Combustion Optimization for Chemical and Refining


ZoloSCAN Benefits of Combustion Optimization for Chemical and Refining

Process heaters and furnaces are used extensively in chemical and refining operations as direct-fired heat exchangers. These furnaces use the hot combustion gas to raise the temperature of a feedstock flowing through coils of tubes inside the furnace. Uniform temperature control is critical to optimizing the process on both steam methane reformers and cracking furnaces.  However, variable fuel quality, high temperatures, multiple burners and multiple control zones provide special challenges to combustion optimization in these types of furnaces/heaters.  A combustion diagnostic system with in-situ, real-time measurements of key combustion constituents can improve the combustion to improve process performance and reduce emissions.

  • Improve combustion efficiency
  • Improve process performance
  • Increase reliability
  • Reduce emissions
  • Improve safety

ZoloSCAN Combustion Diagnostic System

The ZoloSCAN is an innovative laser-based combustion diagnostic system which simultaneously measures temperature, O2, CO and H2O in real-time, directly in a process furnace such as a steam methane reformer or ethylene cracking furnace. There are no probes to insert, no sensitive electronics near the furnace and no regular calibration required. The Control Rack (NEC Class 1, Division 2 compliant for explosive environments) houses all of the critical electronics and lasers but is located away from the furnace. Only small port openings and a line-of-sight across the furnace are required for each laser path.  A simple tube and flange are used to mount the ZoloSCAN heads on the outside furnace wall, and each head has an automated adjustment mechanism to maintain laser alignment through ambient and process temperature changes.

Proven TDLAS Technology

The ZoloSCANutilizes a well-proven technique known as Tunable Diode Laser Absorption Spectroscopy (TDLAS). TDLAS uses the unique light absorption properties of molecules to accurately determine the concentration of those constituents. The ZoloSCAN is designed for ultra-harsh combustion environments and has been successfully installed on steam methane reformers and over 50 coal-fired boilers around the world. For more information on TDLAS click here.

Single ZoloSCAN System: Multiple Species and Multiple Paths

Each ZoloSCAN system simultaneously measures the average concentration of H2O, O2, CO and the flue gas temperature along each laser path.   A single ZoloSCAN system can accommodate up to 30 measurement paths that can be arranged to provide a real-time profile of the combustion process for each constituent.

Traditional sensors, such as zirconium oxide probes (ZrO2), do not permit measurements in the furnace due to the harsh environment. Furthermore, a few “point” measurements may not represent the true combustion conditions.  The ZoloSCAN combustion monitoring system, however, uses well-proven TDLAS technology to measure key combustion parameters such as flue gas temperature, O2 and CO in the furnace of a steam methane reformer or ethylene cracking furnace.  TDLAS measures a path average along each line-of-sight and provides a better representation than a single point or multi-point measurements.

Unlike other TDLAS solutions on the market, the ZoloBOSS combustion monitoring system can provide up to 30 measurement paths from a single ZoloBOSS system. Multiple paths provide a much more accurate representation of the true combustion conditions and allows operators to balance and optimize combustion.  Arrangement of the paths depends on the furnace configuration, combustion improvement objectives and physical access around the furnace.

Key Features of the ZoloSCAN System

  • Real-time, in-situ measurements directly in the furnace
    ZoloBOSS SensAlign Head is mounted on the side of the furnace

    ZoloBOSS SensAlign Head is mounted on the side of the furnace

    • Temperature, H2O, O2 and CO
    • Path average measurement
  • Easy installation
    • Small opening in furnace wall
  • Spatial profiles and furnace balancing information
  • Integrates into Distributed Control System (DCS) or control system via OPC or Modbus
  • Automatic laser alignment
  • No cooling typically required
  • No field calibration required
  • Low maintenance