Combustion Optimization for Industrial Processes


ZoloSCAN System: Benefit of Combustion Optimization for Industrial Processes

Process heaters and furnaces are used in many industrial process operations including steel (electric arc, reheat, blast and basic oxygen furnaces) and glass (float and container) making. These industries use the heat from the furnaces to melt or reheat feedstock to produce product. Tight control of the process temperature or off-gases is critical to optimize the process and ensure the highest product quality, efficiency and safety. However, variable fuel quality, variable feedstock (scrap steel), high temperatures, multiple burners and multiple control cells provide special challenges to combustion optimization in these types of furnaces. A combustion diagnostic system with in-situ, real-time measurements of key combustion constituents can be used to balance the combustion and improve process performance, product quality and reduce emissions.

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

ZoloSCAN Combustion Monitoring and Diagnostic System

The ZoloSCAN System is an innovative laser-based combustion diagnostic system which simultaneously measures temperature, O2, CO and H2O in real-time, directly in an industrial process furnace such as a steel reheat furnace, electric arc furnace or glass melting 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) 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. Some applications require additional cooling and thermal protection.

Proven TDLAS Technology

The ZoloSCAN System utilizes a well proven technique known as Tunable Diode Laser Absorption Spectroscopy (TDLAS). TDLAS uses the unique light absorption wavelengths of molecules to accurately determine the concentration of those constituents. The ZoloSCAN System is designed for ultra-harsh combustion environments and has been successfully installed on steel reheat furnaces, EAF, 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 multiple constituents and the flue gas temperature along each laser path. A single ZoloSCAN  can accommodate multiple paths which can be arranged to provide a real-time profile of the combustion process for each constituent.

Traditional sensors, such as zirconium oxide probes (ZrO2), extractive analyzers or thermocouples, do not permit measurements directly in the furnace due to the harsh environment. Furthermore, a few “point” measurements may not represent the true combustion profile. The Zolo combustion monitoring system, however, uses well proven TDLAS to measure key combustion constituents and flue gas temperature directly in the furnace. TDLAS measures a path average along the entire length of the measurement location and provides a better representation than a single point measurement.

Unlike other TDLAS solutions on the market, the ZoloSCAN combustion monitoring system can provide multiple measurement paths from a single Zolo system. This provides a much more accurate representation of the true constituent concentrations 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
    • 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 field calibration required
  • Low maintenance