Gas is a clean and efficient secondary energy source. However, due to the fact that gasifier stations are auxiliary production equipment in industrial enterprises, their technological advancements have not received sufficient attention. As a result, the industrial gas industry remains largely at the level of the 1950s and 1960s in terms of equipment and technology. This outdated state severely limits the widespread application of gas in industrial settings.
A gasifier is a device that uses coal and air or steam as gasification agents to produce gas. Anthracite coal and the gasification agent are fed into the furnace through the coal feeding system and the bottom of the furnace, respectively. In the furnace, an oxidation-reduction reaction occurs, producing gas. The material layer inside the furnace is distributed from bottom to top as follows: ash layer, oxidation layer, reduction layer, pyrolysis layer, and drying layer. For normal gasification, the furnace requires a properly distributed and stable material layer, along with a high reaction temperature.
The automatic control system for gasifiers involves real-time monitoring of the furnace conditions. Gasifier production is a complex chemical process involving solid-gas phase reactions. The internal conditions of the furnace change based on raw material properties, equipment status, user demands, and human factors. Parameters such as reaction temperature, material layer thickness, position, and distribution are critical in determining the furnace condition. These parameters are difficult to measure directly and are typically assessed through external analysis and manual probing.
By implementing a furnace condition monitoring system, operators can obtain accurate and visualized data without manually checking the fire. Key technologies include detection techniques, signal analysis, and model development. Generally, thermocouples can be used to replace manual checks of the ash barriers located around the lower part of the furnace. By measuring the temperature of these barriers, it's possible to infer the height and position of the ash layer, as well as the fire layer.
However, this method has limitations. When the material layer is uneven or the fire layer is far from the barriers, the temperature readings may not be accurate due to interference from gasifying agents and water jackets. To improve accuracy, additional measurement points, improved probe placement, and advanced signal separation techniques can be used. Comparing measured temperature data with actual material layer data helps establish a relationship between temperature and material height, allowing the system to display the material layer distribution in real time.
Despite these improvements, the system still relies on stable furnace operation. Internal sensors only reflect the temperature near the furnace wall, while the internal material layer temperatures are estimated theoretically. If the furnace conditions are unstable, the monitoring results may become inaccurate. Adding a central ash detection system could enhance the adaptability of the monitoring system.
In addition to furnace condition monitoring, online detection of gas composition using a high-quality gas analyzer can replace traditional manual methods. Combined with the furnace monitoring system, this forms a comprehensive online monitoring system for gasifiers.
Saturation temperature is a crucial parameter that determines the reaction temperature. Its automatic control can be achieved using a PID loop. Depending on the furnace design, saturation temperature can be controlled by adjusting incoming steam or managing self-produced steam. For certain furnace types, adding a steam collection tank can enable more effective automatic regulation.
Emergency power failure handling is also important. During a power outage, the furnace operator must quickly open steam valves to prevent gas backflow. Automating this process ensures rapid response, especially in large gas stations where manual operations may be too slow.
Automated coal feeding and ash removal systems help maintain consistent material layer distribution, reducing the impact of human error. Using furnace outlet temperature and coal feeding intervals as control parameters allows for precise regulation. This approach promotes scientific and regular coal feeding and ash removal, which is difficult to achieve manually.
Load regulation is essential for large gas stations with fluctuating demand. Adjusting the fan speed instead of individual valves simplifies the control system and improves efficiency. Similarly, controlling steam collector water levels and coal bunker levels are straightforward tasks that can be easily automated.
Finally, integrating all these systems into a computer control system enhances overall monitoring and management. Using network technology, the system collects and processes I/O data, communicates via redundant networks, and connects to the company’s information system. This allows remote monitoring and efficient management of the gas production process.
In conclusion, the automation of gasifiers involves standard industrial control technologies and represents an optimization of existing processes and equipment. Success depends on improving and adapting current systems for automation. With the integration of information technology, the computer control system for gasifiers is a significant achievement for the industry, enhancing technical standards, equipment quality, and operational management.
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