyzer can continuously detect the volume concentration of carbon monoxide and methane components to be measured in process gas samples. The sensor technology using imported light sources and detectors greatly improves the stability of the instrument.

Instrument characteristics

• Carbon monoxide and methane are analyzed using the principle of non dispersive infrared spectroscopy;

• High stability infrared light source: The light source filament adopts a special armor process, which extends its service life;

• Single chamber structure receiver, capacitive precision sensor detection output, good instrument stability;

• Measurement chamber gold plating for corrosion resistance, unique grinding process, achieving mirror finish on the inner wall;

• Unitization of instrument components for easy maintenance and repair;

• Alarm output (upper and lower limit extreme value alarm);

• Standard signal isolation output 4-20mA.

Main technical performance

• Zero drift: ≤ ± 1% FS/7d

• Range drift: ≤ ± 1% FS/7d

• Measurement range: CO: 0-10%; CH4:0~30%

• Repeatability error: Cv ≤ 0.5%

• Linear error: ≤ ± 1% FS

• Preheating time: 30 minutes

• Response time: ≤ 5s

• Output signal: 4-20mA ≤ 750 Ω

The JNYQ-I-91 multi-component (including thermal conductivity hydrogen) analyzer is an industrial fixed on-site installation instrument that uses different physical measurement methods for the thermal conductivity of different gases. It can continuously and automatically detect the volume concentration of the hydrogen component to be measured in the process gas sample.

Instrument characteristics

• Unique sensor design, precise constant temperature control, fast response, good linearity, and high stability

• Thin film button operation (zero point, full scale, linear calibration, parameter setting, etc.), flexible and convenient to operate

• Fault self diagnosis function

• Unitization of instrument components, convenient maintenance and repair

• Alarm output (upper and lower limit extreme value alarm)

• Standard signal isolation output 4-20mA

• Cast aluminum alloy chassis

• Unitization of components, convenient maintenance and repair

Main technical performance

• Zero drift: ≤ ± 1% FS/7d

• Range drift: ≤ ± 1% FS/7d

• Measurement range: H2: 0-60%

• Linear error: ≤ ± 1% FS

• Repeatability error: Cv ≤ ± 1%

• Output fluctuation: ≤ ± 1% FS

• Preheating time: 30 minutes

• Response time: T90 ≤ 12s

• Output signal: 4-20mA ≤ 750 Ω

Key words:

Flue gas analyzer, flue gas online monitoring, VOCS online monitoring, waste incineration online monitoring


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