What Are the Advantages of BCST Balance Flow Meter in Coke Blast Furnace Gas Application

What Are the Advantages of BCST Balance Flow Meter in Coke Blast Furnace Gas Application

The manufacturing process used in modern iron production is often of high volume, high air temperature, high smelting intensity, and high pulverized coal injection volume. The blast furnace gas is a byproduct of the iron-making process. Its primary constituents are CO, CO2, N2, H2, CH4, etc., with the combustible component CO content accounting for about 25% of the total, H2, and CH4 content being very low, CO2 and N2 content accounting for 15%, and CO2 content accounting for 55%. Its calorific value is only about 3500KJ/m. The kind of pig iron utilized, the composition of the fuel used in the blast furnace, and the smelting procedure all affect the composition and calorific value of blast furnace gas.

Moreover, because the water was used to wash the gas from the blast furnace, it contained saturated water vapor. Therefore, more water will be present in a gas at a greater temperature, lowering its calorific value. The calculation shows that the gas meter flow must increase by around 12% to maintain the same heat supply when the gas temperature climbs from 20°C to 40°C. As a result, it is necessary that blast furnace gas not exceed 35°C in temperature. To maintain the stability of the overall heat delivered to the coke oven, the switchboard operator should instantly adjust the meter flow of heating gas when the gas temperature varies.

Coke oven gas has been utilized more often in China in recent years. The leftover Coke oven gas is mostly used as city gas, with some also returning to the Coke oven for heating. A sizeable portion of the coke oven gas will be released by flare combustion. An estimated 350108m3 or more of coke oven gas is not properly used and burnt each year, which pollutes the environment and wastes a significant amount of energy. Due to the high hydrogen content of coke oven gas, China’s coking industry should continue to develop application technologies that fit the needs of businesses to maximize the exploitation of gas resources, raise the coke oven gas’s utilization value, and increase the coking industry’s overall competitiveness.

The term “flue gas” (also known as “flue gas” or “stack gas”) refers to the air-polluting gaseous products created when fossil fuels like coal are burned. Often, a flue or stack is used to expel these chemicals. The creation of flue gases is mainly a result of incomplete fuel combustion. Its primary constituents are sulfide, nitrogen, carbon dioxide, and oxygen. However, if the furnace is not used appropriately, carbon monoxide, nitrogen oxide, and other dangerous gases will be created. More than 99% of pollutants are inorganic; the remaining 1% include dust, slag, and sulfur dioxide, which a gas purification system must clean before being released into the atmosphere.

In conclusion, because of the unique characteristics of the blast furnace and coke oven gas flue gas, dust, water vapor, low pressure, and small flow rate, standard flowmeters like vortex flowmeters and turbine flowmeters are unable to adapt to the site environment. Additionally, because most of these installation sites are located in high-altitude chimneys or pipelines and have particularly large pipe diameters, installation poses additional challenges.

BCST Balance Flow meter Features

  1. High measurement accuracy. The porous construction of the BCST balance flow sensor allows the flow field to be balanced, eliminate vortices, and vibrate less, improving the stability of the flow field. Sensor precision can range between 0.3% and 0.5%.
  2. Low straight pipe section requirements. A balance flow sensor can balance the flow field, and pressure recovery is twice as quick with a BCST balance flow meter than a traditional orifice plate. This reduces the need for straight pipe sections, which can be as small as 0.5D by 2D in most cases.
  3. Low permanent pressure loss. The BCST balance flow meter, which is close to the venturi and reduces the formation of vortices and turbulent friction to lessen the loss of kinetic energy, has a pressure loss that is 70% lower than that of conventional throttling devices under the same operating conditions. This makes it an energy-saving device.
  4. Wide range ratio. The BCST balancing flow meter significantly increased the measuring range ratio compared to the conventional throttling device. According to the requirements of the actual industrial measurement application, the necessary parameters might be developed with a balance of 30:1 or more instead of the standard measurement range ratio of 10:1.
  5. Long-term stability and repeatability of the BCST balancing flow sensor is 0.1%. Measurement components with many flow holes diffused force, no acute angle wear, excellent long-term stability, no moving parts across the whole instrument, and service life 5–10 times longer than that of a conventional throttle.
  6. Dirt resistance and should not be blocked. To guarantee that unclean media passes through numerous holes without being obstructed, symmetric measuring elements with multiple holes are designed to limit the production of turbulent shear and eddy currents, which significantly reduces the formation of dead zones.
  7. Wide measurement range. The BCST balance flow meter’s minimum and maximum Reynolds numbers may be less than 200, and its minimum Reynolds number cannot be larger than 107; its design range is 0.25 to 0.9.
  8. Scope of application. The BCST balancing flow meters operating temperature and pressure ranges are up to 850 °C and 42 Mpa. The optimum measurement effect for liquid gas is successfully avoiding vaporization. The BCST balance flow meter can measure solid particles, slurries, and two-phase vapor-liquid flow. In addition, you can measure bidirectional flow with a BCST balance flow meter since its measuring element is perfectly balanced left and right.

BCST Balance Flow Meter Anti-Blocking Design

Standard orifice plates and BCST balancing flow meters are both differential pressure flow meters, but their major throttling element opening designs differ in very glaring ways. Balance flow meter through the multi-hole disc throttle rectification design, greatly reducing the formation of the stagnant dead zone to ensure that dirty media smoothly through the trough. Standard orifice plate due to only one throttle hole, the dead zone around the hole will produce a large number of vortex consumption of fluid kinetic energy and the formation of dirty media accumulation at the upstream edge of the throttle.

Balance Flow Meter Anti-Blocking Design

Comparison of Orifice Plate and BCST Balanced Flow Meter Anti-Blocking Advantages

Firstly , A throttle hole is located in the center of the typical orifice plate.

The main medium flow rate through the middle throttle hole will produce a significant amount of vortex flow on both sides of the hole to form a dead zone, and the closer the area is to the pipe wall, the lower the flow rate or even “zero,” so that the dirty medium will be formed at the upper and lower ends of the orifice plate throttle element to accumulate. The front and rear of the orifice plate’s vertical surface alter somewhat over time due to the long-term buildup of unclean media, and eventually, the throttle hole and take the pressure hole to become blocked.

The measurement of the orifice plate is affected by the deposition of filthy media in the following ways:

  • Variations in the front and back droop of the orifice plate, which impact the outflow coefficient C and, in turn, the accuracy of the flow measurement;
  • A partial or complete blockage at the pressure-taking orifice results in a buildup of contaminated media, which compromises the proper transmission of the differential pressure value △P.

Orifice Plate

Secondly , BCST Balanced Flow Meter

The media in the main flow rate will be through the middle throttle hole at the same time, and N secondary flow rates will be through the other ring hole (each hole as the center to produce a high-speed flow beam, driving the surrounding fluid forward at high speed), reducing the impact of the fluid velocity ladder distribution. This design obviously minimizes the impact of the fluid velocity ladder distribution. In addition, due to the higher sub-flow velocity caused by the dirty media being blown away closer to the tube wall, there won’t be an accumulation of dirty media before and after the throttle, reducing the chance that the throttle hole and the pressure extraction hole will be blocked or impacted by the opportunity.

Due to their anti-clogging solid capabilities, balance flow meters are now frequently employed in the medium with low flow rates and operating pressures and viscous and unclean. In the steel sector, measurements of coke oven gas, blast furnace gas, and other filthy media work incredibly well, resolving customer issues with unclean clogs brought on by historically inaccurate flow meter measurements for many years.

If the site can guarantee long-term use in the higher flow rate (flow rate) conditions, the surface of the throttle attachment will not increase significantly over time, so the actual measurement accuracy is not significant, the site can be used. Combined with using a period after removing the surface of the throttle attachment, we believe that the current outflow coefficient C value and the actual differential pressure △ P impact are relatively small. You can also remove the throttle for surface cleaning as part of routine maintenance if the site is still worried about the measurement inaccuracy brought on by surface adhesion.

Thirdly ,Balance Flow Meter Backblowing Air Design

Coke ovens and blast furnace gas contain pollutants, making flow meters like Willyba prone to clog and requiring routine removal and cleaning. Yet, safety risks are associated with particular operating circumstances, such as high media temperatures and situations when pressure is withdrawn. Therefore, in order to prevent induced dust or filthy media from flowing back into the main line and disrupting the measurement circuit, the BCST balancing flow meter’s initial large diameter measurement was based on the inclusion of a backflowing wind design.

Balance Flow Meter Backblowing Air Design

Blowing operation specifications:

  1. Attach the valve with the number 5 to the air blowing.
  2. Close the three-valve set before opening the shut-off valve while blowing. Until they are clear, purge the pressure port and the pressure line.
  3. Close the primary valve (marked 2), and the balancing valve, open the positive and negative pressure valves, open the transmitter drain screw, and gently open the blowback valve until the transmitter drain is clear; if you need to purge the three-valve manifold and transmitter route.
  4. BCST balance Flow Meter Measurement Accuracy Assurance

At room temperature, the gas medium is stable due to its nature, but as the circumstances change, everything changes. The gas flow rate is often needed to be managed within the safe flow rate, and the pressure loss should be minimal to guarantee the accurate and secure monitoring of gas flow. The qualification rate and quality are directly impacted by the precision of the gas-to-air ratio; hence the procedure calls for a flow accuracy of 0.5%;

Assuring the safety and accuracy of fluid measurement, BCST balancing flow meters use evenly spaced holes to reduce vortices and irregular flow profiles. They also have the capacity to throttle and correct the flow in the event of front and rear straight pipe sections that fulfill the 2D standard. To guarantee that the complete range of the flow meter error is low and the design of the single point error maintains consistency, the temperature and pressure total compensation may be utilized simultaneously to remove the error coming from changes in working circumstances and other parameters. As a result, the requirements of process control are completely met by flow measurement precision of up to 0.5% as well as the assurance of long-term measurement stability.

To successfully reduce the measurement of varied media flow, BCST balancing flow meters are used in a variety of industries. Its exceptional performance completely satisfies the requirements of the process measurement, whether at crucial measurements or challenging measurement places. Field instrumentation engineers have also confirmed its dependability and maintenance-free nature, and it is hoped that more and more successful applications in biological engineering will follow.

Finally , a photo showing the big diameter QMC-FS structural balancing flow meter in use.

The weight of the flow meter body of big equipment is a concern for each designer since large pipe diameters in the design of the flow meter are necessary due to the total pipeline tension and load-bearing. Two pieces of flange clamping throttle, open on the flange to take, two flanges, and the main body are welded together to form the QMC-FS structure that is used by the BCST balancing flow meter. Each meter has positioning pins that make it simple to install or maintain rear parts after positioning has been installed, ensuring measuring accuracy.

Configure the blowing handle plate for the process needs that necessitate blowing. (The purging handle plate is located in the center of the two flanges before the vehicle leaves the factory, and the throttle is inserted and fixed in accordance with the positioning pin’s location when the purging is complete.)

balancing flow meter

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