Senkox HSD™ New surface temperature monitoring system for gasifiers

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Overview of the Senkox HSD™ New Type Gasifier Surface Temperature Monitoring System. This article primarily introduces the features of the Senkox HSD™ 101-TS hotspot detection system, as well as its use as a new type of surface temperature monitoring system for monitoring the surface temperature of gasifiers. Application background: The chemical and coal industries often require many large-scale high-temperature process reactors, such as high-temperature chemical reactors, gasification furnaces, induction furnaces, and boilers. These high-temperature reaction devices typically use refractory materials for their inner walls. The wear and tear, cracks, aging of these refractory materials, as well as the impact of high-temperature flames, can cause the outer protective layer to overheat, thereby reducing its protective capabilities and creating significant safety hazards. Therefore, temperature monitoring of the external surface of such high-temperature reaction devices requires not only the measurement of the average temperature on that surface but also the detection of any hot spots, in order to prevent overheating incidents. Currently, for surface temperature monitoring in gasifiers, distributed point-type temperature measurement systems and infrared thermal cameras are commonly used. Distributed point-type temperature measurement systems generally use analog or digital point sensors, which offer high measurement accuracy. However, such systems have numerous connections, and there are blind spots in the measurement process; the average surface temperature of the vaporization furnace can only be estimated based on the temperatures at discrete points, and it is not possible to detect hot spots on the surface of the container ； Infrared thermal cameras can display real-time temperature images of surfaces as well as the locations of hot spots. However, since they produce planar images, a single camera can only monitor one side of a spherical container; it is not capable of providing real-time 360-degree coverage. Moreover, their installation requirements are strict – there must be no obstructions between the object being measured and the infrared camera, which is difficult to achieve in the complex piping environments found in chemical plants. Therefore, infrared cameras are generally used for portable, mobile temperature monitoring. Introduction to the Senkox HSD™ 101-TS hotspot detection system: The Senkox HSDTM 101-TS hotspot detection system offers an excellent solution for monitoring the surface temperature of gasifiers. It can, just like an infrared thermal imager, detect in real time the temperature of hot spots on the surface of the vaporization furnace, as well as identify local overheating differences on the surface of the container. Moreover, it features a simple system design, is easy to install and maintain, and can be used right away after connection. I. System Introduction The Senkox HSD™101-TS hotspot detection system consists of the following 3 main components: 1. Senkox HSD™ linear temperature sensors (types A, B, C, D); 2. Senkox HSD™-AI-104 data acquisition module; 3. Senkox HSD™-CPU main control module. The Senkox HSD™-AI-104 data acquisition module collects the signals generated by the Senkox HSD™ linear temperature sensors and then transmits these signals to the Senkox HSD™-CPU main control module for processing. The processed data is output to the on-site alarm system or DCS system through analog output channels (capable of outputting 4-20 mA, 0-5 V, or 0-10 V, etc.) and digital communication interfaces (RS485/RS232, standard Modbus/RTU protocols). This system architecture design allows users to flexibly configure on-site alarm systems or connect them to existing monitoring systems. The system architecture diagram is shown in Figure 1: http://bbs.hcbbs.com/forum.php?mod=attachment&aid=NzQ1OTI5fDI5ZmUyNTMxfDEzMjkyMjExMDF8NjQ5NTY4fDgwNzk2Ng%3D%3D&noupdate=yes 2011-3-7 11:27 Upload Download attachment (58.73 KB) Figure 1: System architecture of the Senkox HSD™ 101 series hotspot detection system http://bbs.hcbbs.com/forum.php?mod=attachment&aid=NzQ1OTMwfDNjNTg5NmEwfDEzMjkyMjExMDF8NjQ5NTY4fDgwNzk2Ng%3D%3D&noupdate=yes 2011-3-7 11:28 Upload Download attachment (39.68 KB) Figure 2: Appearance of the Senkox HSD™ 101-TS hotspot detection system (compact version) II. System Applications The Senkox HSD™ 101-TS hotspot detection system enables the monitoring of (1) the surface temperature of gasifiers and (2) local overheating differences; it is widely used for monitoring the surface temperatures of various high-temperature reaction vessels. The Senkox HSD™ linear temperature sensor equipped in the system is heat-resistant and highly flexible, allowing it to be installed flexibly on the surface of the gasification furnace to monitor the temperature of the entire surface of the container in 360 degrees. This enables the staff in the control room to keep track of the condition of the high-temperature reaction vessel in a timely manner, allowing them to detect any issues as soon as they arise and take effective action to prevent further deterioration of the situation. http://bbs.hcbbs.com/forum.php?mod=attachment&aid=NzQ1OTMyfDlkZDNiMWI3fDEzMjkyMjExMDF8NjQ5NTY4fDgwNzk2Ng%3D%3D&noupdate=yes 2011-3-7 11:29 Upload Download attachment (38.81 KB) Figure 3: Application of the Senkox HSD™ 101-TS series hotspot detection system in large-scale gasification furnaces. The Senkox HSD™ 101-TS hotspot detection system provides two parameters regarding the surface temperature of the gasification furnace: Surface hotspot temperature: This represents the temperature of the overheated spots on the surface as detected by the linear sensors, and it serves as an early warning of the highest temperatures on the surface. Local overheating temperature difference: It represents the difference between the temperature at surface hot spots and the integrated average temperature on the linear sensor (i.e., the average temperature on the surface of the vaporization furnace). This local overheating temperature difference serves as an early warning for abnormalities on the container’s surface. The importance of local overheating temperature differences: Vaporization furnaces are designed with a normal operating range for surface temperature. Under normal circumstances, if the maximum surface temperature of the gasifier does not exceed the normal operating range, we consider the gasifier to be operating properly. Therefore, even if local overheating occurs on the surface of the gasifier, due to the temperature differences between day and night and the fluctuations in the internal furnace temperature, its surface temperature does not exceed the normal operating range, which leads us to believe that the gasifier is still operating normally. However, in reality, the gasification furnace has already experienced localized overheating, and if no timely measures are taken, it could pose safety hazards. The local overheating temperature difference is a parameter that can help detect such abnormalities; it represents the difference between the temperature at a surface hotspot and the average surface temperature. This difference is not affected by the ambient temperature or the furnace temperature, and it provides a clear indication of any abnormalities on the container’s surface. Figure 4 below shows the monitoring curves of a gasifier as simulated in a gasifier model for actual applications: http://bbs.hcbbs.com/forum.php?mod=attachment&aid=NzQ1OTMzfDcyMzg3M2YzfDEzMjkyMjExMDF8NjQ5NTY4fDgwNzk2Ng%3D%3D&noupdate=yes Uploaded on 2011-3-7 11:29; Download attachment (39.37 KB). Figure 4: Monitoring curves of a gasifier as simulated in a gasifier model for actual applications. As can be seen from Figure 4, the highest surface temperature of the gasifier varies between 200°C and 250°C (the normal operating range of this gasifier), while the local overheating difference is around 40°C. Therefore, it is clear that local overheating has occurred in this gasification furnace, and it now poses a safety hazard; immediate fault detection and troubleshooting are necessary. Conclusion The Senkox HSD™ 101-TS hotspot detection system offers an excellent solution for monitoring the surface temperature of high-temperature reaction vessels. It features a simple design and is capable of operating reliably in harsh field conditions. It provides information such as the average surface temperature of the reaction vessels as well as the real-time temperatures of surface hotspots. Its various analog output options and digital communication interfaces enable it to function as an independent field control system or to be easily integrated into the user’s existing monitoring systems.