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    • 专利摘要:
    A method for detecting imbalances in an industrial reactor comprising a reaction chamber, wherein the presence of oxidation and reduction zones (2, 3) in the reaction chamber (1) of the industrial reactor is determined by measuring and analyzing oxygen concentration and temperature at measuring points (8) arranged inside the reaction chamber (1) in the industrial reactor and based on the measurements creating a an oxygen distribution profile and a temperature profile in the industrial reactor. The method may be used to minimize the production of environmentally harmful emissions such as NOx and CO in industrial processes without using chemicals. The method may be used to improve energy conversion efficiency in industrial boilers, optimizing combustion and industrial processes, continued monitoring and optimizing of the air factors in industrial boilers, reducing noncombusted fuels, reducing corrosions in industrial boilers.
    公开号:SE1650928A1
    申请号:SE1650928
    申请日:2016-06-28
    公开日:2017-12-29
    发明作者:Reza Shirazi Ahmad
    申请人:Reza Shirazi Ahmad；
    IPC主号:
    专利说明:

    METHOD FÖR CONTROLLENG ÜESTRÉBUTiQN OF AER FACTQRS EN ENDUSTREALREACTÛRS SV PROACTEVE OXYGEN AND TEMPERATURE MEASUREMENTS '!l.1~_._. _: h. 1.1.1. 1.1. -A E. i» k/Ifl! 1.1 y. l.~.,l'..1.«.~,!jl,' I: TECHNICAL FIELD The disclosure pertains to a method for detecting imbalances in an industrial hightemperature reactor comprising a reaction chamber. The method may involve diagnosingthe working condition of an industrial reactor and boiler. A method for counteractingimbalances in an industrial reactor is also disclosed herein. The methods as disclosedherein are applicable to any high-temperature industrial reactors, such as boilers,furnaces, etc.
    BACKGROUND OF THE INVENTION The major challenges for both developed and developing countries are problemsassociated with climate changes. Emission reduction of greenhouse gases and otherenvironmentally harmful emissions such as NOx and CO are of highest priority.
    The climate challenges intensify rapidly due to megatrends such as population growth,industrialization, economic growth, urbanization, improved living standards etc. ln almost all industrial high temperature reactors the concentration of oxygen showimbalance due to a number of thermodynamics and operative factors. Such imbalanceshave been found to cause a number of negative effects on a combustion process or otherhigh-temperature process in an industrial reactor such as increased emissions of NOxand CO, lowered energy and energy conversion efficiency, corrosion problems, non-combusted fuel, etc.
    An object of the present invention is to provide methods of determining the presence ofimbalances in industrial reactors. A further object may be to offer methods of counteracting continued monitored imbalances in industrial reactors.
    This invention offers a new thermodynamic model for high temperature chemistry inindustrial reactors. The innovation based on this new high temperature thermodynamicmodel aims to improve industrial reactor processes by providing one or more beneficialeffects including reducing environmentally harmful emissions such as NOx, CO, improvingenergy conversion efficiency in industrial reactors, optimizing reactors in industrialprocesses, continued monitoring and immediate optimization of the air factors in industrialreactors, reducing the amount of non-combusted fuels, reducing corrosion in industrialreactors, etc.
    SUMMARY OF THE INVENTION One or more of the above objects may be achieved with a method in accordance withclaim 1. Further embodiments are set out in the dependent claims, in the followingdescription and in the drawings.
    Disclosed herein is a method for detecting imbalances in industrial reactors comprisingreaction chambers. The formation and presence of oxidation and reduction zones in thereaction chamber of the industrial reactor is determined by presented novel approach ofmeasuring and analyzing oxygen concentration and temperature inside the reactionchamber in the industrial reactor and making an oxygen distribution profile and atemperature profile in the industrial reactor.
    The formation of oxidation zones and reduction zones in the industrial reactor may becounteracted by redistribution of oxygen in the reaction chamber using the oxygendistribution profile of the oxygen concentration and the temperature in the industrialreactor as a basis for supplying or removing oxygen where and when needed in order tooptimizing the oxygen concentration in the reaction chamber from a thermodynamic viewpoint.
    The method provides conditions to minimize NOx and CO production, optimizing energy conversion efficiency, optimizing combustion and industrial processes, continuous monitoring and optimizing the air factor, reducing non-combusted fuels, reducing corrosion in industrial boilers.
    The formation of oxidation zones and reduction zones in the industrial reactor may i.e. becounteracted by regulating air supply to the reaction chamber based on the oxygendistribution profile of the oxygen concentration and/or the temperature in the industrialreactor. An elevated or lowered temperature detected at a location in the reactionchamber is an indication that an oxidation zone or a reduction zone is emerging or existsin that location. Accordingly, redistribution of oxygen to or from a location with a devianttemperature may be required even if the measured oxygen content or air factor is withinpredetermined limits.
    The oxygen concentration and the temperature may be measured at different heightsinside the reaction chamber.
    The oxygen concentration and the temperature may be measured adjacent to a wall of thereaction chamber. lt has been found that oxidation zones and reduction zones oftenappear close to the walls of the reaction chamber.
    The oxygen distribution and the temperature in the reaction chamber may be continuously monitored.
    The air supply to the reaction chamber may be continuously adapted in response tochanges in the oxygen distribution profile and the temperature profile.
    The method as disclosed herein may be an automated method.
    The efficiency of the method as disclosed herein may be verified by one or more of:- monitoring production of NOx and CO,- monitoring energy conversion efficiency,- monitoring combustion and industrial processes- monitoring corrosion in the reaction chamber, - monitoring the amount of non-combusted fuel in the industrial reactor.
    The method as disclosed herein may be used to minimize the production in the industrialreactor of environmentaily damaging gases such as NOx and CO. By continuouslymeasuring the amount of oxygen and the temperature at selected locations inside thereaction chamber, thereby detecting the emergence of oxidation zones (zones of hightemperature and high oxygen content) and reduction zones (zones of low temperatureand low oxygen content), the formation of oxidation zones and reduction zones candirectly be counteracted by redistributing oxygen in the reaction chamber of the industrialreactor. Redistribution of oxygen is made to optimize the oxygen concentration in thereaction chamber and to maintain optimal reaction conditions throughout operation of the industrial reactor.
    As set out herein, continuous monitoring, mapping and evaluation of the oxygenconcentration and the temperature inside the reaction chamber of the industrial reactoroffers a tool to continuously counteract the creation of oxidation zones and reductionzones by redistributing oxygen in the reaction chamber and thereby not only lowering theproduction of environmentaily damaging gases such as NOx and CO, but also increasingthe energy conversion efficiency of the industrial reactor, minimizing corrosion in thereaction chamber and ascertaining that uniform reaction conditions are maintained in allparts of the reaction chamber. Thereby it is possible to minimize the amount of non-reacted material in the reaction chamber, e.g. the amount of non-combusted fuel in the reaction chamber.
    As disclosed herein, the method of the invention offers a way to monitor and control the reaction conditions in a high-temperature industrial reactor. The method is a clean method and is based on thermodynamic principles, which means that the appearance of oxidationzones and reduction zones can be avoided without the need for adding chemical reduction or oxidation agents for counteracting the emergence of the detrimental oxidation and reduction zones.
    The oxygen distribution profile and the temperature profile of the industrial reactor may beused to diagnose the condition of the reactor during daily operation.
    The present invention has verified the formation of oxidation and reduction zones insidehigh-temperature industrial reaction chambers and that the formation of oxidation and reduction zones inside an industrial reaction chamber is the main source for high production of environmentally harmful gases such as NOx and CO. As set out herein,problems such as corrosion and reduced energy conversion efficiency are also related to the formation of oxidation and reduction zones.
    Therefore it is of outmost importance to prevent the formation of oxidation and reductionzones in industrial reactors and thereby diminish the problems associated with thethermodynamic processes associated with the formation of oxidation and reduction zones.
    The oxidation zones are oxygen enriched and reduction zones are oxygen depleted. Theoxidation zones show higher temperature compared to reduction zones. These zones arequite stable and can persist for long periods of time. The above mentioned problemsassociated with the occurrence of oxidation and reduction zones will remain unless it is countered.
    The oxidation and reduction zones may or may not coexist simultaneously in the reactor.
    The concentrations of NOx and CO (and 02) in the flue gases determine the total airfactor. The total air factor may be balanced by increasing the air factor in case of high COconcentration and the air factor may be decreased in case of high NOx (O2) concentrationin the flue gases. These prevailing approaches have been found to ultimately result ininaccurate air factors and consequent energy losses. lt has proven to be even morechallenging to obtain a correct air factor for demanding fuels such as bio fuels with greatfluctuations of parameters that have impact on the air factor, parameters such as calorificvalue, moisture and ash contents etc.
    By application of the new detailed thermodynamic model on which the present inventionrelies it has been shown that the increased production of NOx or CO may or may not berelated to high or low air factor. lnstead it has been found that it is closely related to theimbalance distribution of oxygen in the reaction chamber and the formation of oxidationand reduction zones which is a result of oxygen distribution imbalance. The continuousand simultaneous production of both NOx (oxidation milieu) and CO (reduction milieu) inindustrial reactors regardless of accurate/ inaccurate air factor confirms this new thermodynamic model.
    Currently there are no procedures of measuring and profiling the temperature and thedistribution of oxygen across the reaction chambers in conventional high-temperatureindustrial reactors of today. The importance of being able to determine the occurrence ofoxidation and reduction zones has not been previously recognized and there are noprocedures to detect these zones and their movement inside the reaction chamber and notechniques to counteract the formation of such zones have been previously presented.
    Disclosed herein is a novel approach to detect and map the movement of oxidation andreduction zones in a high-temperature industrial reactor and to offer counter measures toneutralize and to prevent the formation of oxidation and reduction zones in order to address the environmental and operational problems associated with these zones.
    This new comprehensive and detailed thermodynamic model disclosed herein revealsnew features for production of NOx and CO in industrial processes. The invention basedon this new thermodynamic model presents a new approach to monitor and adjustingreaction conditions and offers a tool for minimizing the production of NOx and CO inindustrial processes. Preferably, the distribution of oxygen in an industrial reactor iscontinuously monitored and the result of the mapped oxygen distribution may becontinuously used to regulate the air factor in an industrial process in order to optimize theenergy conversion efficiency as well as to minimize the NOx and CO emissions and corrosion in industrial reactors etc. ln this invention a novel approach has been implemented. That is to analyze oxygen andtemperature at selected locations, optionally at different heights inside the reactionchambers in industrial reactors in order to determine the distribution profiles of oxygen aswell as the profile of temperature inside the reaction chambers. ln this invention the temperature and oxygen are preferably profiled by sampling insidethe reaction chamber adjacent to the reactor wall. The temperature profile can berecorded by conventional thermocouples. The oxygen distribution can be mapped by GasChromatography (GC) or by Zirconium sensors.
    This novel approach provides a unique opportunity to optimize the total reactor air factorinstantly and continuously in order to optimize the energy conversion of the process in thereactor in spite of often rapid fluctuations of fuel parameters that affect the air factor such 5 as calorific value, ash and moisture contents etc. This continuous correction and optimalair factor results i.e. optimal energy conversion and reduced corrosion in industrial reactors.
    The proactive process control described in this invention may be implemented in anautomated mode in order to detect the formation and movement of the oxidation andreduction zones and automatically redistribute oxygen cross the reaction chamber. Thegoal of these conducts is to distribute oxygen in a manner that the oxygen andtemperature profile show as uniform profiles as thermodynamically is sound consideringother parameters such as NOx and CO production, reactor load etc. at the same time.
    These oxidation and reduction zones can arise from asymmetrical oxygen distribution inindustrial reactors for a number of thermodynamics and operative factors such as: - Variations in proportions between combustible and non-combustible matter in fuels when the total air factors are not adjusted and corrected continuously for these variations duringoperation.
    - Fluctuation of solid fuel quality, e.g. fluctuation in calorific value, moisture, ash content,etc.
    - Fluctuation of gaseous fuel quality, e.g. fluctuation in calorific value, density, combustible constitution, etc.
    - Variations in reactor loads.
    - Faulty or unknown malfunctions or imprecisions of dampers and feeding systems for fueland/or air quantities into the reactor.
    - Soot removing procedures.
    - Asymmetrical distribution of solid fuel in the reactor.
    - Asymmetrical distribution of natural gas into various burners.
    Another application area for this novel approach of monitoring the oxygen andtemperature profiles inside the reaction chamber is the fact that it can be used as adiagnostic tool for daily operations. Faulty fuel and air dampers and feeding systems canbe detected with continuous monitoring of oxygen and temperature.
    For instance, sudden irregularities in the temperature profile despite correct oxygendistribution profile are an indication of faulty fuel dampers and / or irregular distribution ofthe fuel inside the reaction chamber.
    This novel approach further enables a user to evaluate the quality of fuels continuously.This approach reveals a number of important details of reactor and industrial processesthat have to be supervised and managed and would not be detected othen/vise BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be further explained hereinafter with reference to the appended drawings wherein: Fig. 1 shows a schematic representation of a process chamber of anindustrial reactor; andFig. 2 shows the process chamber in Fig. 1 with measuring points. lt also shows the disappearances of oxidation and reduction zones withcorrect air distribution.
    DETAILED DESCRIPTION With reference to Fig. 1, a process chamber 1 of a high-temperature industrial reactorshown in a highly schematic representation. Fig. 1 illustrates the thermodynamic modelfor formation of oxidation zones 2 and reduction zones 3 in the process chamber 1. Fig. 1also shows inlets 4, 5 for secondary air and tertiary air which inlets may be used toregulate oxygen supply to the interior of the process chamber 1.
    This invention has determined the nature and behavioral pattern of the oxidation and reduction zones 2, 3. The new high temperature thermodynamic model that this inventionis based on, demonstrates that the oxidation and reduction zones 3,4 form adjacent to theinner wall 6 of the combustion chamber a and usually rearranges and moves around both vertically and horizontally inside the combustion chamber 1.
    According to the new thermodynamic model which is the basis for the methods asdisclosed herein, thermodynamic and operative factors institute imbalance in the oxygendistribution in industrial reactors and thereby oxidation and reduction zones 2, 3 areformed in industrial reactors. As set out herein, such oxidation and reduction zones 2,3instigate increased production of environmentally damaging gases such as NOx in theoxidation zones 2 and CO in the reduction zones 3 in the f|ue gases regardless of correct/ incorrect air factor quantities.
    Apart from increased NOx and CO the formation of these oxidation and reduction zones2,3 in industrial reactors give rise to problems such as corrosion, poor/incomplete fuelcombustion etc. The production of NOx and CO reduces energy conversion efficiency dueto the endothermic nature for formation enthalpy of NOx and CO. The oxidation zonesshow higher temperature in comparison to reduction zones. NOx is produced in oxidationzones with high oxygen concentration and CO is created in reduction zones with loweroxygen concentration as is illustrated by Fig. 1.
    Fig 2 illustrates a proactive method to counteract the formation of oxidation and reductionzones in industrial reactors based on the thermodynamic model as disclosed herein.
    The creation of oxidation and reduction zones 2,3 can therefore be detected and thedistributions and movements of these zones 2,3 can therefore be monitored byimplementation of the methods as described herein. ln this invention with the novel approaches of continuous monitoring of temperature andoxygen distribution inside the reaction chamber 1, the formation of oxidation and reductionzones is countered by redistributing the oxygen inside the reaction chamber 1 byregulating the oxygen input and/or oxygen removal where and when it is required. Theredistribution system may include control of the air supply from the secondary and tertiaryair inlets 4, 5, and optionally further air inlets (not shown). The reaction chamber 1 is also provided with a primary air inlet, which is not shown in the figures and which is not part ofthe system for regulating the oxygen profile inside the reaction chamber 1.
    As is shown in Fig. 2, measuring points 8 are arranged on the reactor wall 6, formeasuring the oxygen distribution profile and a temperature profile inside the reactionchamber 1. Although Fig. 2 shows measuring points 8 placed at a single level in thereaction chamber, it may be preferred that measuring points are arranged at differentlevels in the reactor wall 6. The number of measuring points 8 at a particular level may beselected as desired and the measuring points 8 may be distributed over the reactor wall 6in a pattern of measuring points.
    The data gathered from the measuring points 8, is analysed and an oxygen distributionprofile and a temperature profile are created which forms the basis for further actions,such as redistribution of oxygen/air in the reaction chamber 1 to optimize the oxygenconcentration in the reaction chamber 1 and eradicate any emerging oxidation zones 2and reduction zones 3, as indicated in Fig. 2. The method is preferably computerized suchthat data can be gathered and processed in a central processing unit (CPU) and such thatmeasuring equipment, valves, etc. can be continuously monitored and controlled electronically.
    The reaction chamber 1 may have a shape different from the rectangular shape shown inthe figures. Accordingly, the reaction chamber 1 may have any useful shape as known inthe art, such as cylindrical, conical, etc. 5
    权利要求:
    Claims (22)
    [1] 1. A method for minimizing the production of environmentally harmful emissions such asNOx and CO in an industrial reactor comprising a reaction chamber (1), c h a r a c t e r i ze d the method comprising detection of the presence and movement of oxidation and i n t h a t imbalances in the reaction chamber (1) are detected and counteracted, reduction zones (2, 3) in the reaction chamber (1) of the industrial reactor by measuringand analyzing oxygen concentration and temperature at measuring points (8) arrangedinside the reaction chamber (1) in the industrial reactor and creating an oxygendistribution profile and a temperature profile in the industrial reactor and counteractingformation of oxidation zones (2) and reduction zones (3) in the industrial reactor byredistribution of oxygen in the reaction chamber (1) based on the oxygen distributionprofile of the oxygen concentration and/or the temperature profile in the industrial reactor,thereby providing conditions for minimizing NOx and CO production, optimizing energyconversion efficiency, optimizing combustion and industrial processes, continuousmonitoring and optimizing the air factor, reducing non-combusted fuels or unprocessed material, reducing corrosion in industrial reactors.
    [2] 2. A method according to claim 1, wherein redistribution of oxygen in the reactionchamber comprises or consists of regulating air supply to the reaction chamber (1) basedon the oxygen distribution profile of the oxygen concentration and the temperature in the industrial reactor.
    [3] 3. A method according to claim 1 or 2, wherein the oxygen concentration and the temperature are measured at different heights inside the reaction chamber (1 ).
    [4] 4. A method according to any one of the preceding claims, wherein the oxygenconcentration and the temperature are measured adjacent to a wall (6) of the reactionchamber (1 ).
    [5] 5. A method according to any one of the preceding claims, wherein oxygen distribution and temperature in the reaction chamber (1) are continuously monitored.
    [6] 6. A method according to claim 5, wherein air supply to the reaction chamber (1) iscontinuously and proactively adapted in response to changes in the oxygen distribution profile and/or the temperature profile.
    [7] 7. A method according to any one of the preceding claims, wherein the method is an automated method.
    [8] 8. A method according to any one of the preceding claims, wherein the energy conversion efficiency of the industrial reactor is optimized.
    [9] 9. A method according to any one of the preceding claims, wherein corrosion in the reaction chamber (1) is minimized.
    [10] 10. A method according to any one of the preceding claims, wherein the amount of non- combusted fuel in the reaction chamber (1) is minimized.
    [11] 11. A method according to any one of the preceding claims, wherein the oxygendistribution profile and the temperature profile of the industrial reactor are used to diagnose a working condition of the industrial reactor.
    [12] 12. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boiler, c h a ra c te riz e d in th at the concentration ofoxygen in industrial boilers show imbalance due to a number of thermodynamics andoperative factors and this imbalance create oxidation and reduction zones in industrial boilers.
    [13] 13. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at the formation ofoxidation and reduction zones results in increase production of environmental damaging gases such as NOx and CO.
    [14] 14. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at the formation ofoxidation and reduction zones and increased formation of NOx and CO results in lower energy conversion efficiency in industrial boilers.
    [15] 15. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at the formation ofoxidation and reduction zones results in increase corrosions in industrial boilers due to non-optimized combustion and process air factor.
    [16] 16. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers c h a ra c te riz e d in th at the concentration ofoxygen in industrial boilers show imbalance due to a number of thermodynamics andoperative factors and this imbalance create oxidation and reduction zones in industrial boilers and this results in increased non-combusted fuels.
    [17] 17. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at to continuouslydetect, monitor the movement and counteract the formation of oxidation and reductionzones, the oxygen concentration and temperature are profiled by sampling and analysingthe oxygen concentration and temperature inside the combustion chamber in industrial boilers.
    [18] 18. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at to continuouslydetect, monitor the movement and counteract the formation of oxidation and reductionzones by sampling inside the combustion chamber, the oxygen concentration is optimizedand redistributed in order to counteract the imbalance and thereby neutralize theformation of oxidation and reduction zones in industrial boilers and thereby minimize the production of environmental damaging gases such as NOx and CO.
    [19] 19. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at to continuouslydetect, monitor the movement and counteract the formation of oxidation and reductionzones by sampling inside the combustion chamber, the oxygen concentration is optimizedand redistributed in order to counteract the imbalance and thereby neutralize theformation of oxidation and reduction zones in industrial boilers and thereby optimizing the energy conversion efficiency.
    [20] 20. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at to continuouslydetect, monitor the movement and counteract the formation of oxidation and reductionzones by sampling inside the combustion chamber, the oxygen concentration is optimizedand redistributed in order to counteract the imbalance and thereby neutralize theformation of oxidation and reduction zones in industrial boilers and thereby reducing the corrosion in industrial boilers.
    [21] 21. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at to continuouslydetect, monitor the movement and counteract the formation of oxidation and reductionzones the oxygen concentration is optimized and redistributed in order to counteract theimbalance and thereby neutralize the formation of oxidation and reduction zones inindustrial boilers and thereby be able to diagnose the condition of industrial boilers at daily basis.
    [22] 22. Method and process of conduct based on a new thermodynamic model for allcombustion and industrial boilers, c h a ra c te riz e d in th at to continuouslydetect, monitor the movement and counteract the formation of oxidation and reductionzones the oxygen concentration is optimized and redistributed in order to counteract theimbalance and thereby neutralize the formation of oxidation and reduction zones in industrial boilers in a proactive manner and in automated mode.
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    同族专利:
    公开号 | 公开日
    SE542301C2|2020-04-07|
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    引用文献:
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    法律状态:
    优先权:
    申请号 | 申请日 | 专利标题
    SE1650928A|SE542301C2|2016-06-28|2016-06-28|Method for controlling distribution of air factors in industrial reactors by proactive oxygen and temperature measurements|SE1650928A| SE542301C2|2016-06-28|2016-06-28|Method for controlling distribution of air factors in industrial reactors by proactive oxygen and temperature measurements|
    PCT/EP2017/065716| WO2018001964A1|2016-06-28|2017-06-26|Method for controlling distribution of air factors in industrial reactors by proactive oxygen and temperature measurements|
    EP17735432.1A| EP3475613A1|2016-06-28|2017-06-26|Method for controlling distribution of air factors in industrial reactors by proactive oxygen and temperature measurements|
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