Feedback-Controlled Post-Combustion of Metallurgical CO Exhaust
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Solution Overview
Problem
Metallurgical processes produce exhaust gases with varying compositions and volumes, making it challenging to achieve safe and efficient post-combustion of carbon monoxide, leading to increased fuel consumption and carbon dioxide emissions.
Innovation Solution
A feedback-controlled method is introduced to condition exhaust gases by adding combustion and inert gases upstream of the post-combustion process, ensuring complete combustion and maintaining a minimum exhaust gas flow velocity, with control loops managing calorific value and volume flow to prevent re-ignition and optimize carbon monoxide conversion to carbon dioxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuel gas is introduced in constant quantities for post-combustion, then safe post-combustion is ensured, but fuel consumption and carbon dioxide emissions increase
Solution Approach 1:
The patent applies dynamics by transitioning from constant fuel gas introduction to dynamic, variable quantity fuel gas introduction. The fuel gas flow rate is continuously adjusted based on real-time measurements of exhaust gas calorific value and volume flow, allowing the system to adapt to varying exhaust gas conditions while maintaining safe post-combustion and minimizing fuel consumption
Solution Approach 2:
The patent implements feedback control through continuous measurement of exhaust gas properties (calorific value via calorimeter, volume flow via flow meter) and using these measurements to automatically adjust the fuel gas flow rate. This closed-loop feedback system ensures safe post-combustion while optimizing fuel consumption by introducing only the necessary amount of fuel gas under varying operating conditions
2Reliability
If fuel gas is introduced in constant quantities for post-combustion, then safe post-combustion is ensured, but carbon dioxide emissions increase
Solution Approach 1:
The system dynamically adjusts fuel gas introduction based on actual exhaust gas conditions, introducing fuel gas only when and where needed for safe post-combustion. This dynamic approach reduces unnecessary fuel combustion and associated carbon dioxide emissions compared to constant quantity introduction
Solution Approach 2:
The feedback control system continuously monitors exhaust gas calorific value and volume flow, automatically reducing fuel gas introduction when exhaust gas conditions allow for reduced fuel consumption, thereby minimizing carbon dioxide emissions while maintaining safe post-combustion operation
3Adaptability or versatility
If exhaust gas composition and volume flow vary discontinuously, then metallurgical process flexibility is maintained, but post-combustion control becomes difficult
Solution Approach 1:
The patent addresses the difficulty of controlling post-combustion with variable exhaust gas by implementing a dynamic control system that continuously adapts to changing conditions. The fuel gas flow rate and air flow rate are dynamically adjusted based on real-time measurements, making the system capable of handling discontinuous variations in exhaust gas composition and volume flow while maintaining effective post-combustion control
Solution Approach 2:
The feedback control mechanism continuously measures exhaust gas calorific value and volume flow, using these measurements to automatically adjust fuel gas and air flow rates. This feedback system simplifies operation by automatically compensating for discontinuous variations in exhaust gas properties, maintaining optimal post-combustion control without requiring manual intervention despite the varying conditions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables safe and environmentally friendly post-combustion of over 97% of carbon monoxide while minimizing fuel consumption and emissions, maintaining a calorific value above 2 kWh/Nm3, and preventing re-ignition in the exhaust gas channel.
Implementation Method 1
at least one combustion gas and/or one further additional gas is introduced in feedback-controlled fashion into the exhaust gas upstream of the post-combustion. The feedback control is performed in a manner dependent on the composition of the exhaust gas and/or in a manner dependent on the exhaust gas volume flow
Implementation Method 2
the post-combustion of the exhaust gas preferably takes place with an open flame in the region of the mouth of an exhaust gas channel to the atmosphere
Implementation Method 3
both the calorific value of the exhaust gas and the exhaust gas volume flow are controlled such that... a combustion that is as complete as possible is secured
Data Source
AI summary
A method for the post-combustion of exhaust gases comprising carbon monoxide from metallurgical processes includes conditioning the exhaust gas prior to post-combustion by metering a combustion gas and/or one additional gas in feedback-controlled fashion. The feedback control depends on the composition of the exhaust gas dependent on the exhaust gas volume flow. A device for post-combustion of exhaust gas during vacuum treatment of liquid steel comprises a flare stack at an exhaust outlet, means for feeding combustion gas to the flare stack, means for feeding an inert gas into the exhaust gas channel of the vacuum pump, means for ascertaining the exhaust gas volume flow and/or for measuring the exhaust gas velocity within the exhaust gas channel, means for analyzing the exhaust gas composition, means for metering the combustion gas and the inert gas, and means for feedback control of the metering of the combustion gas and/or the inert gas dependent on the exhaust gas composition.