Boiler fly ash sampling system and use method

Abstract

A boiler fly ash sampling system and a use method. The system comprises: a detection unit (100), comprising an introduction module (101) connected to a boiler, a collection module (102) provided at an output end of the introduction module (101), and a cleaning module (103) and a testing module (104) respectively provided at an output end of the collection module (102); and extracting a fly ash sample in a boiler flue by means of the introduction module (101) and outputting the fly ash sample to the collection module (102), so that the fly ash sample can enter the testing module (104) from the collection module (102) for testing. By controlling an air pump (101b), the fly ash sample enters a sample collection tube (102a) and then enters a sampling and testing chamber (104a-1), thereby detecting the fly ash sample; and periodic cleaning is performed.

Description

A boiler fly ash sampling system and its usage method Technical Field

[0001] This invention relates to the field of boiler fly ash sampling technology, and in particular to a boiler fly ash sampling system and its usage method. Background Technology

[0002] Boiler fly ash sampling refers to the process of collecting fly ash samples from the boiler flue. These samples are used to analyze the composition and concentration of the fly ash to monitor and control the boiler's combustion efficiency and emission quality. Fly ash consists of fine particulate matter produced after fuel combustion. It is carried in the boiler flue gas and is transported to its final emission location within the flue. The composition of fly ash reflects the combustion of the fuel, including unburned carbon, minerals, heavy metals, etc.

[0003] The inventors know of a sampling device that suffers from problems such as complex structure, inaccurate sampling, and short equipment life, which increases the operating costs and environmental risks of enterprises. In order to make it more automated, accurate and easy to maintain, we propose a boiler fly ash sampling system and its usage method. Summary of the Invention

[0004] In view of the above problems, the boiler fly ash sampling system of the present invention is proposed.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a boiler fly ash sampling system, comprising a detection unit, including an inlet module connected to the boiler, a collection module disposed at the output end of the inlet module, a cleaning module and a testing module disposed at the output end of the collection module; and, the fly ash sample is extracted from the boiler flue through the inlet module and output to the collection module, and the fly ash sample can enter the testing module from the collection module for testing.

[0006] In view of the above problems, the method of use in this invention is proposed.

[0007] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a method of use, comprising a boiler fly ash sampling system; and controlling an air pump to extract fly ash samples, wherein the fly ash samples enter a second connecting pipe from a first connecting pipe and are transferred to a sampling and testing room for analysis through a sample collection pipe. Attached Figure Description

[0008] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Wherein:

[0009] Figure 1 is a diagram of a boiler fly ash sampling system according to one or more embodiments of the present invention.

[0010] Figure 2 is a schematic diagram of the detection unit structure in one or more embodiments of the present invention. Detailed Implementation

[0011] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0012] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0013] Secondly, the term "one embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that is mutually exclusive with other embodiments.

[0014] Secondly, the present invention is described in detail with reference to the schematic diagrams. When detailing the embodiments of the present invention, for ease of explanation, the cross-sectional views illustrating the device structure may be partially enlarged, not according to the usual scale. Furthermore, the schematic diagrams are merely examples and should not limit the scope of protection of the present invention. In addition, actual fabrication should include three-dimensional spatial dimensions of length, width, and depth.

[0015] Example 1

[0016] Referring to Figure 1, which is the first embodiment of the present invention, this embodiment provides a boiler fly ash sampling system and its usage method. The detection unit 100 includes an inlet module 101 connected to the boiler, a collection module 102 located at the output end of the inlet module 101, a cleaning module 103 located at the output end of the collection module 102, and a testing module 104. The fly ash sample is extracted from the boiler flue through the inlet module 101 and output to the collection module 102. The fly ash sample can enter the testing module 104 from the collection module 102 for testing.

[0017] Wherein, G is the boiler furnace; K is the air preheater, which is a device in the boiler used to improve heat exchange performance and reduce energy consumption. Its function is to transfer the heat carried by the flue gas discharged from the tail flue of the boiler to the air before entering the boiler, and preheat the air to a certain temperature.

[0018] When sampling and testing boiler fly ash, it is important to ensure the representativeness of the samples to accurately reflect the boiler combustion efficiency and fly ash composition. The parameters tested typically include fly ash carbon content and loss on ignition (LOI), which reflect the boiler's combustion efficiency. Fly ash carbon content is a key indicator, representing the amount of incompletely burned carbon in the fly ash, usually expressed as a percentage. LOI refers to the percentage decrease in mass of fly ash after burning at a certain temperature, reflecting the content of combustibles in the fly ash. Additionally, the air preheater leakage rate needs to be checked, as excessive leakage can lead to oxygen deficiency during combustion, affecting the fly ash carbon content.

[0019] In summary, by setting up the inlet module 101, the fly ash sample passes through the collection module 102 and then enters the analysis module 104, whereby the fly ash sample can be tested. The operation process is simple.

[0020] Example 2

[0021] Referring to Figures 1 and 2, this is the second embodiment of the present invention. This embodiment is based on the previous embodiment, except that a sampling port Q is provided in the direction opposite to or perpendicular to the airflow, and the angle between the sampling port Q and the horizontal line is set between 15° and 30°. The introduction module 101 includes a first connecting pipe 101a connected to the sampling port Q.

[0022] By installing and sampling at key locations in the boiler tail flue, specifically near the flue outlet and about 5 to 10 meters from the chimney inlet, the flue gas velocity at this location was tested. The average velocity was between 10 and 12 m / s, with velocity fluctuations not exceeding 5%, demonstrating stable airflow characteristics.

[0023] Furthermore, through continuous monitoring of fly ash concentration data, it was verified that the concentration variation at this location was within 3%, remaining basically uniform. These data indicate that this sampling point can effectively reflect the overall fly ash level emitted by the boiler, thereby ensuring the representativeness and accuracy of the monitoring results.

[0024] In one embodiment, an air pump 101b is provided at the end of the first connecting pipe 101a away from the sampling port Q, and a control motor 101b-1 is electrically connected to one side of the air pump 101b.

[0025] Control is achieved by introducing a timer, which allows for programming to set the sampling time interval. Flexible time settings are supported. Depending on the boiler's operating characteristics and monitoring needs, the sampling time interval is typically set between 30 minutes and 1 hour. The specific time interval can be adjusted via programming on the timer. If a higher frequency of fly ash concentration monitoring is desired, a sample can be drawn every 30 minutes. If a longer time period is preferred for representativeness, a time of 1 hour or longer can be set. Upon triggering, it will initiate the entire sampling process.

[0026] Once the timer is set and triggered, the air pump 101b starts and generates negative pressure to extract fly ash samples from the flue into the sample collection tube 102a. The air pump 101b is usually installed near the sampling device outside the flue and is connected to the sampling point inside the flue through a high-temperature and corrosion-resistant pipe. This location ensures that the air pump is not directly exposed to the high-temperature flue gas, extending its service life, while also enabling effective extraction of fly ash samples through the pipe. At the same time, the air pump installation location 101b facilitates maintenance and repair, ensuring the long-term stable operation of the system.

[0027] The detection unit 100 is installed at a predetermined location near the boiler tail flue outlet, approximately 5 to 10 meters from the chimney inlet. The mounting bracket, reinforced with high-temperature resistant stainless steel materials such as 316L stainless steel or nickel-based alloys, is secured by multiple thickened frame beams and employs a double-layer structure. The inner frame supports and stabilizes the external equipment, while the outer frame provides additional protection and shock absorption. It can withstand the impact of flue gas flow and high-temperature environments, ensuring long-term stable operation of the device at this location. The bracket's design focuses on high-temperature resistance, corrosion resistance, and stability to ensure long-term operation in the harsh environment of the boiler tail flue. The bracket is equipped with adjustable support rods for adjusting the height and angle of the sampling port. These support rods have rotation and tilt adjustment functions, ensuring the sampling port angle is accurately positioned within the optimal airflow sampling area. The support rod adopts a double-bearing structure to reduce stress caused by thermal expansion and contraction, thereby maintaining the stability and angle of the sampling port. The base is fixed to the outer wall of the flue using expansion bolts or welding, and has a high-temperature resistant and corrosion-resistant coating to ensure that the support is firmly installed on the flue and is not affected by flue temperature changes. The base is designed with a wide base plate structure to distribute the force to enhance stability, and has anti-slip protrusions and high-temperature pads to reduce vibration. The parts of the support that are in direct contact with the flue are equipped with heat insulation materials, such as ceramic fiber or composite heat insulation materials, to prevent heat from being conducted into the support and reduce high temperature damage to the structure. The heat insulation layer can also prevent high temperature from adversely affecting sensitive components such as air pumps and electrical control equipment, improving the overall durability of the system. Anti-vibration rubber pads or spring shock absorbers are installed at key nodes of the support to reduce vibration caused by flue gas flow and equipment operation, and extend the service life of the equipment. The anti-vibration design also reduces the displacement or loosening of the equipment caused by vibration, ensuring the accuracy of sampling and the stability of the device. The bracket design is simple and robust, able to adapt to the high temperature and high flow rate environment of the boiler tail flue, and is easy to maintain and adjust later, effectively supporting the stable operation of the timed fly ash sampling device.

[0028] The orientation and tilt angle of the sampling port are rigorously calibrated during the design process to ensure accurate capture of fly ash samples. The sampling port should face the opposite direction of the flue gas flow or perpendicular to the flow direction to avoid over-sampling or uneven sampling caused by directly aligning with the airflow. The orientation range is controlled within ±15 degrees of the flue centerline to ensure that the sample represents the average fly ash concentration in the entire flue. This angle range balances the uniformity and representativeness of the sampling, avoiding collecting too much or too little fly ash. The tilt angle of the sampling port relative to the horizontal line is usually set between 15 and 30 degrees. This avoids direct impact of fly ash on the sampling pipe, reducing blockage and wear, while ensuring that fly ash enters the sampling port smoothly. The angle range is determined based on the flue gas velocity and fly ash particle size characteristics. At this angle, fly ash particles can be guided into the sampling port without causing equipment wear or sampling errors due to excessive impact force. The selection of this range of orientation and tilt angles is mainly to obtain stable and accurate fly ash samples without disrupting the flue gas flow and to extend the service life of the equipment.

[0029] In one embodiment, the output end of the air pump 101b is provided with a second connecting pipe 101c.

[0030] In one embodiment, the collection module 102 includes a sample collection tube 102a having an inlet end M and two outlet ends N.

[0031] The sample collection tube 102a is used to collect fly ash samples extracted from the flue. The sample collection tube 102a is designed to be sealed to prevent the sample from being contaminated or lost during transportation. Its material is resistant to high temperature and corrosion and can resist the chemical substances in the flue gas.

[0032] In one embodiment, the inlet end M is connected to the second connecting pipe 101c, and the cleaning module 103 includes a dredging pipe 103a connected to one of the outlet ends N.

[0033] In one embodiment, a sewage tank 103a-1 is provided at the end of the dredging pipe 103a away from the sample collection pipe 102a.

[0034] After each sampling is completed, the cleaning module 103 is activated. Compressed air is used to purge the first connecting pipe 101a at the location indicated by the arrow in Figure 1 to prevent fly ash from accumulating and causing blockage. The introduction of the cleaning module effectively improves the long-term operational reliability of the equipment. Each pipe used for sample transfer adopts a sealed structure and transfers the sample from the collection tube to the analytical instrument pneumatically to prevent sample loss or contact with external gases. The pipe material is made of high-temperature and corrosion-resistant material, which is suitable for long-term high-temperature operation.

[0035] By incorporating safety protection modules, including temperature and pressure sensors, the system can monitor flue gas temperature and airflow pressure in real time, ensuring that the device operates within a safe range. If the temperature or pressure exceeds the safe range, the system will issue an alarm and stop sampling operations.

[0036] In one embodiment, the testing module 104 includes a delivery pipe 104a connected to another outlet end N, and a sampling testing room 104a-1 is provided at the end of the delivery pipe 104a away from the outlet end N.

[0037] The fly ash sample is transported to the automated analysis instrument via pipeline 104a. The entire system integrates data acquisition and control functions. The system is tightly connected, with lossless transmission. Real-time data is automatically uploaded to the monitoring platform for environmental protection departments and operators to monitor in real time. The equipment is equipped with fault detection function. Once the system operation is abnormal, such as pipeline blockage or failure to extract samples normally, the system will trigger an alarm to prompt maintenance personnel to handle it in time. After installation, fly ash samples need to be extracted regularly for debugging and calibration.

[0038] During the commissioning process, by comparing sampling results from different locations and at different times, the equipment parameters and settings were optimized to ensure data accuracy and system stability. The equipment is automatically calibrated periodically to ensure the accuracy and representativeness of the sampling and to avoid deviations caused by long-term operation.

[0039] In summary, the automatic extraction of fly ash samples by the timed control system reduces errors caused by human intervention, ensures data continuity, and reduces the frequency and complexity of manual cleaning by integrating an automatic cleaning module. Furthermore, by optimizing the sampling location, the samples are highly representative, the data are accurate and reliable, and the tediousness is reduced.

[0040] By selecting a sampling port Q, installing the first connecting pipe 101a, and connecting it to the air pump 101b, and connecting the air pump 101b to the sample collection pipe 102a via the second connecting pipe 101c, when it is necessary to test the fly ash sample, the air pump 101b is started to draw the fly ash from the boiler into the sample collection pipe 102a. The fly ash sample flows out from the conveying pipe 104a and then enters the sampling and testing room 104a-1, thereby enabling the fly ash sample to be tested and simplifying the overall workflow.

[0041] Example 3

[0042] Referring to Figures 1 and 2, this is the third embodiment of the present invention. This embodiment is based on the previous embodiment, except that the air pump 101b is controlled to extract fly ash samples. The fly ash samples enter the second connecting pipe 101c from the first connecting pipe 101a and are then transferred to the sampling and testing room 104a-1 for analysis through the sample collection pipe 102a.

[0043] In one embodiment, after each sampling is completed, compressed air is used at the first connecting pipe 101a to allow the residual fly ash sample to enter the sewage tank 103a-1 from the sample collection pipe 102a, thereby completing the cleaning of the sample collection pipe 102a.

[0044] This boiler fly ash sampling and testing method accurately reflects the boiler combustion efficiency and fly ash composition. It improves heat exchange performance and reduces energy consumption by using an air preheater. Compressed air is used to clean the sample collection tube 102a to ensure the cleanliness of the sampling tube, avoid cross-contamination, and improve the accuracy of the test. This improves combustion efficiency, reduces energy waste, and ensures the representativeness of the samples through regular cleaning, thus improving the accuracy of the test results.

[0045] By controlling the air pump 101b to automatically extract fly ash samples, manual operation is reduced, and the accuracy and consistency of sampling are improved. Using compressed air to clean the sample collection tube 102a can quickly remove residual fly ash, reduce cleaning time and labor intensity, and avoid fly ash deposition and blockage in the tube.

[0046] It is important to note that the constructions and arrangements of this application shown in several different exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those who consult this disclosure will readily understand that many modifications are possible (e.g., changes in the size, dimensions, structure, shape, and proportions of various elements, as well as parameter values ​​(e.g., temperature, pressure, etc.), mounting arrangements, use of materials, color, orientation, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in this application). For example, an element shown as integrally formed may be composed of multiple parts or elements, the position of elements may be inverted or otherwise altered, and the nature or number or position of discrete elements may be changed or altered. Therefore, all such modifications are intended to be included within the scope of the invention. The order or sequence of any process or method steps may be changed or rearranged according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure described herein that performs the function, and not only structurally equivalent but also equivalent in structure. Other substitutions, modifications, alterations, and omissions may be made in the design, operation, and arrangement of the exemplary embodiments without departing from the scope of the invention. Therefore, the present invention is not limited to the specific embodiments, but extends to various modifications that still fall within the scope of the appended claims.

[0047] Furthermore, in order to provide a concise description of exemplary embodiments, not all features of actual embodiments (i.e., those features that are not relevant to the best mode of carrying out the invention as currently considered, or those features that are not relevant to implementing the invention) may be omitted.

[0048] It should be understood that numerous specific implementation decisions can be made during the development of any practical implementation, such as in any engineering or design project. Such development efforts may be complex and time-consuming, but for those skilled in the art who benefit from this disclosure, the development effort will be a routine work of design, manufacturing, and production without requiring much experimentation.

[0049] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A boiler fly ash sampling system characterized by: include, The detection unit (100) includes an inlet module (101) connected to the boiler, a collection module (102) located at the output end of the inlet module (101), a cleaning module (103) and a testing module (104) located at the output end of the collection module (102); and, By introducing the module (101) to extract fly ash samples from the boiler flue and outputting them to the collection module (102), the fly ash samples can enter the testing module (104) from the collection module (102) for testing.

2. The boiler fly ash sampling system as claimed in claim 1, wherein: A sampling port (Q) is provided in the direction opposite to or perpendicular to the flue gas flow, and the angle between the sampling port (Q) and the horizontal line is set between 15° and 30°. The inlet module (101) includes a first connecting pipe (101a) connected to the sampling port (Q).

3. The boiler fly ash sampling system as claimed in claim 2, wherein: An air pump (101b) is provided at one end of the first connecting pipe (101a) away from the sampling port (Q), and a control motor (101b-1) is electrically connected to one side of the air pump (101b).

4. The boiler fly ash sampling system as claimed in claim 3, wherein: The output end of the air pump (101b) is provided with a second connecting pipe (101c).

5. A boiler fly ash sampling system according to any one of claims 1 to 4, wherein: The collection module (102) includes a sample collection tube (102a) having one inlet end (M) and two outlet ends (N).

6. The boiler fly ash sampling system as claimed in claim 5, wherein: The inlet end (M) is connected to the second connecting pipe (101c), and the cleaning module (103) includes a dredging pipe (103a) connected to one of the outlet ends (N).

7. The boiler fly ash sampling system as claimed in claim 6, wherein: A sewage tank (103a-1) is provided at the end of the dredging pipe (103a) away from the sample collection pipe (102a).

8. The boiler fly ash sampling system as claimed in claim 7, wherein: The testing module (104) includes a delivery pipe (104a) connected to another outlet (N), and a sampling testing room (104a-1) is provided at the end of the delivery pipe (104a) away from the outlet (N).

9. A method of use, characterized by: Includes the boiler fly ash sampling system according to any one of claims 1 to 8; and, The air pump (101b) is controlled to extract fly ash samples. The fly ash samples enter the second connecting tube (101c) from the first connecting tube (101a) and are then transferred to the sampling and testing room (104a-1) for analysis through the sample collection tube (102a).

10. The method of use of claim 9, wherein: After each sampling is completed, compressed air is used at the first connecting pipe (101a) to allow the residual fly ash sample to enter the sewage tank (103a-1) from the sample collection pipe (102a), thus completing the cleaning of the sample collection pipe (102a).

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