US20180372315A1 - Electronic control module and method for controlling the operation and safety of at least one radiant tube burner - Google Patents

Electronic control module and method for controlling the operation and safety of at least one radiant tube burner Download PDF

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Publication number
US20180372315A1
US20180372315A1 US16/062,963 US201616062963A US2018372315A1 US 20180372315 A1 US20180372315 A1 US 20180372315A1 US 201616062963 A US201616062963 A US 201616062963A US 2018372315 A1 US2018372315 A1 US 2018372315A1
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United States
Prior art keywords
burner
combustion
fuel
oxidant
measuring device
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US16/062,963
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English (en)
Inventor
Patrick Thomas
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Fives Stein SA
Original Assignee
Fives Stein SA
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Filing date
Publication date
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Assigned to FIVES STEIN reassignment FIVES STEIN ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: THOMAS, PATRICK
Publication of US20180372315A1 publication Critical patent/US20180372315A1/en
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N1/00—Regulating fuel supply
    • F23N1/02—Regulating fuel supply conjointly with air supply
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N5/00—Systems for controlling combustion
    • F23N5/003—Systems for controlling combustion using detectors sensitive to combustion gas properties
    • F23N5/006—Systems for controlling combustion using detectors sensitive to combustion gas properties the detector being sensitive to oxygen
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23C—METHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C3/00—Combustion apparatus characterised by the shape of the combustion chamber
    • F23C3/002—Combustion apparatus characterised by the shape of the combustion chamber the chamber having an elongated tubular form, e.g. for a radiant tube
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/12—Radiant burners
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/12—Radiant burners
    • F23D14/126—Radiant burners cooperating with refractory wall surfaces
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23D—BURNERS
    • F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/46—Details, e.g. noise reduction means
    • F23D14/60—Devices for simultaneous control of gas and combustion air
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N1/00—Regulating fuel supply
    • F23N1/02—Regulating fuel supply conjointly with air supply
    • F23N1/025—Regulating fuel supply conjointly with air supply using electrical or electromechanical means
    • F23N2021/10—
    • F23N2037/02—
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2221/00—Pretreatment or prehandling
    • F23N2221/10—Analysing fuel properties, e.g. density, calorific
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23N—REGULATING OR CONTROLLING COMBUSTION
    • F23N2237/00—Controlling
    • F23N2237/02—Controlling two or more burners

Definitions

  • the invention concerns an electronic control module and a method for optimally controlling the combustion and safety of industrial radiant tube burners equipping horizontal or vertical lines for the continuous heat treatment of metal strips.
  • FIG. 1 of the drawings it is shown a schematic example of a part of a vertical line for the continuous heat treatment of metal strips according to the state of the art. It comprises a zone Z1 for preheating the strip 2 , for example by hot gas jets, a zone Z2 for heating the strip by radiant tube burners, a zone Z3 for maintaining the temperature of the strip also equipped with radiant tube burners and zones Z4 and following undetailed used for other processing of the strip, for example its cooling.
  • This line is composed of an insulated enclosure 1 in which the strip 2 enters on a variety of rollers 3 guiding it in a multitude of vertical passes. At the top of each vertical pass are arranged radiant tubes 4 , 5 schematically represented by rectangles. On a modern annealing line, the number of radiant tubes—thus burners—installed can be between 200 and 400. Each of these burners is controlled individually and works in on-off mode, with the radiant tubes operating for example in push-pull mode.
  • the maximum heating power P max that can be produced by the heating zone Z2 corresponds to the simultaneous switching on of all the radiant tubes.
  • each of the burners of the radiant tubes in the heating zone is ignited for 60% of the cycle time, typically set at 1 or 2 minutes.
  • FIG. 2 is a column of radiant tubes 4 , 5 located on one side of the strip 2 , which runs on rollers 3 .
  • the supplies/exhaust of each of the radiant tubes 4 , 5 in this column are shown in this figure; the supply of oxidant, for example the combustion air, is schematized by 6 , the supply of liquid or gaseous fuel, for example natural gas, by 7 and the exhaust of flue gas by 8 . It is understood that according to the location of the fluid connections of the radiant tubes on the supply/exhaust ducts, the air supply or gas supply or flue gas exhaust pressures are different for each of the radiant tubes.
  • the ignition and extinction of a burner can also induce pressure fluctuations on the burner ducts located nearby or in the same zone of the furnace.
  • the nature or the composition of the gas can fluctuate, sometimes in significant proportions, for example with variations in heating value of +/ ⁇ 10% compared to an average value.
  • the equipment can also be supplied with several types of gas, for example natural gas and coke oven gas having very different characteristics in density or heat values. It can be seen that the operating conditions of the burners can be extremely variable according to air or gas supply or flue gas exhausting pressures, the characteristics of the gas used, the operating temperatures of the radiant tube, the influence of the ignition and extinction of neighboring burners in the column, in the zone or in a fluid circuit.
  • the equipment according to the state of the art does not make it possible to effectively control the quality of the flame according to the variations in the characteristics of the gas or its supply, and during the flame ignition and extinction phases, which occur in large numbers on an installation comprising a large quantity of burners operating in on-off mode.
  • the air-gas ratio at each moment of the burner ignition, operation and extinction phases is the result, at each moment, of the opening percentage of the air and gas valves, of the air and gas pressure in supply ducts and the actual heating value of the gas with respect to the theoretical setting value.
  • These differences are particularly important during the flame ignition and extinction phases according to the opening and closing characteristics of the valves, their actual sealing, the wear of their sealing devices and the variations in the characteristics of the air and gas supplies (e.g. pressure variations due to clogging of pipes) or heat values variations in the gas.
  • the current control equipment installed according to the standards in force, for example EN 746-2 and EN 298, control the existence of the flame without the quality of said flame being verified. This means they are open-loop operating modes that do not optimize the combustion.
  • Some commercial equipment includes sensors located in the air and gas supplies or in the flue gas to make corrections to the operating conditions of the burners, but none makes it possible to optimize each operating phase of the on-off cycle and to compensate for variations in heating value of the supply gas.
  • equipment according to the state of the art does not make it possible to quickly detect a malfunction in a radiant tube, whether it is the failure of an element or a degraded mode of operation.
  • the electronic-control module and the method according to the invention make it possible to optimize the combustion of the radiant tube burners, to reduce the quantities of pollutants emitted, to compensate for the variations in the heating power of the supply gas, to improve combustion efficiency by reducing the excess air required to ensure the proper operation of the burner and quickly detect a malfunction on said radiant tube.
  • a control module for at least one radiant tube burner comprising a fuel supply valve, an oxidant supply valve and a combustion flue gas exhaust duct
  • the control module is characterized in that it comprises:
  • control module comprises a means for calculating the combustion power Va of the fuel using the data provided by the combustion quality measuring device, the fuel flow measuring device and the oxidant flow measurement device, the calculated Va value by means of calculation being compared with a theoretical value to detect a deviation exceeding a predefined threshold.
  • the means for controlling the quality of the combustion could be a residual oxygen sensor.
  • the module may be able to control two radiant tube burners, the combustion power Va of the fuel being calculated for each burner, based on the data supplied by the oxidant flow and fuel flow measuring devices and the information delivered by the combustion quality control device, the two Va values obtained for the two burners being compared in order to detect a deviation exceeding a defined threshold.
  • the invention also includes a method for controlling at least one radiant tube burner, the burner comprising a fuel supply valve, an oxidant supply valve and a combustion flue gas exhaust duct, the method being characterized in that it consists of:
  • control method also makes it possible to:
  • the invention thus provides a fast and efficient system for managing the operation of radiant tube burners installed in large numbers in an industrial furnace. It optimizes combustion and reduces the amount of pollutants produced while ensuring the safe operation of the burners.
  • the invention provides a solution to controlling the burners even when the supply gas has variable characteristics (heat value or supply fuel pressure), by controlling the amount of gas depending on the amount of air to permanently maintain the air/gas ratio required for each burner.
  • the radiant tube burners are supplied by air 6 and gas 7 ducts.
  • the air supply of the burner is equipped with a flow measuring device, for example a diaphragm 13 and a differential pressure sensor 12 and an electrically or pneumatically controlled opening valve 14 , possibly with an opening position feedback signal.
  • the combustion air is heated by the flue gases in a heat exchanger schematized by 10 to supply the burner 20 with hot air.
  • the gas supply of the burner comprises a flow measuring device, for example a diaphragm 16 and a differential pressure sensor 15 and two electrically or pneumatically controlled opening valves 17 and 18 performing the function of dual sealing according to EN 746-2 and possibly at least one delivers a feedback of open position (in the figure valve 18 ) and a pressure switch 26 between valves 17 and 18 .
  • the burner 20 is thus supplied with gas and air.
  • the controlled opening valves 14 , 17 and 18 may also be equipped with sensors or limit switches to confirm the position of the valves at full opening or closing.
  • the burner 20 is equipped with a flame detection device 21 , for example an ultraviolet-type optical cell, and an ignition device 22 , for example an ignition electrode.
  • a flame detection device 21 for example an ultraviolet-type optical cell
  • an ignition device 22 for example an ignition electrode.
  • the radiant tube is equipped with temperature sensors, for example at least one thermocouple 25 for measuring its surface temperature and a sensor 24 located on the wet flue gas exhaust 8 of the radiant tube 4 to control the quality of combustion, for example a residual oxygen sensor.
  • the combustion system is equipped with an electronic control module 23 located near the burner, with output 23 a and input 23 b signals.
  • the input signals according to the example presented are the positions of the controlled valves 14 and 18 , flame detection 21 , the air and gas flow measurements 12 and 15 , the residual oxygen in the wet flue gas measured by the sensor 24 and the temperature of the tube measured by the thermocouple 25 .
  • the output signals are the controls of the valves 14 , 17 and 18 as well as the ignition control 22 .
  • a digital link makes it possible to transmit and receive information between a centralized control/command system and the electronic control modules 23 and/or between the electronic control modules 23 .
  • This electronic control module provides all the functions processed by the burner control systems existing on the market according to the state of the art and as defined in the standards, in particular the functions of ignition operation sequencing, burner extinction and safety related to each of these operating phases. It also has a combustion control and a failure control as detailed below.
  • the proposed system regulates a quantity of air, which is the reflection of the instantaneous power to be delivered by the burner in its various operating phases, using the valve 14 .
  • the differential pressure sensor 12 is connected to the electronic control module 23 , which calculates the instantaneous flow of air delivered to the burner.
  • the sensor 24 for measuring residual oxygen in the flue gas is connected to the electronic control module 23 , which determines the quantity of gas necessary to meet the required oxygen level in the wet flue gas in the different operating phases of the burner such as ignition, stabilized operation and extinction and it regulates this flow by controlling the valve 18 .
  • the differential pressure sensor 15 is connected to the electronics module 23 , which calculates the instantaneous flow rate of gas delivered to the burner.
  • the air and gas flow rates are calculated using the formula described in ISO 5167-2 which integrates the geometric characteristics of the primary measuring elements 13 , 16 , the parameters relating to the properties of the fluids and operating conditions such as atmospheric pressure, pressures, temperatures and densities which are common dynamic data or individual measured data and transmitted to the electronic control module 23 .
  • the electronic control module 23 calculates the rate of residual oxygen expected in the wet flue gas and adjusts the gas flow to maintain the required oxygen level in the wet flue gas. The invention thus maintains the quality of the combustion whatever the gas and air supply pressure fluctuations.
  • the invention also proposes other functionalities such as a gas valve tightness test sequencer controlled by the pressure switch 26 as well as a protection in case of exceeding a maximum operating temperature controlled by the thermocouple 25 .
  • the sensor 25 for measuring the temperature of the radiant tube 4 is connected to the electronic control module 23 .
  • the module 23 can thus control the shutdown of the burner in the event the radiant tube exceeds a maximum safety temperature.
  • the electronic control module 23 makes it possible to rapidly detect a malfunction in the radiant tube to which it is connected and to place said tube in the safety position if the malfunction is deemed to be serious.
  • the electronic module will issue an alert locally and/or to the centralized control/command system, while keeping the radiant tube concerned in service, or stopping it by placing it in the safety position.
  • the electronic control module 23 exchanges information with the devices for measuring and controlling air 12 , 13 , 14 and gas flow rates 15 , 17 , 18 , 26 , as well as the residual oxygen sensor 24 and the temperature sensor 25 .
  • the electronic control module 23 can thus detect a discrepancy between the information provided by one of these elements or sensors, the information provided by the other elements or sensors, and the theoretically expected data.
  • this discrepancy may consist of:
  • the electronic control module 23 calculates the Va of the fuel and compares it to the theoretical Va of the fuel.
  • This theoretical Va is advantageously supplied to the module by the centralized control/command system. It can also be directly input in the module by an operator.
  • the electronic control module 23 emits an alert beyond a certain differential threshold. When this difference reaches a second higher threshold, the radiant tube is stopped and secured.
  • the first threshold is for example 10% deviation and the second is 15% deviation.
  • Va of the fuel is for example calculated according to the composition of the gas according to the following formula in which the chemical formulations of the gases are to be replaced by the content of these gases in the fuel expressed in m 3 of gas per m 3 of fuel:
  • the electronics module 23 is placed in the immediate vicinity of the radiant tube that it controls. This allows a fast exchange of information between the electronic control module and the elements placed on the radiant tube due to a reduced cable length. This solution makes it possible to control and secure radiant tube assemblies faster than they would be through a centralized control/command system.
  • the proximity between the electronic control module and the radiant tube to which it is connected also facilitates the intervention of the operators during the commissioning of the equipment and during its maintenance.
  • the electronic control module 23 is connected to two radiant tubes located close to each other. It can detect a different behavior of the two radiant tubes that may reveal a malfunction of one of the two.
  • This solution is particularly advantageous because it makes it possible to erase the disturbances that would be related to a variation in the characteristics of the gas and/or air, these being common to the two radiant tubes.
  • the electronic control module 23 detects a deviation between the residual oxygen content announced by the sensor 24 of one of the radiant tubes and the flow rates measured in the air and the gas of this radiant tube, this deviation can be interpreted as being linked to a change in the composition of the fuel and its Va.
  • the control module 23 verifies if the same deviation is present on the second radiant tube. If this is the case, it is a change in the characteristics of one of the fluids. If this is not the case, it is a malfunction of a component on the first radiant tube and an alert is given by the electronic control module.
  • This analysis also makes it possible to detect the perforation of a radiant tube as it would result in the furnace atmosphere entering the tube, if the radiant tube operates in push-pull mode (the pressure inside the tube is lower than that outside the tube), and therefore a drop in the residual oxygen content measured in the flue gas.
  • the electronic control module of the invention comprises, in an optimized embodiment:

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Regulation And Control Of Combustion (AREA)
  • Combustion Of Fluid Fuel (AREA)
US16/062,963 2015-12-17 2016-12-15 Electronic control module and method for controlling the operation and safety of at least one radiant tube burner Abandoned US20180372315A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
FR1562629 2015-12-17
FR1562629A FR3045783B1 (fr) 2015-12-17 2015-12-17 Module de controle electronique et procede de controle du fonctionnement et de la securite d'au moins un bruleur a tube radiant
PCT/EP2016/081282 WO2017103000A1 (fr) 2015-12-17 2016-12-15 Module de contrôle électronique et procédé de contrôle du fonctionnement et de la sécurité d'au moins un brûleur à tube radiant

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US20180372315A1 true US20180372315A1 (en) 2018-12-27

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US16/062,963 Abandoned US20180372315A1 (en) 2015-12-17 2016-12-15 Electronic control module and method for controlling the operation and safety of at least one radiant tube burner

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US (1) US20180372315A1 (pl)
EP (1) EP3390911B1 (pl)
JP (1) JP2018537649A (pl)
KR (1) KR20180094932A (pl)
CN (2) CN112066408A (pl)
ES (1) ES2890881T3 (pl)
FR (1) FR3045783B1 (pl)
PL (1) PL3390911T3 (pl)
WO (1) WO2017103000A1 (pl)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11421874B2 (en) 2019-03-19 2022-08-23 Midea Group Co., Ltd. Digital gas valve burner control systems and methods

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112178914A (zh) * 2020-10-09 2021-01-05 苏州金猫咖啡有限公司 一种喷雾干燥塔用直燃热风系统的控制方法

Citations (8)

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Publication number Priority date Publication date Assignee Title
US4162889A (en) * 1976-12-14 1979-07-31 Measurex Corporation Method and apparatus for control of efficiency of combustion in a furnace
US4493635A (en) * 1982-02-27 1985-01-15 Osaka Gas Company Limited Oxygen-enriched air ratio control device for combustion apparatus
US4585161A (en) * 1984-04-27 1986-04-29 Tokyo Gas Company Ltd. Air fuel ratio control system for furnace
US4586893A (en) * 1981-12-08 1986-05-06 Somerville Michael J Control apparatus
US4749122A (en) * 1986-05-19 1988-06-07 The Foxboro Company Combustion control system
US5401162A (en) * 1989-10-30 1995-03-28 Honeywell Inc. Microbridge-based combustion control
US20120291679A1 (en) * 2009-11-30 2012-11-22 Five Stein Method for correcting the combustion settings of a set of combustion chambers and apparatus implementing the method
US20130302738A1 (en) * 2012-05-11 2013-11-14 Fisher-Rosemount Systems, Inc., A Delaware Corporation Methods and apparatus to control combustion process systems

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JPH061122B2 (ja) * 1984-06-06 1994-01-05 新日本製鐵株式会社 吸引式ラジアントチユ−ブバ−ナ−炉の最適燃焼制御方法
FR2712961B1 (fr) * 1993-11-26 1995-12-22 Lorraine Laminage Réglage en temps réel d'un brûleur à combustible de caractéristiques variables, notamment pour four métallurgique de réchauffage.
US7128818B2 (en) * 2002-01-09 2006-10-31 General Electric Company Method and apparatus for monitoring gases in a combustion system
TWI270638B (en) * 2002-03-29 2007-01-11 Chiyoda Chem Eng Construct Co Reaction furnace and method for controlling combustion thereof
FR2934033B1 (fr) * 2008-07-15 2010-09-03 Fives Stein Dispositif de pilotage de bruleurs regeneratifs.
FR3015009B1 (fr) * 2013-12-17 2019-01-25 Fives Stein Procede et bruleur pour reduire l'emission d'oxydes d'azote lors de la combustion d'un combustible gazeux

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4162889A (en) * 1976-12-14 1979-07-31 Measurex Corporation Method and apparatus for control of efficiency of combustion in a furnace
US4586893A (en) * 1981-12-08 1986-05-06 Somerville Michael J Control apparatus
US4493635A (en) * 1982-02-27 1985-01-15 Osaka Gas Company Limited Oxygen-enriched air ratio control device for combustion apparatus
US4585161A (en) * 1984-04-27 1986-04-29 Tokyo Gas Company Ltd. Air fuel ratio control system for furnace
US4749122A (en) * 1986-05-19 1988-06-07 The Foxboro Company Combustion control system
US5401162A (en) * 1989-10-30 1995-03-28 Honeywell Inc. Microbridge-based combustion control
US20120291679A1 (en) * 2009-11-30 2012-11-22 Five Stein Method for correcting the combustion settings of a set of combustion chambers and apparatus implementing the method
US20130302738A1 (en) * 2012-05-11 2013-11-14 Fisher-Rosemount Systems, Inc., A Delaware Corporation Methods and apparatus to control combustion process systems

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11421874B2 (en) 2019-03-19 2022-08-23 Midea Group Co., Ltd. Digital gas valve burner control systems and methods

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Publication number Publication date
CN112066408A (zh) 2020-12-11
ES2890881T3 (es) 2022-01-24
PL3390911T3 (pl) 2021-12-13
EP3390911B1 (fr) 2021-07-21
CN108463671A (zh) 2018-08-28
FR3045783B1 (fr) 2019-08-16
FR3045783A1 (fr) 2017-06-23
WO2017103000A1 (fr) 2017-06-22
KR20180094932A (ko) 2018-08-24
JP2018537649A (ja) 2018-12-20
EP3390911A1 (fr) 2018-10-24

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