Metallurgical Process Gas Online Analysis System

Metallurgical Process Gas Online Analysis System

1、 Product Overview

The indirect fusion smelting of modern steel industry mainly takes the form of reduction smelting and oxidation refining. Process analysis systems are required for coke ovens, blast furnaces, hot blast stoves, coal injection systems, heating furnaces, electric furnaces, converters, and gas holders. The smelting process of steel and other metals produces a large amount of gases, and analyzing these gases plays a very important role in optimizing production, improving quality, recycling energy, environmental protection and energy conservation, and safety control.

2、 Product Introduction

The TK-2000 series metallurgical process gas analysis system is designed specifically for measuring the oxygen content and online calorific value analysis of process gases in domestic boiler bituminous coal powder production, gas generator gas, blast furnace coal injection and gas, and converter gas. It is specifically designed for blast furnace coal injection/converter gas and various high dust process conditions. The system is stable and reliable, ensuring process safety, and is equipped with single point and multi-point switching automatic sampling analysis systems.

The TK-2000 series metallurgical online analysis system is a process analysis instrument for measuring gas composition. In many production processes, especially those involving chemical reactions, automatic control based solely on physical parameters such as temperature, pressure, and flow rate is often insufficient. Due to the vast differences in the analyzed gases and the diverse analysis principles, there are numerous types of gas analyzers. Commonly used gas analyzers include thermal conductivity gas analyzers, electrochemical gas analyzers, and infrared absorption analyzers. The analyzer is a programmable PLC fully automatic control system, with LCD display and providing industrial standard 4-20mA analog signals, which can be synchronized with industrial computers and controlled through signal interlocking.

3、 Product application

1. Blast furnace and coal injection system

The main purpose of blast furnace gas analysis is to optimize control, with control points after gravity dust removal and bag dust removal. The detection of O2 in the coal injection system is for safety control, and when O2 exceeds 10%, NH3 dilution is required.

• Filter analysis and detection points for blast furnace and coal injection system

co

（o2）

• 0～1500ppm

o2Recycling control

Same cold end

Analyze system characteristics

：For the hot and humid, high dust gas at the top of the blast furnace, dual high-efficiency filtration sampling probes are used for sampling, and nitrogen gas is periodically blown back to ensure the long-term reliable operation of the probe filter. The sample gas is analyzed by the pre-treatment system and the component content is measured by the analytical instrument. The system is a programmable PLC fully automatic control system, with LCD display and providing industrial standard 4-20mA analog signals, which can be synchronized with industrial computers and controlled through signal interlocking.

Instrument analysis components: CO, CO2, N2, H2, CH4, and calorific value.

Scope of application

：

Analysis of gas composition at the top of the furnace after gravity dust removal, analysis of blast furnace gas after spray dust removal, and analysis of mixed gas composition.

Note: The system can be installed and used in gas explosion hazardous areas.2. Gas Analysis System for Nonferrous Metal Smelting Furnace

The high-temperature smelting system for non-ferrous metals requires analyzing the composition of furnace gas to provide important data parameters for stable and optimized operation to the operator, as well as evaluating the economic value of waste gas recovery.

Analyze system characteristics

：

For corrosive gases with high dust, TK-2000 samples through a filtering sampling probe and regularly cleans with nitrogen or instrument air to ensure long-term continuous and reliable operation. The sample gas is processed by a pre-treatment system and sent to the analytical instrument for precise measurement of component content through acid mist, sample pump pressurization, and filtered clean sample gas. The system is a programmable PLC fully automatic control system, with LCD display and providing industrial standard 4-20mA analog signals, which can be synchronized with industrial computers and controlled through signal interlocking.

Instrument analysis components: SO2, O23. Wet refining gas analysis system

The wet smelting system for non-ferrous metals requires analyzing the composition of the reaction gas to provide the operator with important data parameters for stable and optimized operation.

Analyze system characteristics

：

The leaching process uses high-pressure and high humidity gas, and adopts a special sampling process to ensure the long-term continuous and reliable operation of the system. The sample gas is processed by a pre-treatment system and filtered before being sent to an analytical instrument to measure its component content. The system is a programmable PLC fully automatic control system, with LCD display and providing industrial standard 4-20mA analog signals, which can be synchronized with industrial computers and controlled through signal interlocking.

Instrument analysis components: h2, o24. Powder milling system, gas composition analysis system for powder coal bin

The coal powder preparation system in ironworks poses a risk of coal powder and oxygen explosion, as well as the risk of carbon monoxide gas and oxygen mixture explosion generated during coal grinding, transportation, and storage. To ensure equipment safety, multiple measurement points need to be set up to detect oxygen and carbon monoxide content to guide operations and ensure safe production.

Analyze system characteristics：

For high dust gases, the TK-2000 adopts a dual filter sampling probe sampling process, which regularly uses nitrogen back blowing to remove dust inside the filter and probe to ensure long-term reliable operation of the probe. The clean sample gas is sent to the analytical instrument for precise measurement of component content through the pre-treatment system. The system is a programmable PLC fully automatic control system, with LCD display and providing industrial standard 4-20mA analog signals, which can be synchronized with industrial computers and controlled through signal interlocking.

Analyze the components

：

Electrochemical/magnetic oxygen analyzer measures oxygen content, infrared analyzer measures carbon monoxide content; It can output 4-20mA standard signals and high/low alarms, and can also transmit signals through RS485.

Note: The system can be installed and used in areas with dust explosion hazards.5. Coke oven gas electric tar catcher oxygen analyzer system

By measuring the oxygen content in coke oven gas, ensure the safe operation of electric tar capturing equipment.

Analyze system characteristics

：For coke oven gas containing tar, dust, benzene, naphthalene, etc., TK-2000 uses multi-stage filtration, tar removal, condensation dehumidification, and filtered clean sample gas to send to analytical instruments for measuring the content of components. The system is a programmable PLC fully automatic control system, with LCD display and providing industrial standard 4-20mA analog signals, which can be synchronized with industrial computers and controlled through signal interlocking.

Note: The system can be installed and used in gas explosion hazardous areas.

4、 System technical indicators

：

System response time: ≤ 10 seconds

Measurement range: customized according to customer requirements

Measurement accuracy: ± 1% f.s

Drift: Zero point: ≤ 1% of the range per month; Range drift: ≤ 1% of the range per month

Solid particle filtration accuracy: 1 μ m

System maintenance cycle: 1 year

Repeatability: ≤ 1% of the measuring range

Signal output: 4-20mA isolated current signal

Alarm output: Contact capacity 3a/220V, customizable function

System reliability: mean time between failures: mtbf ≥ 20000 hours

PLC automatic control, continuous sampling, automatic blowback, analysis result over limit warning, interlock control function.

Output signal: 4-20mA, control alarm signal no/nc

Working power supply: 220vac 50hz

Working temperature:+5 ℃~+45 ℃

Environmental humidity: ≤ 90%

Working gas source: clean nitrogen source ≤ 1.6mpa 30nm3/24h