Calcium carbide furnace gas analyzer (carbon monoxide, oxygen, hydrogen, carbon dioxide, CO, O2, H2, CO2 and other calcium carbide furnace analyzers)
TR-9700 calcium carbide furnace gas analyzer is a safe and reliable, real sampling, fast response and high analysis accuracy of closed calcium carbide furnace exhaust gas analysis system design.
Foreword: Calcium carbide (CaC2) is a basic organic chemical raw material, once known as the mother of organic synthesis. Acetylene gas produced by it can replace petroleum products to produce acetic acid, vinyl acetate, polyvinyl chloride, polyvinyl alcohol, acetylene carbon ink and other gas raw materials for thousands of organic products. As a branch of coal chemical industry, calcium carbide chemical is a vital industry on the one hand, and a high energy consumption and high pollution industry on the other. In the production of calcium carbide, the flue gas emitted by the calcium carbide furnace is the biggest source of pollution. In order to strengthen environmental protection governance and achieve energy recovery and utilization, reduce production costs, and improve corporate and social benefits, in accordance with the opinions of the National Development and Reform Commission Document No. 70 of 2007 "Access Conditions for the Calcium Carbide Industry" (revised in 2007). Newly built calcium carbide furnaces must meet the following four requirements: (1) construction of large-scale enclosed calcium carbide furnaces; (2) the capacity of a single furnace above 25,000KVA; (3) the initial total capacity of 100,000KVA; (4) calcium carbide furnace gas must be comprehensively utilized. The purification and utilization of calcium carbide furnace gas is a problem at home and abroad. To fully, safely and effectively use calcium carbide furnace gas, it is necessary to effectively monitor the calcium carbide furnace exhaust gas. There are three main methods of calcium carbide furnace exhaust gas analysis: manual (Austria gas analyzer) analysis, chromatographic analysis, and online analysis. This article only briefly analyzes the online monitoring of the enclosed calcium carbide furnace gas, and briefly introduces the design of the calcium carbide furnace exhaust gas analysis system. Hope to throw bricks and attract jade, so as to realize the full utilization of the exhaust gas after the reconstruction of the new calcium carbide furnace and the old calcium carbide furnace, and then realize environmental protection, labor protection and energy recovery and utilization, reduce production costs, and improve business and social economic benefits. 1. Characteristics of the furnace gas In the enclosed calcium carbide furnace in the production process, the main reaction formula of the product produced after power-on is shown in (1):
1.1 Furnace gas volume: calcium carbide;
1.2 Temperature: Normal 400-800 ℃, (instantaneous) 1000 ℃.
1.3 Composition of furnace gas (general)
1.4 Dust content and components Dust content:
2. Characteristics of furnace gas The exhaust gas of the sealed calcium carbide furnace has the following characteristics:
(1) The exhaust gas temperature of calcium carbide furnace is high and unstable;
(2) The furnace gas volume fluctuates and is not stable, the concentration of carbon monoxide in the exhaust gas is high, about 74-85%, and the temperature is high, which is a flammable and explosive gas;
(3) The tail gas dust content is large and the particle size is small, 5 ~ 10μm accounts for about 40% of the dust, less than 11% greater than 40μm, soot up to 150g / Nm3 makes the recovery of tail gas very unfavorable;
(4) The exhaust gas has a certain calorific value of about 2300-2600 Kcal / Nm3;
(5) The tail gas contains traces of tar, which sticks to the dust after precipitation, which causes inconvenience to low temperature dust removal.
3. The general analysis system of the exhaust gas analysis series of the sealed calcium carbide furnace can be divided into three parts from the structure, namely the sampling system, the pretreatment system and the analysis system. According to the above characteristics of furnace gas, after years of experience accumulation, Xi'an Joneng Instrument Co., Ltd. has divided the analysis system into several parts as shown in Figure 1. According to the design and manufacture of the complete system, a new large-scale sealed calcium carbide furnace (50,000 tons) and the application of the old calcium carbide furnace transformation have achieved good results.
The following briefly introduces the design of the analysis system.
3.1 Selection of sampling points The selection of sampling points should meet the following requirements: it can truly and timely reflect the furnace parameters of interest to the user; the sampling point temperature, pressure and flow rate are relatively stable; the amount of dust and tar is as small as possible. If the sampling point is not selected properly, it will bring additional burden to the subsequent system, and it may not even truly reflect the required furnace condition parameters.
3.2 Design of the sampling system The sampling system is the first pass of the entire analysis system. Whether it succeeds will directly lead to the success or failure of the entire analysis system. The temperature of the sampling point of the calcium carbide furnace tail gas is about 200-300 ℃, and the relative pressure is between slightly positive pressure and slightly negative pressure. Due to the special nature of the furnace gas, the sampling system must have a preliminary physical separation of the sample components. The solid particles around the probe are separated from the gaseous fluid, so the sampling system must not only have a probe (sampling tube), but also a filtration system, a probe cleaning system, etc. In addition, it should have a structure that is easy to maintain. The sampling probe independently developed by Xi'an Joneng Instrument Company can filter out 99% of the dust larger than 0.3μm. Using PP1190 sampling probe, and then equipped with program-controlled automatic purge device, can take on this important task.
3.3 Design of the pretreatment system The pretreatment system mainly completes the safe, timely and effective treatment of the gas sample delivered from the sampling system to meet the conditions of use of the instrument analysis system. First, the design of the transmission pipeline must meet the aerodynamic requirements, so that the sample gas flow path is unobstructed; then, the sample gas is subjected to a series of continuous inertial treatments such as dust removal, tar removal, pressure regulation, water removal, and steady flow. The processed sample gas is dried and cleaned, so that the key components entering the instrument analysis system can be accurately analyzed. So as to provide a scientific basis for the production safety of calcium carbide and the effective use of furnace gas.
Dust removal system includes filtering, cleaning, re-filtering, etc. to prevent pipeline blockage; decoking and degreasing system includes temperature control, washing out, adsorption, etc., which is conducive to the smoothness of the pipeline and protects the analysis equipment; Mist trapping, gas-water separation, dry filtration, etc., protect the analyzer and ensure the accuracy of the test; the pressure adjustment system includes pumps, regulating valves, fast loops, etc., to ensure the normal working conditions of the instrument. Programmable control (PLC) system, mainly including PLC, program software, execution mechanism, man-machine interface, etc., is mainly used to realize automatic control of the sampling pretreatment system, and alarm when an abnormal situation occurs.

3.4 Instrument analysis system This system includes flow adjustment device, anti-abnormal water inlet device, calibration device, analysis instrument, etc. Among them, the anti-abnormal water inlet device uses a patented liquid stopper of Xi'an Energy Concentration Instrument. In the event of an abnormal process, it will ensure that the analytical instrument will not damage the instrument due to water ingress. The analysis instrument is configured according to the production process of calcium carbide and the use of exhaust gas. Generally, O2, H2, CO and other gases in the exhaust gas of a sealed calcium carbide furnace are required items. Among them, the content of O2 and H2 is a safety index, and CO is the core of exhaust gas utilization. For the measurement of O2, choose O6F, PA200 / PA300-GT, etc .; for the measurement of H2, choose PA100 / PA200 / PA300-RQD, etc .; for the measurement of CO, choose PA200 / PA300-GXH, etc. For locations where CH4 and CO2 need to be measured, the TR-9700 analyzer can be selected.
4. Application of calcium carbide furnace exhaust gas complete analysis system The calcium carbide furnace exhaust gas analysis system manufactured by Xi'an Joneng Instrument will be designed on the basis of the functional block diagram shown in the figure, according to the working conditions and requirements of different users. Since the application of this system in Yihua in 2007, after continuous exploration and improvement, up to now, dozens of sets have been successfully put into operation, especially since 2009, the market has been getting better and better.
In short, the closed calcium carbide furnace is suitable for large-capacity furnace type, and the furnace gas can be comprehensively used after being drawn out from the furnace, which not only reduces the energy consumption of smelting, but also reduces the huge waste of energy, while greatly reducing the direct emission of flue gas. Conducive to environmental protection. In line with the relevant industrial policies of the country, it will surely achieve rapid development. At the same time, the on-line exhaust gas analysis system will have higher and higher requirements. Therefore, the calcium carbide furnace exhaust gas analysis system should put forward higher requirements in terms of advancedness, applicability, reliability, stability, and safety.
1. The composition of the device The device is a complete set of analysis and control device (see the schematic diagram of sampling and analysis of the system) of machine, electricity and instrument. The whole adopts the analysis cabinet structure. The complete device consists of the analysis cabinet components and the sampler installed on the process pipeline Component composition.
1.1 The integrated sampler components of electric half-heat automatic temperature control include: a. Special stainless steel electric semi-heating automatic temperature control sampling probe;
b. Stainless steel sintered candle wick type special probe filter (imported material);
c. Special electric half-heat automatic temperature control sampling tube assembly;
Complete on-site collection, delivery and first-stage filtration of sample gas, and then send it to the sample gas pretreatment unit in the analysis room.
1.2 Analysis cabinet components The analysis cabinet contains the following units:
a. Pretreatment unit The pretreatment unit is composed of special filter components, imported peristaltic drainage pump, compressor dehumidifier, imported special anti-corrosion suction pump, imported electric ball valve, precision filter, etc. Its function is to complete sample gas purification, dust removal, dehumidification, voltage stabilization, steady flow, etc., and its filtering accuracy can reach 0.1u. Then, the ultra-clean, stable flow of the sample gas that meets the requirements of the analyzer is continuously sent to the analysis instrument.
b. Analysis unit and analyzer function The analysis unit is equipped with the latest infrared and electrochemical sensors of the German Haak company to complete the online continuous analysis of sample gas CO, O2, H2. The analyzer has stable and reliable analysis performance, fast response time, and intelligence high.
The function of 1CO analyzer will produce a large amount of CO in the production process of calcium carbide. In order to ensure the heating value of waste gas reuse, it is necessary to detect CO and analyze the concentration of CO.
The role of 2O2 analyzer in the production process of calcium carbide, various pipelines can not meet the standard requirements of zero leakage, and air will enter from different locations, because there will be a large amount of combustible gas in the production process, plus oxygen in the air Higher, in order to ensure safety, therefore, the O2 in the process gas must be analyzed to ensure the safety of production.
For technical details, please consult! Zhang Bin 15091580679 18789429993

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