Patent Application
20250180204
The present disclosure relates to a measuring device, in particular to a flame measuring system of an industrial burner and a method thereof.
At present, it is impossible to effectively measure appearance geometry and temperature characteristics of a flame of an industrial burner in an industrial furnace, and the industrial burner can only be arranged in an open space, thus making flame characteristics of the industrial burner different from those in the industrial furnace. Furthermore, a flame temperature of the industrial burner can only be measured directly via a thermocouple at present, and most thermal imagers cannot capture flame temperature images. The thermocouple carries out single-point measurement, and it will take a lot of time to measure flame temperature characteristics of the industrial burner completely with the thermocouple.
Based on the above reasons, an object of the present disclosure is to provide a flame measuring system of an industrial burner and a method thereof. The industrial burner may be operated under an operation state simulating an industrial furnace and simultaneously carry out flame measurement. In this way, a measuring result is closer to an actual situation. Moreover, the industrial burner may be operated under the operation state simulating the industrial furnace, and a flame temperature distribution corresponding to a heated area on a flame detection rod may be obtained at one time under a condition of minimal interference to a flame flow field. The measuring manner belongs to linear measurement, thus greatly shortening a measuring time.
To achieve the above object, the present disclosure provides a flame measuring system of an industrial burner, comprising: a test chamber in a barrel-shaped structure; an industrial burner installed on an end face of the test chamber, a front pipeline of a fuel inlet and a front pipeline of a combustion air inlet of the industrial burner respectively comprising a regulating valve and a flow gage, each regulating valve being configured to adjust a volume of fuel and a volume of combustion air entering the industrial burner per unit time, and each flow gage being configured to measure the volume of the fuel and the volume of the combustion air entering the industrial burner per unit time; a flame detection rod having an end inserted in the test chamber and having a heated area corresponding to the industrial burner; a thermal radiation sensor disposed outside the test chamber for receiving a thermal radiation of each heated position of the heated area on the flame detection rod; a pressure gage having an end inserted in the test chamber to measure a pressure in the test chamber; a control module electrically connected to the regulating valves for controlling and changing openings of the regulating valves; a signal module electrically connected to the flow gage, the pressure gage, and the thermal radiation sensor; and a host electrically connected to the control module and the signal module. The control module receives a digital signal transmitted by the host, converts the digital signal into an analog signal, transmits the analog signal to the regulating valve, and changes the opening of the regulating valve. The signal module receives analog signal data of the flow gage, the pressure gage, and the thermal radiation sensor, converts the analog signal data into digital signal data, and then transmits the digital signal data to the host for processing, calculation, and analysis.
In some embodiments, the test chamber comprises a body, a flue gas box, and a length adjusting mechanism. The body is communicated with the flue gas box, and the length adjusting mechanism is axially movable in the body.
In some embodiments, the body internally has at least one flame tube and a plurality of flue gas tubes. The flame tube is in a hollow tubular structure and is disposed coaxially with the body. The flue gas tubes are disposed in an axial direction of the body, and the flue gas tubes are disposed in an outer area of the flame tube.
In some embodiments, the body has a first circular end face and a second circular end face. The first circular end face has a first opening, and the industrial burner is installed in the first opening. The second circular end face has a second opening communicated with the flame tube and a third opening communicated with the plurality of flue gas tubes.
In some embodiments, the flue gas box is in a cylindrical structure and is communicated with an exhaust tube by mechanical connection. A third circular end face of the flue gas box is communicated with the second circular end face of the body by mechanical connection. The flue gas box is disposed coaxially with the body.
In some embodiments, the length adjusting mechanism has a stopper, a screw rod, and a control wheel. The stopper is in a columnar structure and is connected to the screw rod mechanically. The stopper is disposed coaxially with the screw rod. The screw rod is connected to the control wheel mechanically. The length adjusting mechanism is disposed on the first circular end face of the flue gas box. The screw rod is disposed coaxially with the flame tube. The control wheel is rotated to move the stopper in an axial direction of the flame tube so as to adjust a position of the stopper in the flame tube.
In some embodiments, the body further comprises a cooling cavity, a plurality of sensing channels, and a flame viewing window. The cooling cavity is defined in an area formed by an outer side of the flame tube and a cylindrical inner side of the body. The cooling cavity is internally filled with a cooling medium, and has a first cooling cavity opening and a second cooling cavity opening both located at a surface of the body. The first cooling cavity opening is a cooling medium inlet, and the second cooling cavity opening is a cooling medium outlet. The sensing channels are disposed in a radial direction of the body. Each sensing channel is in a tubular structure and has a first sensing channel opening and a second sensing channel opening. The first sensing channel opening is located at a surface of the body, and the second sensing channel opening is located on an inner surface of the flame tube. The flue gas tube and the sensing channels may pass through the cooling cavity. The flame viewing window is disposed at the surface of the body, and is in positional correspondence with a flame viewing opening on the flame tube. The flame viewing window has a function of opening and closing. After the flame viewing window is opened, a configuration of a cover plate on the flame tube may be adjusted to change a range of the flame viewing opening.
The present disclosure further provides a flame measuring method of an industrial burner, comprising: obtaining an estimated emissivity value of a flame detection rod; installing an industrial burner in a test chamber; setting a configuration of the test chamber, and adjusting a position of a stopper in a flame tube in the test chamber according to a burning condition of a burning furnace to be simulated, thus changing a working length of the flame tube; setting a fuel flow rate and a combustion air flow rate of the industrial burner; starting the industrial burner; adjusting a pressure of the flame tube; installing a flame detection rod; measuring a thermal radiation of the flame detection rod; and calculating a temperature of each heated position in a heated area of the flame detection rod.
In some embodiments, the step of obtaining an estimated emissivity value of a flame detection rod comprises installing the industrial burner, setting the configuration of the test chamber, setting the fuel flow rate and the combustion air flow rate, starting the industrial burner, adjusting the pressure of the flame tube, sequentially installing flame detection rods in a plurality of sensing channels, sequentially measuring a thermal radiation of a front end of each flame detection rod and a temperature of a thermocouple in the plurality of sensing channels, and calculating an emissivity of each flame detection rod to select the estimated emissivity value.
In some embodiments, the front end of each flame detection rod in the step of obtaining an estimated emissivity value of a flame detection rod has a thermocouple to measure a temperature of the thermocouple at the front end of each flame detection rod.
In some embodiments, a formula for a relationship between the thermal radiation and the temperature is P=ΣσT4, where P is a thermal radiation intensity, E is the emissivity, a is a Stefan-Boltzmann constant, and Tis the temperature.
In some embodiments, in the step of calculating an emissivity of each flame detection rod to select the estimated emissivity value, the emissivity of each flame detection rod is changed via try and error, and a temperature of the front end of each flame detection rod is calculated by the formula. In addition, an error of the two temperatures is calculated by comparing temperature data of the thermocouple. An average value is calculated by a plurality of errors of each flame detection rod disposed in a plurality of sensing channels, and an emissivity corresponding to a minimum average error is selected as the estimated emissivity value of the flame detection rod.
In some embodiments, the step of sequentially installing flame detection rods in a plurality of sensing channels is followed by a step of installing a standard detection rod in at least one sensing channel. The standard detection rod has a standard length size.
In some embodiments, after the step of sequentially measuring the thermal radiation of the front end of the flame detection rod and the temperature of the thermocouple in the plurality of sensing channels, a step of measuring a size conversion ratio value of a two-dimensional signal of a thermal radiation sensor in at least one sensing channel is added to obtain an actual space length corresponding to adjacent signal points, thus obtaining temperature information of a flame and length and size information of the flame.
The technical features and advantages of the present disclosure have been summarized fairly broadly above to enable better understanding of the following detailed description of the present disclosure. Other technical features and advantages forming the subject matter of the patent application scope of the present disclosure will be described below. Those of ordinary skill in the art to which the present disclosure pertains will appreciate that the concepts and specific embodiments disclosed below may be readily utilized to modify or design other structures or processes to achieve the same purposes as the present disclosure. Those of ordinary skill in the art to which the present disclosure pertains will also appreciate that such equivalent constructions cannot depart from the spirit and scope of the present disclosure as defined in the appended patent application scope.
Specific embodiments of the present disclosure will be described in detail below with reference to specific situations.
Referring also to
In some embodiments, the body 111 is in a cylindrical structure, and internally has a flame tube 114, a plurality of flue gas tubes 115, a cooling cavity 116, a plurality of sensing channels 117, and a flame viewing window 118. The body 111 externally has a cylindrical curved surface 119, a first circular end face 120, and a second circular end face 121. The first circular end face 120 has a first opening 122. The industrial burner 102 to be tested may be installed via the first opening 122. The second circular end face 121 has a second opening 123 communicated with the flame tube 114 and a third opening 124 communicated with the plurality of flue gas tubes 115.
The flue gas box 112 is in a cylindrical structure and is communicated with an exhaust tube 125. The flue gas box 112 externally has a cylindrical curved surface 126 and a third circular end face 127. The cylindrical curved surface 126 has a fourth opening 128 communicated with an inlet of the exhaust tube 125 by mechanical connection. The third circular end face 127 of the flue gas box 112 is communicated with the second circular end face 121 of the body 111 by mechanical connection, and an axis of the flue gas box 112 coincides with an axis of the body 111. That is, the flue gas box 112 is disposed coaxially with the body 111.
In some embodiments, the exhaust tube 125 is disposed in a radial direction of the flue gas box 112. The exhaust tube 125 has at least one fourth opening 132. A bolt 148 may be disposed to close the fourth opening 132. Alternatively, a connector may be disposed, and a gas composition detection rod 133, the pressure gage 107, or a thermocouple (not shown) are connected via the connector. An outlet of the exhaust tube 125 includes a regulating valve 134. Based on a sensed measurement value of the pressure gage 107, an opening of the regulating valve 134 may be changed via the control module 108, whereby a pressure in the flame tube 114 meets test requirements.
The length adjusting mechanism 113 has a stopper 129, a screw 130, and a control wheel 131. The stopper 129 is in a cylindrical structure. The stopper 129 is mechanically connected to the screw rod 130. An axis of the stopper 129 coincides with an axis of the screw rod 130 (that is, the stopper 129 is disposed coaxially with the screw rod 130), and the screw rod 130 is mechanically connected to the control wheel 131. A position of the stopper 129 is designed to simulate an actual size and pattern of a burning furnace, so as to predict a burning performance of the burning furnace at a given power of the industrial burner during a high temperature process. The length adjusting mechanism 113 is disposed on the third circular end face 127 of the flue gas box 112, and the axis of the screw rod 130 coincides with an axis of the flame tube 114 (that is, the screw rod 130 is disposed coaxially with the flame tube 114). Therefore, the stopper 129 may be moved in an axial direction of the flame tube 114 by rotating the control wheel 131 to adjust the position of the stopper 129 in the flame tube 114. Therefore, the length adjusting mechanism 113 may be axially moved via the stopper 129 to simulate an actual influence of patterns of various burning furnaces on burning flames.
The flame tube 114 is in a hollow tubular structure. The flame tube 114 is disposed in an axial direction of the body 111. The axis of the flame tube 114 coincides with the axis of the body 111 (that is, the flame tube 114 is disposed coaxially with the body 111). The flame tube 111 has a flame viewing opening 135. The flame viewing opening includes a plurality of cover plates 136. The cover plates 136 may be removed according to individual test requirements to adjust a range of the flame viewing opening 135.
The flue gas tubes 115 are disposed in the axial direction of the body 111. The flue gas tubes 115 are disposed in an outer area of the flame tube 114 and are communicated with the flame tube 114. Since the stopper 129 prevents flue gas from flowing directly into the flue gas box 112, the plurality of flue gas tubes 115 communicated with the flame tube 114 is disposed. After flowing into the flue gas tubes 115, the burned flue gas is guided into the flue gas box 112 and then discharged via the exhaust tube 125. The process will be described in subsequent paragraphs.
The sensing channels 117 are disposed in a radial direction of the body 111. Referring to
The cooling cavity 116 is defined in an area formed by an outer side of the flame tube 114 and a cylindrical inner side of the body 111. The cooling cavity 116 is filled with a cooling medium and has a first cooling cavity opening 139 and a second cooling cavity opening 140 both located on a cylindrical surface of the body 111. That is, the first cooling cavity opening 139 is a cooling medium inlet, and the second cooling cavity opening 140 is a cooling medium outlet. The flue gas tubes 115 and the sensing channels 117 may pass through the cooling cavity 116.
The flame viewing window 118 is disposed on the cylindrical surface of the body 111 and is in positional correspondence with the flame viewing opening 135 on the flame tube 114. The flame viewing window 118 has a function of opening and closing. After the flame viewing window 118 is opened, configurations of the cover plates 136 on the flame tube 114 may be adjusted to change a range of the flame viewing opening 135.
The industrial burner 102 is installed on the first circular end face 120 of the body 111, and an axis of the industrial burner 102 coincides with the axis of the flame tube 114. That is, the industrial burner 102 is disposed coaxially with the flame tube 114. Referring also to
A front pipeline 144 of the fuel inlet 141 and a front pipeline 145 of the combustion air inlet 142 of the industrial burner 102 respectively include a regulating valve 105 and a flow gage 106. Each regulating valve 105 is configured to adjust a volume of fuel and a volume of combustion air entering the industrial burner 102 per unit time. Each flow gage 106 is configured to measure the volume of the fuel and the volume of the combustion air entering the industrial burner 102 per unit time. The regulating valve 105 is electrically connected to the control module 108. After receiving a signal transmitted by the host 110, the control module 108 adjusts an opening of each regulating valve 105. For example, the control module 108 may receive a digital signal transmitted by the host 110, convert the digital signal into an analog signal, and transmit the analog signal to the regulating valve 105 to change the opening of the regulating valve 105. The flow gage 106, the pressure gage 107, the thermocouple 146 (see
After the industrial burner 102 is started and ignited, the flame detection rod 103 will be heated by the flame to generate a thermal radiation, and the thermal radiation sensor 104 may receive the thermal radiation of each heated position in the heated area on the flame detection rod 103. An emissivity of the flame detection rod 103 is stored in the host 110. When the thermal radiation generated by the flame detection rod 103 is stabilized, a temperature of each heated position in the heated area of the flame detection rod 103 may be calculated by using the following formula. That is, a flame temperature distribution of a flame cross section where the flame detection rod 103 is located may be obtained. The formula is P=ΣσT4, where P is a thermal radiation intensity, c is the emissivity, a is a Stefan-Boltzmann constant, and Tis the temperature.
In step S120, the burning condition may be a power of the industrial burner, a size of a furnace body of the burning furnace to be simulated, a relative distance between a furnace wall and the industrial burner, or a combination of the foregoing factors.
In the step of setting a fuel flow rate and a combustion air flow rate (step S130), a flow rate of fuel entering the industrial burner 102 and a flow rate of air entering the industrial burner 102 are set to adjust flame appearance geometry and flame temperature characteristics to conform to design specifications of the industrial burner.
In the step of starting the industrial burner (step S140), a flame is ignited via an ignition device, and a flame detector determines whether the flame is generated.
In the step of adjusting a pressure of the flame tube (step S150), an opening of the regulating valve 134 at the outlet of the exhaust tube 125 is changed according to a measurement value of the pressure gage (not shown) or the pressure gage 107 disposed at the first sensing channel opening 137 of the sensing channel 117, whereby the pressure in the flame tube 114 meets demands. That is, the pressure of the flame tube is adjusted to conform to a pressure condition of a burning furnace to be simulated.
In the step of installing a flame detection rod (step S160), reference is made to a schematic arrangement of the flame detection rod 103 for measuring a flame temperature of the industrial burner shown in
In the step of measuring a thermal radiation of the flame detection rod (step S170), the thermal radiation sensor 104 receives a thermal radiation of each heated position of a heated area 1031 (see
In the step of calculating a temperature of each heated position in a heated area of the flame detection rod (step S180), the host 110 calculates the temperature of each heated position in the heated area 1031 on the flame detection rod 103 based on the stored estimated emissivity value of the flame detection rod 103, so as to obtain a flame temperature distribution of a flame cross section where the flame detection rod 103 is located.
In the step of sequentially installing flame detection rods in a plurality of sensing channels (step S260), as shown in
In the step of sequentially measuring a thermal radiation of a front end of the flame detection rod and a temperature of a thermocouple in the plurality of sensing channels (step S270), the thermal radiation sensor 104 receives a thermal radiation of the front end of the flame detection rod 103. After analog signal data is converted into digital signal data via the signal module 109, the digital signal data is transmitted to the host 110. Furthermore, after analog signal data of the temperature measuring point 1461 of the thermocouple 146 at the front end of the flame detection rod 103 is converted into digital signal data via the signal module 109, the digital signal data is transmitted to the host 110.
In the step of calculating an emissivity of each flame detection rod to select the estimated emissivity value (step S280), the emissivity of each flame detection rod 103 is changed via try and error, and a temperature of the front end of each flame detection rod 103 is calculated by the foregoing formula. In addition, an error of the two temperatures is calculated by comparing temperature data of the thermocouple 146. An average value is calculated by a plurality of errors of each flame detection rod 103 disposed in the plurality of sensing channels 117, and an emissivity corresponding to a minimum average error is selected as the estimated emissivity value of the flame detection rod 103.
In some embodiments, after the step of sequentially measuring a thermal radiation of a front end of each flame detection rod and a temperature of a thermocouple (step S270), a step of installing a standard detection rod in at least one sensing channel (step S271) may be further added. The standard detection rod has a standard length size. Moreover, after the step of sequentially measuring a thermal radiation of a front end of the flame detection rod and a temperature of a thermocouple in the plurality of sensing channels (step S270), a step of measuring a size conversion ratio value of a two-dimensional signal of a thermal radiation sensor in at least one sensing channel (step S272) is added to obtain an actual space length corresponding to adjacent signal points. Thus, with the flame measuring method S100 of the industrial burner according to the present disclosure, temperature resource of the flame and length size information of the flame may be obtained. The thermal radiation of the flame detection rod 103 is sensed via a thermal radiation sensor. The thermal radiation sensor may be a thermal imager disposed outside the test chamber 101. The thermal radiation of the heated area 1031 of the flame detection rod 103 is received via the flame viewing window 118. A radial thermal distribution of the flame in a specific section of the flame tube may be viewed by a single flame detection rod, and an axial thermal distribution of the flame may be viewed by integrating a plurality of flame detection rods, thus obtaining an overall flame temperature distribution.
With the above structure and method, the industrial burner may be operated under an operation state simulating an industrial furnace and simultaneously carry out flame measurement. In this way, a measuring result is closer to an actual situation. Moreover, the industrial burner may be operated under the operation state simulating the industrial furnace, and a flame temperature distribution corresponding to a heated area on a flame detection rod may be obtained at one time under a condition of minimal interference to a flame flow field. The measuring manner belongs to linear measurement, thus greatly shortening a measuring time.
