Online gas sampling analysis device and method

Abstract

The invention relates to the technical field of industrial process gas monitoring, in particular to an online gas sampling and analyzing device and method, and the device comprises an integrated pretreatment unit, a gas analyzing and detecting device and a pipeline system. The pretreatment unit adopts a two-stage dust removal structure combining rotational flow inertial separation and electrostatic dust removal, so that dust is efficiently removed; and then the temperature of the gas is controlled through the micro-channel heat exchange module, and gas-liquid separation is achieved through a super-hydrophobic membrane integrally formed through vacuum diffusion welding. According to the method, the pretreatment unit with an innovative structural design is adopted, two-stage dust removal is combined with micro-channel heat exchange temperature control, filter element blockage caused by condensate water generated and mixed with dust is avoided, loss of water-soluble gas is prevented, and the detection accuracy is improved. In addition, the pressure loss and energy consumption of the system are reduced through the integrated design of the modules, and the system is convenient to maintain and suitable for long-term online monitoring in complex industrial environments such as high temperature, high humidity and high dust.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial process gas monitoring, and in particular to an online gas sampling and analysis device and method. Background Art

[0002] The information disclosed in the background of the invention is only intended to enhance understanding of the overall background of the invention and should not necessarily be regarded as an admission or any form of suggestion that the information constitutes the prior art already known to a person skilled in the art.

[0003] In the field of industrial process gas monitoring technology, the stable operation of online gas sampling and analysis equipment is highly dependent on the pretreatment process, which is the core support for ensuring the system maintains accurate monitoring performance and reduces the incidence of failures over the long term. The core function of the pretreatment process is to purify the collected gas and adjust the operating conditions, specifically covering key operations such as particulate matter removal, interfering component separation, and temperature and pressure regulation. Therefore, a high-performance pretreatment system can significantly extend the analyzer's service life, reduce maintenance frequency, and lower operating costs, thereby significantly improving the automation level and actual usability of the entire online analysis system.

[0004] Although existing technologies have improved the pretreatment process through optimization methods such as multi-stage filtration and gradient dehumidification, difficult-to-overcome technical bottlenecks remain. The current mainstream pretreatment process generally adopts a common serial mode of dehumidification followed by fine filtration, or dust removal, dehumidification, and secondary dust removal. This has exposed significant flaws in actual operation: during the compressor refrigeration and dehumidification process, the condensed water generated easily mixes with the dust particles remaining in the gas, forming a sticky, muddy mixture. This mixture quickly adheres to the filter surface during the subsequent fine filtration step, resulting in a sharp reduction in the effective filtration area of ​​the filter element and a significant shortening of the clogging cycle. This not only increases maintenance workload and consumables costs, but also may affect monitoring continuity due to frequent maintenance downtime. Furthermore, the serial configuration of multiple processing units significantly increases the cumulative pressure drop of the gas as it flows through the entire pretreatment system. To ensure the stability of the gas sampling flow rate, a high-power vacuum pump must be configured to provide driving force. This directly leads to a high energy consumption proportion in the system, which does not meet the current development needs of industrial energy conservation and consumption reduction.

[0005] Therefore, how to break through the inherent limitations of the existing pretreatment process and solve the problems of easy filter clogging and excessive system energy consumption has become an important technical direction for improving the performance of online gas sampling and analysis devices. Summary of the Invention

[0006] In response to the problems existing in the prior art, the purpose of the present invention is to provide an online gas sampling and analysis device and method, aiming to solve the problems of lack of coordinated optimization and superposition of flow resistance and energy consumption caused by the separate design of dust removal, dehumidification and temperature control units in the pretreatment process.

[0007] In order to achieve the above purpose, the present invention adopts the following technical solutions: An online gas sampling and analysis device comprises a box body, in which a pretreatment system, a gas analysis and detection device, a gas pipeline system and a control component are installed; The pretreatment system includes an integrated pretreatment unit, the pretreatment unit includes a dust removal module, and a deep processing module is sealed and installed on the top of the dust removal module; The dust removal module includes a cyclone inertial separation shell, a cyclone separation chamber is provided in the cyclone inertial separation shell, an air inlet is tangentially provided on the top side wall of the cyclone separation chamber, a cylindrical airflow purification cylinder is provided at the top center of the cyclone separation chamber, a dust outlet is provided at the bottom center of the cyclone separation chamber, a dust collecting box is sealed on the dust outlet, and an electrostatic dust removal assembly is installed at the center of the airflow purification cylinder; The deep processing module includes a mounting cylinder, a microchannel heat exchange module is installed in the mounting cylinder, and the microchannel heat exchange module includes an integrally formed heat exchange main body, a plurality of microchannel pores and heat exchange channels are opened in the heat exchange main body, and the microchannel pores and the heat exchange channels are separated by a heat exchange core plate, and the heat exchange core plate is arranged through the heat exchange main body so that the microchannel pores are communicated with the upper and lower ends of the heat exchange main body, and the upper and lower ends of the heat exchange main body are further provided with water inlet and water outlet channels that are communicated with the heat exchange channels; the water inlet and water outlet channels are communicated with the water inlet pipe and the water outlet pipe respectively; the upper end of the heat exchange main body is provided with a super hydrophobic film through vacuum diffusion welding; A gas collecting hood is sealed and installed on the top of the deep processing module, and the gas collecting hood is connected with the gas analysis and detection device and the gas outlet in sequence through a gas pipeline system.

[0008] Preferably, the top of the cyclone inertial separation housing is configured as a conical cylinder, and the airflow purification cylinder is integrally formed and arranged at the center of the bottom end of the cyclone inertial separation housing; A micro-dust nozzle is integrally formed below the center of the airflow purification cylinder. The micro-dust nozzle leads to the dust outlet. An airflow outlet is provided between the airflow purification cylinder and the micro-dust nozzle.

[0009] Preferably, the gas pipeline system includes a first electromagnetic three-way valve connected to the air inlet and the calibration port, the first electromagnetic three-way valve is also connected to the power pump, the pressure regulating valve, and the working flow meter in sequence through the pretreatment unit, the working flow meter is connected to the air inlet end of the gas analysis and detection device, and the air outlet end of the gas analysis and detection device is connected to the air outlet through the second electromagnetic three-way valve and the pipeline; The second electromagnetic three-way valve is also communicated with the air inlet end of the back-blowing flowmeter, and the outlet end of the back-blowing flowmeter is communicated with the outlet end of the gas collecting hood of the pre-treatment unit through a pipeline.

[0010] Preferably, the air inlet is also connected to a straight-through detection branch, and a third electromagnetic three-way valve and a fourth electromagnetic three-way valve are respectively provided at both ends of the straight-through detection branch; the air collecting hood outlet end of the pretreatment unit is also connected to a straight-through outlet branch, and a fifth electromagnetic three-way valve and a sixth electromagnetic three-way valve are respectively provided at both ends of the straight-through outlet branch.

[0011] Preferably, the outer side wall of the airflow purification cylinder is provided with a swirl guide plate; The lower end of the airflow purification cylinder is configured to have a smaller diameter than the contraction opening of the particle dust spraying cylinder.

[0012] Preferably, the air collecting hood, the heat exchange body and the cyclone inertial separation shell are all sealed and connected to form an integrated structure through flanges.

[0013] At the same time, in order to better solve the above technical problems, the present invention also provides the following technical solutions: A method for performing online gas sampling and analysis using any of the above-mentioned online gas sampling and analysis devices includes a method for pretreating the gas to be tested, wherein the method comprises the following steps: S1, cyclone inertial separation: the gas to be tested enters through the air inlet and is subjected to coarse separation of large dust particles in the conical ring-shaped cyclone separation chamber; S2, electrostatic dust removal: The coarsely separated gas to be tested enters the air purification cylinder from the air outlet located in the center of the cyclone separation chamber, and the electrostatic dust removal component in the air purification cylinder refines the fine dust; S3, microchannel heat exchange temperature control: The subdivided gas to be tested enters the microchannel air holes on the bottom side of the heat exchange body and exchanges heat with the process cooling water in the heat exchange flow channel, making the temperature of the gas to be tested suitable for detection; S4, super-hydrophobic membrane dehumidification: The gas to be tested, which has been coarsely separated, finely divided and temperature-controlled, passes through the super-hydrophobic membrane on the top side of the heat exchange body to remove liquid water and oil mist.

[0014] Preferably, the heat exchange body is made of titanium alloy, and the thickness of the heat exchange core plate therein is 20-30 μm; the super hydrophobic membrane is made of polytetrafluoroethylene, and the membrane pore size of the super hydrophobic membrane is 0.2-0.4 μm.

[0015] The present invention has at least the following beneficial effects: Compared with the traditional serial pretreatment, which causes the condensed water and residual dust to mix into mud and clog the fine filter element, and the multi-stage units are connected in series, resulting in a large cumulative flow resistance, requiring a high-power vacuum pump and high energy consumption; in the present invention, on the one hand, the dust removal is thoroughly pre-placed and strengthened. Before dehumidification, most of the dust is removed through two-stage high-efficiency dust removal of cyclone inertial separation and electrostatic dust removal, ensuring that the dust content of the gas entering the dehumidification link is extremely low. On the other hand, the temperature is reduced by the microchannel heat exchange module, and no condensed water is generated. The combination of the two eliminates the formation of mud from the root, and then adopts efficient microchannel heat exchange and super-hydrophobic membrane dehumidification to coordinate treatment, while ensuring the treatment effect, minimizing the impact of the treatment link on the gas flow rate and response time.

[0016] Furthermore, integrating key pre-treatment units into a compact unit module significantly shortens the gas flow path, significantly reducing system flow resistance. This efficient dust removal and compact design reduce pumping power and energy consumption. Furthermore, the modular and maintainable design of this invention greatly enhances operational convenience. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 Schematic diagram of the internal structure of the deep processing module; Figure 3 It is a structural diagram of the dust removal module; Figure 4 Schematic diagram of the cross-sectional structure of the heat exchanger body; Figure 5 Schematic diagram of the bottom structure of the heat exchanger; Figure 6 Schematic diagram of the gas pipeline system.

[0018] The reference numerals are as follows: 100, housing; 200, dust removal module; 210, cyclone separation chamber; 211, dust collection box; 212, air inlet; 220, air purification cylinder; 221, electrostatic dust removal assembly; 222, cyclone guide plate; 230, micro-dust spray cylinder; 240, air outlet; 250, contraction port; 260, top of cyclone inertial separation shell; 300, deep processing module; 310, heat exchange body; 311, heat exchange core plate; 312, microchannel air hole; 313, heat exchange flow Channel; 314, super-hydrophobic membrane; 320, water inlet pipe; 330, water outlet pipe; 400, gas collecting hood; 411, first electromagnetic three-way valve; 412, power pump; 413, pressure regulating valve; 414, working flow meter; 415, second electromagnetic three-way valve; 416, backflush flow meter; 417, fifth electromagnetic three-way valve; 418, sixth electromagnetic three-way valve; 419, third electromagnetic three-way valve; 420, fourth electromagnetic three-way valve; 500, air outlet; 600, control component. DETAILED DESCRIPTION

[0019] The present invention will be further described below with reference to specific embodiments and accompanying drawings.

[0020] Example 1 Figures 1 to 6 An online gas sampling and analysis device is presented, comprising a housing 100, which houses a pretreatment system, a gas analysis and detection device, its gas piping system, and a control assembly 600. Housing 100 serves as both the mounting platform and protective housing for the entire device, providing a closed operating environment for the pretreatment system, gas analysis and detection device, and other components. This reduces interference from external dust and temperature fluctuations, while facilitating integrated layout and on-site installation.

[0021] The pretreatment system includes an integrated pretreatment unit, which is the key to ensuring the accuracy of gas analysis and is used to achieve graded purification and working condition regulation of the gas. It specifically includes a dust removal module 200, and the top of the dust removal module 200 is sealed with a deep processing module 300.

[0022] Among them, the dust removal module 200 includes a cyclone inertial separation shell, and a cyclone separation chamber 210 is arranged in the cyclone inertial separation shell. The cyclone separation chamber 210 serves as the basic structure of the dust removal module 200, and a closed cyclone separation chamber 210 is formed inside to provide a physical space for gas cyclone separation.

[0023] An air inlet 212 is tangentially provided at the top side wall of the cyclone separation chamber 210. Gas enters the cyclone separation chamber 210 tangentially from the top side wall, forming a high-speed rotating airflow in the chamber. The centrifugal inertia force is used to throw large particles of dust larger than 5μm toward the chamber wall, thereby achieving coarse dust removal and reducing the dust load of subsequent fine processing.

[0024] A cylindrical airflow purification cylinder 220 is provided at the top center of the cyclone separation chamber 210. Located at the top center of the cyclone separation chamber 210, it is the channel for the gas to enter the next processing link. At the same time, its outer wall can guide the rotating airflow to flow stably and avoid eddy current loss.

[0025] A dust outlet is located at the center of the bottom end of the cyclonic separation chamber 210. A dust box 211 is sealed within the outlet. An electrostatic dust removal assembly 221 is mounted in the center of the airflow purification cartridge 220. This assembly captures fine dust particles, such as PM2.5 particles, remaining after cyclonic separation through electrostatic adsorption, achieving fine dust removal. Dust separated by cyclonic separation and electrostatic precipitation settles through the outlet and is collected by the dust box 211. The dust box 211 is threadedly connected to the outlet, ensuring a tight seal and facilitating disassembly.

[0026] The deep processing module 300 includes a mounting tube, in which a microchannel heat exchange module is installed. The microchannel heat exchange module includes an integrally formed heat exchange body 310, which is conducive to reducing leakage points and has both corrosion resistance and high thermal conductivity. A number of microchannel pores 312 and heat exchange channels 313 are opened in the heat exchange body 310. The microchannel pores 312 and heat exchange channels 313 are separated by a heat exchange core plate 311. This is conducive to increasing the overall effective heat exchange area and maximizing the heat exchange efficiency, thereby achieving stable and precise control of the gas temperature, such as cooling high-temperature gas to a suitable temperature for the analyzer, or heating low-temperature gas to above the dew point.

[0027] The heat exchange core plate 311 is arranged through the heat exchange main body 310, so that the microchannel pores 312 are communicated with the upper and lower ends of the heat exchange main body 310, and the upper and lower ends of the heat exchange main body 310 are also provided with water inlet channels and water outlet channels that are communicated with the heat exchange channel 313; the water inlet channel and the water outlet channel are communicated with the water inlet pipe 320 and the water outlet pipe 330 respectively; the upper end of the heat exchange main body 310 is integrally formed by vacuum diffusion welding and is provided with a super hydrophobic membrane 314; to avoid the leakage problem caused by traditional bonding, because the pre-dust removal is thorough, there is no dust attached to the membrane surface, which solves the pain point of dust and condensed water mixing and clogging the filter element in the traditional dehumidification process.

[0028] The core principle of vacuum diffusion welding for forming the super-hydrophobic membrane 314 is to eliminate interference from impurities such as air and moisture in a vacuum environment. A certain temperature and pressure are applied to the closely fitting contact surfaces of dissimilar or homogeneous materials, causing plastic deformation and breaking the surface oxide layer. This encourages the diffusion and migration of material atoms across the interface, ultimately forming a continuous, dense metallurgical bond layer through recrystallization. This process requires no solder filler and enables seamless connection between, for example, titanium alloys and the metal-based super-hydrophobic membrane 314 substrate. This process preserves the physical properties and microstructure of the substrate itself, providing critical support for the efficient heat exchange, reliable dehumidification, and low flow resistance characteristics of the deep processing module 300.

[0029] The specific implementation process is as follows: The surface to be welded of the heat exchanger body 310 is precision machined to a roughness of ≤ Ra0.8μm, removing any burrs and oxide layers. It is then cleaned to remove oil and impurities, and finally dried under inert gas to prevent secondary oxidation. The super-hydrophobic membrane 314 is then treated. In actual operation, a composite structure consisting of a metal-based support layer and a polytetrafluoroethylene coating can be used. The metal-based support layer can be made of stainless steel to ensure welding feasibility. Finally, the pre-treated heat exchanger body 310 and super-hydrophobic membrane 314 are heated in a vacuum environment to fuse them together.

[0030] During the heating process, slowly increase the temperature to the process temperature at a rate of 5-10°C / min. Taking into account the material properties of the titanium alloy and the metal support layer of the super-hydrophobic membrane 314, the process temperature is controlled at 800-950°C. This prevents the super-hydrophobic membrane 314 coating from decomposing due to high temperatures while ensuring sufficient atomic activity at the metal contact surface. It is important to note that after reaching the process temperature, appropriate heat and pressure holding operations are required to further eliminate gaps. High temperatures enable metal atoms to obtain sufficient diffusion energy, achieving interfacial atomic fusion through grain boundary migration and dislocation motion, forming a continuous bond layer. The heat and pressure holding time is adjusted according to the bonding area, typically 30-60 minutes, to ensure sufficient diffusion.

[0031] After diffusion is complete, heating is stopped and the mold is allowed to cool in a vacuum furnace to below 200°C at a cooling rate of ≤5°C / min to avoid thermal stress caused by rapid cooling that could lead to cracking of the microchannels or membrane structure. After cooling to room temperature, the pressure is released and the integrated molded component is removed.

[0032] A gas collection hood 400 is sealed and mounted on the top of the deep processing module 300. This hood 400 is connected to the gas analysis and detection device and the gas outlet 500 via a gas piping system. The hood 400 is used to collect clean, processed gas, reduce eddy currents and pressure loss, and ensure stable delivery to the gas analysis and detection device. The hood 400, the heat exchanger body 310, and the cyclonic inertial separation housing are all sealed and connected via flanges, forming an integrated structure that ensures both sealing and strength.

[0033] In order to further ensure a stable cyclone coarse separation effect, the top 260 of the cyclone inertial separation shell is set as a conical cylinder. The conical structure can also guide the gas entering the cyclone separation chamber 210 to form a more stable and more reasonably gradient spiral downward airflow, thereby reducing the turbulent disturbance of the airflow during the rotation process, making the centrifugal force distribution more uniform, and ensuring that large particles are effectively thrown to the cylinder wall under the action of centrifugal force, and slide down along the conical wall to the dust outlet.

[0034] The airflow purification cartridge 220 is integrally formed and positioned at the center of the bottom end of the cyclonic inertial separation housing. A fine dust ejector 230 is integrally formed below the center of the airflow purification cartridge 220 and feeds into the dust outlet. An airflow outlet 240 is located between the airflow purification cartridge 220 and the fine dust ejector. This integral molding enhances the overall structural strength, making it resistant to high-frequency vibrations and airflow shocks in industrial settings.

[0035] In order to further enhance the guidance of the swirling airflow to flow stably, a swirl guide plate 222 is provided on the outer side wall of the airflow purification cylinder 220 .

[0036] In order to ensure the dust spraying effect and prevent the fine dust after backblowing from entering the cyclone separation chamber 210 through the air flow outlet 240, the lower end of the air flow purification cylinder 220 is set to a contraction opening 250 with a diameter smaller than that of the fine dust spray cylinder 230. At the same time, such a setting also increases the space at the air flow outlet 240, which is conducive to the air flow entering the air flow purification cylinder 220 more smoothly, thereby improving the processing efficiency.

[0037] Gas piping system such as Figure 6 As shown, it includes a first electromagnetic three-way valve 411 connected to the air inlet 212 and the calibration port. The first electromagnetic three-way valve 411 is also connected to the power pump 412, the pressure regulating valve 413, and the working flow meter 414 in sequence through the pre-processing unit. The working flow meter 414 is connected to the air inlet of the gas analysis and detection device. The air outlet of the gas analysis and detection device is connected to the air outlet 500 through the second electromagnetic three-way valve 415 and the pipeline, forming the detection gas circuit system. The control component 600 includes a controller, a switch knob, etc. installed on the box 100 for controlling the gas pipeline system.

[0038] The second electromagnetic three-way valve 415 is also connected to the air inlet of a backflush flowmeter 416. The outlet of the backflush flowmeter 416 is connected to the outlet of the pre-treatment unit's gas hood 400 via a pipeline, ensuring smooth backflush cleaning. Backflush can be used to periodically clean the electrostatic precipitator plates and membrane surface, extending the operation and maintenance cycle.

[0039] In order to improve adaptability and ensure suitability for various personalized scenarios, the air inlet 212 is also connected to a straight-through detection branch, and a third electromagnetic three-way valve 419 and a fourth electromagnetic three-way valve 420 are respectively provided at both ends of the straight-through detection branch; the outlet end of the air collecting hood 400 of the pretreatment unit is also connected to a straight-through outlet branch, and a fifth electromagnetic three-way valve 417 and a sixth electromagnetic three-way valve are respectively provided at both ends of the straight-through outlet branch.

[0040] Example 2 In order to better solve the above technical problems, the present invention also provides the following technical solutions: A method for performing online gas sampling and analysis using any of the above-mentioned online gas sampling and analysis devices includes a method for pretreating the gas to be tested, wherein the method comprises the following steps: S1: Cyclone Inertial Separation: The dust-laden gas to be tested enters the conical, annular cyclone separation chamber 210 tangentially through the air inlet 212. The gas forms a high-speed rotating vortex within the chamber, generating a strong centrifugal force. Larger dust particles are flung toward the sidewalls of the cyclone inertial separation housing under the action of centrifugal force. Guided by gravity and downward airflow, they settle down along the conical cylinder wall. The settled large dust particles eventually fall through the dust outlet at the bottom into the sealed dust box 211. The initially purified gas converges toward the center of the separation chamber.

[0041] S2: Electrostatic Precipitation: After preliminary purification, the gas passes from the top center of the cyclone separation chamber 210 through the airflow outlet 240 and enters the airflow purification cylinder 220. The electrostatic precipitation assembly 221 comprises a high-voltage discharge electrode and a grounded dust collecting electrode, generating an electric field within the cylinder. Fine dust particles in the gas are charged in the electric field and attracted to the dust collecting electrode by the electric force. The attracted dust, under the influence of gravity or periodic backflushing, falls through the fine dust spray cylinder 230 into the dust collection box 211 below.

[0042] The gas that has undergone two-stage dust removal has an extremely low dust content and flows upward into the deep processing module 300. At this time, the gas has not yet come into contact with condensed water and the dust has been basically removed.

[0043] S3: Microchannel Heat Exchange and Temperature Control: Dust-removed gas enters through the numerous microchannel pores 312 on the bottom side of the heat exchange body 310. Simultaneously, in this embodiment, 30–40°C process cooling water flows through the water inlet channel into the heat exchange channels 313. The extremely thin heat exchange core plate 311, with a thickness of 20–30 μm, effectively separates the microchannel pores for air flow from the heat exchange channels 313 for water flow, creating a larger heat exchange area. In this embodiment, the heat exchange body 310 is made of titanium alloy, but other more suitable materials can be used depending on the implementation.

[0044] When the gas flows in the microchannel, its heat is quickly transferred to the flowing cooling water through the heat exchange core plate 311, or vice versa, depending on the process requirements, so as to achieve precise regulation of the gas temperature, such as dropping below the dew point or raising it to the required temperature. After heat exchange, the water is discharged through the outlet channel.

[0045] S4: Dehumidification of the super-hydrophobic membrane 314: After temperature control, in this embodiment, taking cooling to below the dew point as an example, the water vapor in the gas condenses into liquid water droplets. The gas continues to flow upward with the water droplets and reaches the polytetrafluoroethylene super-hydrophobic membrane 314 with a membrane pore of 0.2-0.4μm. The super-hydrophobic membrane 314 has a strong repulsion to liquid water and a large contact angle, but allows gas molecules to pass through. The liquid water droplets cannot infiltrate and pass through the membrane pores, and are blocked on the downstream side of the membrane and discharged into the dust collecting box 211. The dry gas molecules pass through the super-hydrophobic membrane 314 smoothly and enter the gas collecting hood 400. Due to the high-efficiency pre-dust removal, the condensed water here is relatively clean and not easy to form mud that blocks the membrane.

[0046] Dry, clean, and temperature-appropriate gas is drawn out from the gas collecting hood 400, and after pressure regulation and flow measurement by the gas pipeline system, enters the gas analysis and detection device. The gas analysis and detection device can use existing technologies, such as spectrometers, chromatographs, sensors, etc., to analyze the composition or concentration of the gas to be tested. The waste gas after analysis is discharged or processed through the outlet 500.

[0047] The purpose of traditional condensation is to cool the gas below its dew point, condensing the gaseous water into liquid water for discharge. This prevents the liquid water from corroding sensors, clogging gas lines, or interfering with optical detection. However, the condensation process causes water-soluble gases such as SO2, NH3, and HCl to be lost with the condensate, resulting in compositional distortion. Furthermore, the cooling efficiency is low, creating a significant bottleneck that causes system delays.

[0048] This method replaces traditional condensation with a micro-channel heat exchange module, rapidly cooling high-temperature gas from approximately 150°C to approximately 45°C without generating condensate, completely eliminating the risk of component distortion and the formation of sludge. The pore size and surface properties of the super-hydrophobic membrane 314 are then utilized to block liquid water and oil mist. The pre-positioned dust removal module 200, which performs coarse and fine dust separation, ensures that dust does not adhere to the membrane surface, thus ensuring the normal, stable, and efficient operation of the overall sampling, analysis, and testing process.

[0049] In summary, the present invention utilizes an innovative pretreatment unit with a two-stage dust removal system combined with microchannel heat exchange and temperature control to prevent condensation and dust from mixing with the filter element, leading to filter clogging and loss of water-soluble gases, thereby improving detection accuracy. Furthermore, the present invention's modular integrated design reduces system pressure drop and energy consumption, facilitates maintenance, and is suitable for long-term online monitoring in complex industrial environments such as those characterized by high temperature, high humidity, and high dust levels.

[0050] The various embodiments in this specification are described in a progressive manner. Each embodiment focuses on the differences from other embodiments. The same and similar parts between the various embodiments can be referenced to each other.

[0051] The terms "upper," "lower," "outer," "inner," and the like, if used in the present description and claims, and in the accompanying drawings, are used to distinguish relative positions and are not necessarily qualitative. It should be understood that the terms used in this manner are interchangeable where appropriate, such that the embodiments of the present invention described herein can be implemented in sequences other than those illustrated or described herein. Furthermore, the terms "including," "having," and any variations thereof are intended to cover non-exclusive inclusions.

[0052] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An online gas sampling and analysis device, comprising a housing, in which a pretreatment system, a gas analysis and detection device, a gas piping system, and a control component are installed; characterized in that: The pretreatment system includes an integrated pretreatment unit, the pretreatment unit includes a dust removal module, and a deep processing module is sealed and installed on the top of the dust removal module; The dust removal module includes a cyclone inertial separation shell, a cyclone separation chamber is provided in the cyclone inertial separation shell, an air inlet is tangentially provided on the top side wall of the cyclone separation chamber, a cylindrical airflow purification cylinder is provided at the top center of the cyclone separation chamber, a dust outlet is provided at the bottom center of the cyclone separation chamber, a dust collecting box is sealed on the dust outlet, and an electrostatic dust removal assembly is installed at the center of the airflow purification cylinder; The deep processing module includes a mounting cylinder, a microchannel heat exchange module is installed in the mounting cylinder, and the microchannel heat exchange module includes an integrally formed heat exchange main body, a plurality of microchannel pores and heat exchange channels are opened in the heat exchange main body, and the microchannel pores and the heat exchange channels are separated by a heat exchange core plate, and the heat exchange core plate is arranged through the heat exchange main body so that the microchannel pores are communicated with the upper and lower ends of the heat exchange main body, and the upper and lower ends of the heat exchange main body are further provided with water inlet and water outlet channels that are communicated with the heat exchange channels; the water inlet and water outlet channels are communicated with the water inlet pipe and the water outlet pipe respectively; the upper end of the heat exchange main body is provided with a super hydrophobic film through vacuum diffusion welding; A gas collecting hood is sealed and installed on the top of the deep processing module, and the gas collecting hood is connected with the gas analysis and detection device and the gas outlet in sequence through a gas pipeline system.

2. The online gas sampling and analysis device according to claim 1, wherein: The top of the cyclone inertial separation housing is configured as a conical cylinder, and the airflow purification cylinder is integrally formed and arranged at the center of the bottom end of the cyclone inertial separation housing; A micro-dust nozzle is integrally formed below the center of the airflow purification cylinder. The micro-dust nozzle leads to the dust outlet. An airflow outlet is provided between the airflow purification cylinder and the micro-dust nozzle.

3. The online gas sampling and analysis device according to claim 1, wherein: The gas pipeline system includes a first electromagnetic three-way valve connected to the air inlet and the calibration port, the first electromagnetic three-way valve is also connected to the power pump, the pressure regulating valve, and the working flow meter in sequence through the pretreatment unit, the working flow meter is connected to the air inlet end of the gas analysis and detection device, and the air outlet end of the gas analysis and detection device is connected to the air outlet through the second electromagnetic three-way valve and the pipeline; The second electromagnetic three-way valve is also communicated with the air inlet end of the back-blowing flowmeter, and the outlet end of the back-blowing flowmeter is communicated with the outlet end of the gas collecting hood of the pre-treatment unit through a pipeline.

4. The online gas sampling and analysis device according to claim 3, wherein: The air inlet is also connected to a straight-through detection branch, and a third electromagnetic three-way valve and a fourth electromagnetic three-way valve are respectively provided at both ends of the straight-through detection branch; the air collecting hood outlet end of the pretreatment unit is also connected to a straight-through outlet branch, and a fifth electromagnetic three-way valve and a sixth electromagnetic three-way valve are respectively provided at both ends of the straight-through outlet branch.

5. The online gas sampling and analysis device according to claim 2, wherein: The outer side wall of the airflow purification cylinder is provided with a swirl guide plate; The lower end of the airflow purification cylinder is configured to have a smaller diameter than the contraction opening of the particle dust spraying cylinder.

6. The online gas sampling and analysis device according to claim 2, wherein: The air collecting hood, the heat exchange main body and the cyclone inertia separation shell are all sealed and connected to form an integrated structure through flanges.

7. A method for performing online gas sampling and analysis using the online gas sampling and analysis device according to any one of claims 1 to 6, comprising a method for pretreating the gas to be tested, characterized in that: The gas pretreatment method comprises the following steps: S1, cyclone inertial separation: the gas to be tested enters through the air inlet and is subjected to coarse separation of large dust particles in the conical ring-shaped cyclone separation chamber; S2, electrostatic dust removal: The coarsely separated gas to be tested enters the air purification cylinder from the air outlet located in the center of the cyclone separation chamber, and the electrostatic dust removal component in the air purification cylinder refines the fine dust; S3, microchannel heat exchange temperature control: The subdivided gas to be tested enters the microchannel air holes on the bottom side of the heat exchange body and exchanges heat with the process cooling water in the heat exchange flow channel, making the temperature of the gas to be tested suitable for detection; S4, super-hydrophobic membrane dehumidification: The gas to be tested, which has been coarsely separated, finely divided and temperature-controlled, passes through the super-hydrophobic membrane on the top side of the heat exchange body to remove liquid water and oil mist.

8. The method for performing online gas sampling and analysis using the online gas sampling and analysis device according to claim 7, wherein: The heat exchange body is made of titanium alloy, and the thickness of the heat exchange core plate therein is 20-30 μm; the super hydrophobic membrane is made of polytetrafluoroethylene, and the membrane pore size of the super hydrophobic membrane is 0.2-0.4 μm.

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