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Application of online gas analyzer in industrial processes
In the field of industrial automation, applying gas analysis systems presents significant challenges. Those working in this area understand the complexities involved, especially when it comes to process analysis under harsh conditions. Industrial environments often involve high temperatures, dust, moisture, negative pressure, and corrosive gases. Additionally, pretreatment equipment may not be effective, and there are often delays caused by the process, pretreatment, and analysis instruments. Dust, splash, and corrosion resistance requirements are also high, making automation more demanding and reducing maintenance workload.
Gas composition analysis is one of the most commonly used techniques in industry. Based on the working principle of gas analyzers, they can generally be divided into two types: direct measurement and indirect (sampling) measurement. Direct measurement involves placing a probe directly into the gas pipeline, such as with infrared, ultraviolet, or laser analyzers. Indirect measurement requires extracting the gas, treating it for dust removal, and then analyzing it. The main challenge in indirect methods lies in obtaining suitable sample gas, especially in harsh industrial conditions. This is where a reliable pretreatment system becomes essential.
For direct measurements, optical technologies allow for non-intrusive, fast, and accurate readings without altering the gas state. These systems eliminate the need for a pretreatment unit, reducing costs and maintenance. However, they come with limitations: high cost, unsuitability for large dust particles, and inefficiency for gases that do not interact well with the light source.
In some smelting processes, like those in lead and zinc production, online analyzers are used for monitoring gases such as CO, COâ‚‚, SOâ‚‚, and for measuring Hâ‚‚SOâ‚„ concentration, pH, moisture, and calorimetry. One example is the SIELINS 800 analyzer, which uses infrared technology to measure SOâ‚‚ and CO levels in dust collection systems. Although it offers real-time and accurate results, issues such as poor purge performance and lack of probe heating were identified. Improvements like using purified compressed air and tracing sampling significantly enhanced its performance, leading to near-maintenance-free operation.
When selecting an analysis system, several factors must be considered. First, ensure that the system is compatible with the process conditions. Detailed information about the measured substance—such as composition, temperature, humidity, particle size, and corrosivity—is crucial for proper matching. Second, the pretreatment device must have sufficient capacity and reliability, as over 90% of system failures occur here. Third, the manufacturer’s technological advancement and after-sales support should be evaluated. Fourth, if economically feasible, importing advanced equipment can improve performance, while domestic pretreatment devices may offer better customization. Finally, case studies from different manufacturers can provide valuable insights before making a final decision.
In conclusion, successful application of online gas analyzers depends on careful selection, adaptation to field conditions, and regular maintenance. While advanced imported systems may offer better performance, proper setup and ongoing care are essential for long-term success.