Introduction
To detect air leaks, an oxygen analyzer is used. The ZR22/ZR802 Direct In-Situ Zirconia Oxygen Analyzer has been well received due to its good response speed, stability, and maintainability. It has been confirmed that the ZR22/ZR802 can be used in DL type sintering furnaces under harsh conditions that include large quantities of dust, high humidity, and a pressure of approximately −5 kPa.
In sintering furnaces, periodic equipment maintenance has proven to be the most effective way to prevent air leaks. While cost reduction is a concern, energy loss from air leaks is also an issue. Air leak detection is performed so that equipment can be repaired in a timely manner or some other appropriate measure be taken.
Expected Benefits
- Saves energy and improves the efficiency of sintering furnaces, thereby maintaining high quality
- Ensures stable air leak detection
- Reduces operating costs
Process Overview
A sintering furnace mixes powdered ore with auxiliary materials such as powdered coke and sinters them to make lump ore, which is used as a raw material in blast furnaces. Since modern blast furnaces are large and require sophisticated and efficient operation, stringent control of the quality (lump size) of the sintered ore is essential. Air leakage detection is of paramount importance not only because it saves energy but also because it ensures the proper operation that produces high quality sintered ore through proper operation.
Flow Diagram of a Sintering Furnace
Solution Details
Field Data
Process conditions
| Measurement point: | Wind box |
|---|---|
| Temperature: | 200°C or less |
| Pressure: | −5 to 0 kPa |
| Composition: | CO2: approx. 10%; CO: approx. 2%; O2: 8 to 16%; N2: approx. 76%, SO2: approx. 600 ppm |
| Humidity: | 4 to 17% (with water droplets) |
| Dust: | 1 to 5 g/Nm3 (sintered powder/lumps: approx. 30 mm in diameter) |
| Flow rate: | Approx. 2 to 5 m/s |
Measurement system
| Detector: | ZR22G-100-C-K-P-☐-☐-E-A/C/CV |
|---|---|
| Probe protector: | ZO21R-L-100-J*B |
| Converter: |
ZR802G-☐-☐-N-N /□ |
| Automatic calibration unit: | ZR40H-☐-☐-A |
| Standard gas unit: | ZO21S-☐-E*A |
| Zero gas cylinder: | G7001ZC |
| Pressure regulator: | G7013XF or G7014XF |
| Case for calibration gas cylinder: | E7044KF |
Note: the calibration gas cylinder must be purchased locally.
Utilitie
| Rated voltage: | 100 to 240 V AC | |
|---|---|---|
| Rated frequency: | 50/60 Hz | |
| Power consumption: | 330 VA (Max. 800 VA) | |
| Instrument air (reference gas): | pressure: 300 to 700 kPa | |
| consumption: approx. 1 l/min | ||
Notes
- Since the sample gas contains large quantities of sintered powder, a probe protector should be used to protect the detector.
- If the sample gas contains CO, compensation may be required. Contact Yokogawa.
- The detector should be installed so that the probe head does not point upstream into the gas flow. It is best to mount the detector vertically with the probe tip pointing downward. If necessary, it can be installed at any angle between 0°C and 90°C with respect to the vertical
相关行业
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钢铁
在钢铁工业中，不但要提高产品质量，而且要提高制造和运营技术，解决环境问题、提高能源效率。横河帮助客户创造理想的工厂，并与客户共同成长。
相关产品&解决方案
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氧分析仪
氧分析仪在燃烧控制、工艺质量、安全环保等领域提供有价值的测量数据。
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氧化锆氧/湿度分析仪ZR22G、ZR802G
该氧浓度和湿度分析仪可在高温下使用，由ZR22G检测器和ZR802G转换器组成。ZR22G检测器配备寿命长且高度可靠的氧化锆传感器，ZR802G转换器配备数字通信和数据记录功能。
ZR22G 和 ZR802G无需采样设备即可直接连续测量。通过传感器劣化的自诊断（不使用校准气体）、现场更换加热器组件，易于维护并降低运营成本。
