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
Related Industries
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철강
철강 산업에서는 제품뿐만 아니라 제조 및 운영 기술의 품질을 향상시키고 환경 및 에너지 효율 문제를 해결하는 것 또한 중요합니다. Yokogawa는 고객이 이상적인 플랜트를 만들 수 있도록 돕고 동반 성장을 위해 발전해 나가고 있습니다.
Related Products & Solutions
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Oxygen Analyzers
산소 분석계는 연소 제어, 공정 품질, 안전 및 환경 응용 분야에서 중요한 측정을 제공합니다.
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지르코니아식 산소/습도 분석기 ZR22G, ZR802G
이 장비는 고온에서 산소 및 습도 측정이 가능하며 매우 정교한 지르코니아 센서가 장착된 ZR22G 검출기와 디지털 통신 및 데이터 로그 기능을 갖춘 변환기 ZR802G로 구성됩니다. ZR22G 및 ZR802G는 샘플링 장치 없이 연속적으로 측정할 수 있습니다. 센서의 성능을 자가진단하고 (교정 가스를 사용하지 않음) 현장에서 Heater assembly를 교체하여 유지 보수를 용이하게 하여 작업 비용을 줄일 수 있습니다.