An endothermic gas generator is an atmosphere generated by mixing raw gas (natural gas or propane) with a certain amount of air, under the action of high temperature and catalyst, through incomplete combustion reaction, commonly known as RX gas. Can be used as a carrier gas in chemical heat treatment equipment or as a protective atmosphere for heating furnaces. Due to the stable composition of RX gas, it has the characteristics of low operating cost and high degree of automation for chemical heat treatment, especially as the basic atmosphere for controlled atmosphere carburizing and annealing protection atmosphere; Compared to a nitrogen methanol atmosphere or a pure methanol atmosphere, it can greatly improve the quality of carburizing and effectively protect the material from decarburization. Resolve many atmosphere related challenges during the heat treatment process.
The RX atmosphere reaction equation is as follows:
2CH4+ O2 = 2CO + 4H2
The reaction between natural gas and oxygen
2CH4 +O2+3.84N2=2CO+4H2 +3.84N2
The reaction between natural gas and air
RX gas made from natural gas air is an ideal thermal processing protective atmosphere, with the following components:
CO: 19.0-21.0%, H2: 39.0-40.5%, N2: 38.5-40.0%; CH4:<0.5%,CO2:<0.5%, Dew point: 4 ° C -+8 ° C
An endothermic gas generator consists of a furnace body and insulation materials, a heating system, a gas supply section, a gas generation section, a gas output section, an atmosphere measurement and control section, and an electrical control cabinet. The RX gas generated by the generator has a stable composition, and regular charcoal burning is carried out. With regular annual maintenance, the single start-up operation time can exceed one year, achieving "on-demand gas production" and greatly reducing waste. The cost of producing RX gas per cubic meter is much lower than that of methanol cracking or drip injection.
Furnace body and insulation materials:
The furnace shell is constructed by welding steel plates with locally reinforced steel sections, and the outer shell is installed on a structural steel base. The base will support the entire generator assembly, including all pipelines and controllers. The top cover of the furnace is a movable top structure. Repair the furnace after lifting. There are thermocouple insertion holes on the side for temperature control.
The reaction vessel is made of 2535 high-temperature alloy heat-resistant steel, which has a long service life.
The unique suspension structure can provide catalytic efficiency and reduce the production of carbon black.
Insulation layer: The furnace top, bottom, and sides are composed of folded aluminum silicate fiber blocks.
The temperature rise of the outer wall of the furnace shell is ≤ ambient temperature+45C.
Heating system:
Composed of thermocouples, temperature controllers, power regulators, heaters, etc.
A single heating unit is equipped with a control thermocouple for temperature control, and another monitoring thermocouple for overheating alarm control, which stops heating when the temperature is too high.
Temperature control is measured by thermocouples, PID calculation is performed by temperature controllers, and SCR method is used to achieve temperature control.
The heating resistor wire is made of high-temperature iron chromium aluminum, with a long service life.
The heater is installed in a hanging manner, with the heater inserted from the top for easy maintenance, and there is no need to stop for a long time to replace the heater.
temperature controller 2 sets
Thermocouple (S-type thermocouple) 1400 ° C 2 pcs
Power regulator 1 set
Note: Advantages of using electric heating
Gas heating used to be the mainstream method for generators, and the latest on-site feedback shows that electric heating has a significant improvement in the gas production quality of generators, mainly manifested in the following aspects:
1. Two zone heating greatly improves the temperature uniformity of the upper and lower parts of the reaction vessel.
2. The catalyst efficiency is improved, greatly reducing the generation of carbon deposits, and the Rx gas quality is high.
3. The squirrel cage heater is easy to replace and easy to maintain in the later stage.
4. The service life of the furnace body and reaction kettle has been greatly extended.
5. Not affected by the quality of natural gas
Gas supply section
1. Magnetic flowmeter
2. Electronic flow regulator
3. Roots blower
4. Pressure switch and pressure gauge
5. Safety control solenoid valve
6. Flame check valve
7. Composition of distribution and mixing devices, etc
8. Configure electronic inspection of intake pressure, pressure switch and pressure gauge, intake filter, safety control solenoid valve, mass flow meter, flame check valve, distribution and mixing device, etc.
The first party is responsible for providing, with a total sulfur content of less than 10 milligrams per cubic meter.
Gas generation part
The gas generation part is composed of a reaction tank and a catalyst. The reaction tank is welded from special heat-resistant materials and connected with a top flange. It can be lifted as a whole, with nickel based block catalysts arranged inside the tube, located in the middle and lower parts of the reaction tank, to catalyze the cracking reaction of the mixed gas.
Using specially customized nickel based catalysts, the nickel oxide content is higher than 12%, which is 10% higher than the nickel oxide content used in ordinary generators. The catalytic effect and service life of the catalyst are significantly better than ordinary catalysts, and the probability of carbon deposition is greatly reduced.
The gas output part consists of a gas cooler, pressure switch pressure gauge, output valve group, temperature detection, constant flame system, pressure control system, carbon collector, etc.
The gas cooler consists of two parts: a straight through type and a pipeline type. The straight through type quickly cools the produced gas to avoid the precipitation of carbon black. The cooler is made of stainless steel pipes, which are clean and not easily clogged; Install a secondary cooler on the manifold to cool the gas and ensure that the pipeline instruments, flow meters, etc. operate within safe temperatures. Pressure
The force switch pressure gauge detects the pressure of RX gas. When the pressure is higher than the specified range, the pressure relief device is put into operation. When the pressure relief cannot meet the requirements, the pressure protection device is put into operation and the input gas supply is cut off; When it falls below the specified range, an alarm signal will be issued and a chain reaction will occur in the generator, causing it to stop working. The output valve is a set of automatic pressure maintaining and releasing valve group, ensuring the stability and reliability of gas production.
The pressure control system includes an outlet pressure detector and a pressure relief device. The pressure detector sends pressure signals to the PLC as inputs for pressure control. At the same time, when the pipeline pressure exceeds the safe value, the pressure relief valve opens and ensures that there is no pressure loss.
The carbon collector is a special device with a valve installed at the outlet to collect carbon and water from the pipeline. Compared to air cooling devices, the advantages of cooling circulating water are:
High cooling efficiency;
Greatly reduce the production of carbon powder;
Belonging to 'static devices' with low noise;
Compared to air cooling devices, it has a longer service life and is easy and quick to maintain;
The surrounding environment of the workshop is good.
Electrical Control Cabinet
The electrical control cabinet of the generator is installed next to the generator. All controllers used, such as temperature controllers, operation panels, voltmeters, ammeters, etc., are installed on the control box panel. Inside, there are heater circuit breakers, circuit breakers for each motor and control power supply, control transformers, contactors, control relays, PLCs, etc
characteristic:
Good intuitiveness;
Running three component analyzer
Greatly reduce the generation of carbon deposits
Directly measure CO2 and control core parameters;
The measurement of CO can reflect the quality of natural gas and has great reference significance for gas equipment; The measurement of CH4 can accurately grasp the degree of catalyst consumption, which is beneficial for annual maintenance;
By using a three gas analyzer combined with dew point control, the gas composition is stable and reliable, and the RX atmosphere fluctuates less.
Remote monitoring, convenient and fast, achieves on-site management, remote service, and other advantages!
Characteristics of Generator:
1. Meet the requirement of 24-hour uninterrupted gas supply;
2. The main accessories are all selected from branded accessories
3. Form an on-site LAN for equipment and provide data exchange
4. Experience in the production, commissioning, construction, and on-site piping of new generators to ensure safe use on site;
5. A specially designed heating rod serves as the heating element, making maintenance and replacement convenient and quick;
6. The temperature is measured using high-precision instruments, ensuring stable and reliable control;
The gas production output adopts a pressure transmission unit control unit, which realizes constant pressure and on-demand gas production, and can automatically adapt to the interference of daily actions such as external atmosphere adjustment, switching, blowing, etc. on gas production;
Online gas analyzer can measure CO%, CO2%, and CH4% in gas in real time; Using a three gas analyzer for online analysis, measurement, and control of CO2 content, and online control of the reaction process; The system is capable of switching gas usage among one or more gas units.
Adopting Taiwan Yonghong PLC automatic control system:
Using Kunlun Tongtai high-definition touch screen to record and display operational data;
Low voltage electrical equipment adopts Schneider products, with Weidmuller wiring terminals and multiple safety devices and alarms, ensuring the safety and reliability of the system;
When the internal parameters are exceeded, the system notifies the operator to reset through sound and light alarms; Multiple settings to control the operation of users and corresponding permissions;
Using specially customized catalysts, the nickel oxide content exceeds 12% (usually 10%), resulting in a long service life and more stable gas production components;
Adopting a specially designed flame retardant valve system to effectively protect pipelines and equipment;
Modular design, strong interchangeability, and easy maintenance;
One click operation, easy on-site operation.
- What is nominal gas production?
---- The gas produced is about 20% carbon monoxide, 40% hydrogen, and 40% nitrogen;
What is the nominal gas consumption?
-----Based on a maximum gas production of 30 cubic meters per hour ,a natural gas consumption of 6 cubic meters;
What is the weight of ready equipment?
---The total weight of the equipment is about 3 tons
- How is the retort made (cast or welded)?
The reactor body of the generator is centrifugally cast, and the connecting end face is flange welded!
- How does the catalyst change in the retort?
The catalyst surface aggregates and activates reactant molecules through physical or chemical adsorption, weakening their original chemical bonds and promoting the formation of new bonds.
What is the weight of retort with catalyst?
Weight=Tank+Catalyst=Approximately 100 kilograms
Is it possible to dismantle without a crane beam?
It is recommended to use a car or a movable chain hoist to extract the reaction kettle. Without auxiliary equipment or tools, it must be extracted at room temperature to avoid burns and damage to the heating element caused by improper extraction!
- What are the Scheduled maintenance regulations?
The maintenance cycle is 6 months
Project: Charcoal burning, filter cleaning, pipeline cleaning
- what is security system?
Multiple protections for over temperature, over voltage, and open circuit,
- What is the price of cost of installation supervision?
Customer pay visa cost, round air ticket, food, hotel , water, local transportation, and per day 1000 RMB salary
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Advanced RX Generator Controlled Atmosphere Carburizing And Annealing Protection Atmosphere Images
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