Industrial gas burner flue gas monitoring system

Abstract

The utility model relates to the technical field of flue gas monitoring, and disclose industrial gas burner flue gas monitoring system, include: sensor group, flue gas monitoring control system, audible -visual annunciator, actuating mechanism and remote communication module, sensor group includes temperature sensor, oxygen content sensor, air quality sensor and pressure sensor, each sensor is inserted into the burner exhaust port and burner exhaust pipe, is fixed and sealed through quick -release sealing structure and exhaust port or exhaust pipe, and flue gas monitoring control system is equipped with touch -control display screen, can show each sensor monitoring data in real time. The industrial gas burner flue gas monitoring system, flue gas monitoring control system can transmit data in real time, fast instruction, timely intervention burner anomaly, remote communication module can push data and alarm to remote terminal, avoid the failure expansion of on -the -spot alarm misjudgment, and the ladder type control logic is first alarm adjustment, and the abnormality is not improved again, and then closes the burner, and the equipment safety and production continuity are taken into account.

Description

Technical Field

[0001] This utility model relates to the field of flue gas monitoring technology, specifically to an industrial gas burner flue gas monitoring system. Background Technology

[0002] The industrial gas burner flue gas monitoring system is applied in the field of industrial furnace gas burner technology. It is mainly used to monitor the parameters of the flue gas status of gas burners in industrial furnaces, assist operators in understanding the burner operation, thereby ensuring stable burner operation and reducing various problems caused by abnormal burner operation. It is an important auxiliary system for realizing status monitoring and risk prevention and control during the operation of industrial furnace gas burners.

[0003] In existing technologies, although sensors used for monitoring flue gas from industrial gas burners are equipped with mounting structures, the sealing performance of these structures is poor. In actual use, flue gas leakage or outside air infiltration into the flue can easily occur, causing interference with the exhaust parameters collected by the sensors and making it difficult to guarantee the accuracy of the monitoring data. This, in turn, affects the accurate judgment of the burner's operating status. At the same time, although existing monitoring and control systems have data transmission and command issuance functions, the data transmission efficiency is low and the command response speed is slow. When faced with abnormal conditions of the burner, they cannot quickly complete data feedback and command execution, resulting in untimely intervention in abnormalities and making it easy for the abnormal situation to escalate further. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model provides an industrial gas burner flue gas monitoring system to solve the technical problems of slow command response speed, inability to quickly complete data feedback and command execution when faced with abnormal burner conditions, resulting in untimely intervention in abnormalities and easy expansion of abnormal situations.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an industrial gas burner flue gas monitoring system, comprising: a sensor group, a flue gas monitoring and control system, an audible and visual alarm, an actuator, and a remote communication module. The sensor group includes a temperature sensor, an oxygen content sensor, an air quality sensor, and a pressure sensor. Each sensor is inserted into the burner exhaust port and the burner exhaust pipe, and is fixed and sealed to the exhaust port or exhaust pipe through a quick-release sealing structure.

[0006] The quick-release sealing structure includes a first connector and a second connector. The first connector is rotatably connected to a rotating arm, and the second connector is connected to a retaining frame. The retaining frame has a groove for accommodating the rotating arm. The rotating arm is threadedly connected to a torsion wheel. The first connector is connected to a sensor group, and the second connector is connected to a smoke exhaust port and an exhaust pipe.

[0007] This quick-release sealing structure allows for sensor installation and removal without tools, significantly reducing downtime during sensor maintenance. The sealing design also effectively prevents flue gas leakage or outside air infiltration, ensuring uninterrupted monitoring data and guaranteeing data accuracy. The flue gas monitoring and control system integrates a PID adaptive adjustment module and a fault diagnosis module, which are connected to the sensor group, burner control system, actuator, audible and visual alarm, and remote communication module via cables.

[0008] It can realize the real-time transmission of monitoring data and the rapid issuance of control commands, ensuring timely intervention in abnormal burner states. The remote communication module supports 4G and Ethernet communication and is used to push monitoring data and alarm signals to a remote central control platform or mobile terminal.

[0009] Even when operators are not on-site, the system can receive burner operation data and abnormal information in real time, preventing the escalation of faults due to undetected alarms. When the temperature monitored by the sensor group is higher than the preset temperature threshold, the oxygen content is lower than the preset oxygen content threshold, the pollutant concentration is higher than the preset pollutant threshold, or the flue pressure exceeds the preset pressure range, the flue gas monitoring and control system triggers an audible and visual alarm and pushes alarm information through the remote communication module. It also controls the actuator to adjust the burner gas and combustion air flow, and outputs a signal to the burner control system to shut down the corresponding burner. The system is set by default to a stepped control logic of "alarm-adjustment-delay shutdown". That is, it first triggers an audible and visual alarm and attempts to adjust the air-fuel ratio through the actuator. If the monitoring data does not return to normal within a certain time (which can be set), the burner shutdown operation is then performed, ensuring equipment safety while minimizing production interruptions.

[0010] Preferably, the air quality sensor includes a CO sensor and a NO sensor. x Sensors; the temperature sensor, oxygen content sensor, CO sensor, NO sensor x The sensors and pressure sensors are evenly distributed along the circumference of the burner exhaust pipe cross-section.

[0011] It can comprehensively collect flue gas parameters from different locations in the flue, avoiding misjudgments caused by data deviations from a single monitoring point. In particular, it can accurately capture the uniformity of pollutant concentration and pressure within the flue, ensuring a comprehensive assessment of burner combustion completeness and environmental compliance.

[0012] Preferably, the actuator includes a burner gas pipeline actuator and a burner combustion air pipeline actuator, both of which are equipped with replaceable adapters. These adapters cover common pipeline specifications from DN15 to DN100, eliminating the need to customize dedicated actuators for different projects, significantly reducing equipment adaptation costs, and expanding the system's applicability to industrial burners of different power levels.

[0013] Preferably, the PID adaptive adjustment module can dynamically adjust the control parameters according to the gas type and furnace load; the gas type includes natural gas and liquefied petroleum gas, and the furnace load includes high load, medium load and low load; since natural gas and liquefied petroleum gas have different calorific values ​​and required air coefficients, the gas consumption and combustion air demand of the burner differ under high load (load rate ≥ 80%), medium load (load rate 30%-80%) and low load (load rate < 30%). The PID module can ensure that the burner is in the best combustion state under different operating conditions by dynamically adjusting the temperature-oxygen threshold range and the air-fuel ratio adjustment coefficient, thereby reducing energy waste and pollutant emissions.

[0014] Preferably, the fault diagnosis module has a built-in fault logic judgment library, which outputs fault types and maintenance suggestions based on the combination of multiple parameters of the sensor group. Compared with single parameter judgment, multi-parameter combination judgment can avoid misdiagnosis caused by accidental factors. For example, low oxygen content alone may be caused by multiple reasons, but combined with high CO concentration, it can accurately locate "incomplete combustion", improving the accuracy of fault judgment, and directly providing maintenance suggestions, shortening the troubleshooting and maintenance time of operators. When the oxygen content is detected to be below the threshold and the CO concentration is detected to be above the threshold, it is judged as incomplete combustion and prompts to check the combustion air flow. When the flue pressure is detected to rise sharply and the exhaust temperature drops, it is judged as flue blockage and prompts to clean the flue ash. It can quickly guide operators to deal with faults in a targeted manner. For example, "check the combustion air flow" can directly point to the opening of the combustion air valve or the blockage of the pipeline, and "clean the flue ash" can avoid poor exhaust and reduced thermal efficiency caused by ash accumulation.

[0015] Preferably, the flue gas monitoring and control system is equipped with a touch screen display, which can display real-time monitoring data from each sensor, data fluctuation curves, and fault prompts. The touch screen display supports gesture zooming, making it convenient for operators to view historical data fluctuation trends (such as temperature and oxygen change curves over the past 24 hours). Simultaneously, fault prompts are highlighted in a pop-up window to ensure that operators do not miss key abnormal information. Furthermore, parameters such as temperature and oxygen thresholds and pollutant thresholds can be directly modified via touch, making operation convenient. The outer walls of the probes of the temperature sensor, oxygen content sensor, air quality sensor, and pressure sensor are all coated with a high-temperature resistant ceramic coating. This ceramic coating is made of Al₂O₃ material, which prevents the sensor probes from being damaged by high-temperature oxidation or corrosion, extending the sensor's service life and reducing maintenance costs associated with frequent replacements.

[0016] Compared with the prior art, this utility model provides an industrial gas burner flue gas monitoring system, which has the following beneficial effects:

[0017] This industrial gas burner flue gas monitoring system features a tool-free, quick-release sealed structure for the sensor array, reducing maintenance downtime and preventing flue gas leakage and air infiltration, ensuring accurate monitoring data. The flue gas monitoring and control system can transmit data in real time and issue commands quickly to intervene in burner anomalies promptly. The remote communication module can push data and alarms to a remote terminal to avoid missed alarms on-site, which could lead to escalation of the fault. The tiered control logic first alarms and adjusts the system, and only shuts down the burner if the anomaly is not resolved, balancing equipment safety and production continuity. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of this utility model;

[0019] Figure 2 This is a schematic diagram of the sensor assembly installed at the burner exhaust port.

[0020] Figure 3 A schematic diagram showing the installation of temperature and oxygen sensors in the exhaust gas duct;

[0021] Figure 4 A schematic diagram of the actuator for adjusting the flow rate of combustion gas and combustion air to the burner;

[0022] Figure 5 This is a schematic diagram of the quick-release sealing structure of this utility model.

[0023] In the diagram: 1. Temperature sensor; 2. Oxygen content sensor; 11. Air quality sensor; 22. Pressure sensor; 3. Flue gas monitoring and control system; 4. Burner control system; 5. Audible and visual alarm; 6. Burner gas pipeline actuator; 7. Burner combustion air pipeline actuator; 8. Quick-release sealing structure; 81. First connecting pipe; 82. Second connecting pipe; 83. Rotating arm; 84. Frame; 85. Torsion wheel. Detailed Implementation

[0024] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0025] This utility model provides a technical solution, please refer to [link / reference]. Figures 1-5The industrial gas burner flue gas monitoring system includes: a sensor group, a flue gas monitoring and control system 3, an audible and visual alarm 5, an actuator and a remote communication module. The sensor group includes a temperature sensor 1, an oxygen content sensor 2, an air quality sensor 11 and a pressure sensor 22. Each sensor is inserted into the burner exhaust port and the burner exhaust pipe, and is fixed and sealed to the exhaust port or exhaust pipe through a quick-release sealing structure 8.

[0026] The quick-release sealing structure 8 includes a first connecting pipe 81 and a second connecting pipe 82. The first connecting pipe 81 is rotatably connected to a rotating arm 83. The second connecting pipe 82 is connected to a retaining frame 84, and the retaining frame 84 has a groove on its outside to accommodate the rotating arm 83. The rotating arm 83 is threadedly connected to a torsion wheel 85. The first connecting pipe 81 is connected to the sensor group, and the second connecting pipe 82 is connected to the exhaust port and the exhaust pipe. The first connecting pipe 81, the second connecting pipe 82, the sensor group, and the pipe are all connected by a detachable flange structure, which can be removed and replaced separately each time.

[0027] The quick-release sealing structure 8 allows for sensor installation and removal without tools, significantly reducing downtime during sensor maintenance. The sealing design also effectively prevents flue gas leakage or outside air infiltration, ensuring uninterrupted monitoring data and guaranteeing data accuracy. The flue gas monitoring and control system 3 integrates a PID adaptive adjustment module and a fault diagnosis module, which are connected to the sensor group, burner control system 4, actuator, audible and visual alarm 5, and remote communication module via cables.

[0028] Real-time transmission of monitoring data and rapid issuance of control commands are achieved to ensure timely intervention in abnormal burner conditions. The remote communication module supports 4G and Ethernet communication and is used to push monitoring data and alarm signals to the remote control platform or mobile terminal.

[0029] Even when operators are not on-site, the system can receive burner operation data and abnormal information in real time, preventing the escalation of faults due to undetected alarms. When the temperature monitored by the sensor group is higher than the preset temperature threshold, the oxygen content is lower than the preset oxygen content threshold, the pollutant concentration is higher than the preset pollutant threshold, or the flue pressure exceeds the preset pressure range, the flue gas monitoring and control system 3 triggers the audible and visual alarm 5 and pushes the alarm information through the remote communication module. It also controls the actuator to adjust the burner gas and combustion air flow, and outputs a signal to the burner control system 4 to shut down the corresponding burner. The system is set by default to a stepped control logic of "alarm-adjustment-delay shutdown". That is, the audible and visual alarm is triggered first, and the actuator attempts to adjust the air-fuel ratio. If the monitoring data does not return to normal within a certain time (this time can be set), the burner shutdown operation is then performed, ensuring equipment safety while minimizing production interruptions.

[0030] Air quality sensors include CO and NO sensors.x Sensors; Temperature sensor 1, Oxygen content sensor 2, CO sensor, NO sensor x The sensors and pressure sensors are evenly distributed along the circumference of the burner exhaust pipe cross-section.

[0031] It can comprehensively collect flue gas parameters from different locations in the flue, avoiding misjudgments caused by data deviations from a single monitoring point. In particular, it can accurately capture the uniformity of pollutant concentration and pressure within the flue, ensuring a comprehensive assessment of burner combustion completeness and environmental compliance.

[0032] The actuators include burner gas pipeline actuator 6 and burner combustion air pipeline actuator 7, both of which are equipped with replaceable adapters. These adapters cover common pipeline specifications from DN15 to DN100, eliminating the need to customize dedicated actuators for different projects, significantly reducing equipment adaptation costs, and expanding the system's applicability to industrial burners of different power levels.

[0033] The PID adaptive control module can dynamically adjust control parameters according to the gas type and furnace load. The gas type includes natural gas and liquefied petroleum gas (LPG), and the furnace load includes high load, medium load, and low load. Since natural gas and LPG have different calorific values ​​and required air coefficients, the gas consumption and combustion air demand of the burner differ under high load (≥80%), medium load (30%-80%), and low load (<30%). The PID module can ensure that the burner is in the optimal combustion state under different operating conditions by dynamically adjusting the temperature-oxygen threshold range and the air-fuel ratio adjustment coefficient, thereby reducing energy waste and pollutant emissions.

[0034] The fault diagnosis module has a built-in fault logic judgment library. Based on the combination of multiple parameters from the sensor group, it outputs the fault type and maintenance suggestions. Compared with single-parameter judgment, multi-parameter combination judgment can avoid misdiagnosis caused by accidental factors. For example, low oxygen content alone may be caused by multiple reasons. Combining it with high CO concentration can accurately locate "incomplete combustion", improving the accuracy of fault judgment. At the same time, it directly provides maintenance suggestions, shortening the troubleshooting and maintenance time of operators. When the oxygen content is below the threshold and the CO concentration is above the threshold, it is judged as incomplete combustion and prompts to check the combustion air flow. When the flue pressure rises sharply and the exhaust temperature drops, it is judged as flue blockage and prompts to clean the flue ash. It can quickly guide operators to deal with the fault in a targeted manner. For example, "check the combustion air flow" can directly point to the opening of the combustion air valve or the blockage of the pipeline. "clean the flue ash" can avoid poor exhaust and reduced thermal efficiency caused by ash accumulation.

[0035] The flue gas monitoring and control system 3 is equipped with a touch screen that can display real-time monitoring data from each sensor, data fluctuation curves, and fault prompts. The touch screen supports gesture zooming, allowing operators to easily view historical data fluctuation trends, such as temperature and oxygen change curves over the past 24 hours. Fault prompts are highlighted in pop-up windows to ensure operators don't miss key anomalies. Parameters such as temperature and oxygen thresholds and pollutant thresholds can be directly modified via touch, making operation convenient. The probes of temperature sensor 1, oxygen content sensor 2, air quality sensor 11, and pressure sensor 22 are all coated with a high-temperature resistant ceramic coating. This ceramic coating is made of Al₂O₃ material, preventing sensor probe damage from high-temperature oxidation or corrosion, extending sensor lifespan, and reducing maintenance costs associated with frequent replacements.

[0036] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0037] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An industrial gas burner flue gas monitoring system, including: The sensor group, flue gas monitoring and control system (3), audible and visual alarm (5), actuator and remote communication module are characterized in that: the sensor group includes a temperature sensor (1), an oxygen content sensor (2), an air quality sensor (11) and a pressure sensor (22), each sensor is inserted into the burner exhaust port and the burner exhaust pipe, and is fixed and sealed to the exhaust port and exhaust pipe by a quick-release sealing structure (8); The quick-release sealing structure (8) includes a first connector (81) and a second connector (82). The first connector (81) is rotatably connected to a rotating arm (83). The second connector (82) is connected to a retaining frame (84). The retaining frame (84) has a groove on its outside to accommodate the rotating arm (83). The rotating arm (83) is threadedly connected to a torsion wheel (85). The first connector (81) is connected to the sensor group. The second connector (82) is connected to the exhaust port and the exhaust pipe. The flue gas monitoring and control system (3) integrates a PID adaptive adjustment module and a fault diagnosis module, and is connected to the sensor group, burner control system (4), actuator, audible and visual alarm (5) and remote communication module respectively via cables; The remote communication module supports 4G and Ethernet communication and is used to push monitoring data and alarm signals to the remote central control platform and mobile terminal. When the temperature monitored by the sensor group is higher than the preset temperature threshold, the oxygen content is lower than the preset oxygen content threshold, the pollutant concentration is higher than the preset pollutant threshold, and the flue pressure exceeds the preset pressure range, the flue gas monitoring and control system (3) triggers the audible and visual alarm (5) to alarm, and pushes the alarm information through the remote communication module, and controls the actuator to adjust the flow of burner gas and combustion air, while outputting a signal to the burner control system (4) to shut down the corresponding burner.

2. The industrial gas burner flue gas monitoring system according to claim 1, characterized in that: The air quality sensor includes a CO sensor and a NO sensor. x Sensors; the temperature sensor (1), oxygen content sensor (2), CO sensor, NO sensor x The sensors and pressure sensors are evenly distributed along the circumference of the burner exhaust pipe cross-section.

3. The industrial gas burner flue gas monitoring system according to claim 1, characterized in that: The actuators include a burner gas pipeline actuator (6) and a burner combustion air pipeline actuator (7), both of which are equipped with replaceable adapters.

4. The industrial gas burner flue gas monitoring system according to claim 1, characterized in that: The PID adaptive adjustment module dynamically adjusts the control parameters according to the gas type and furnace load; the gas type includes natural gas and liquefied petroleum gas, and the furnace load includes high load, medium load and low load.

5. The industrial gas burner flue gas monitoring system according to claim 1, characterized in that: The fault diagnosis module has a built-in fault logic judgment library, which outputs fault types and maintenance suggestions based on the combination of multiple parameters of the sensor group.

6. The industrial gas burner flue gas monitoring system according to claim 1, characterized in that: The flue gas monitoring and control system (3) is equipped with a touch screen display, which displays the monitoring data of each sensor, the data fluctuation curve and the fault prompt information in real time. The outer walls of the probes of the temperature sensor (1), oxygen content sensor (2), air quality sensor (11) and pressure sensor (22) are all coated with a ceramic high temperature resistant coating.

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