The rigidity of a pure oxygen flame primarily lies in its high temperature and strong penetration, determined by the high-purity oxygen combustion technology (oxygen concentration ≥90%). Core Advantage Analysis: Significantly Increased Flame Temperature. Traditional air-assisted flames reach approximately 800°C, while pure oxygen flames can reach over 1000°C.

Combustion products are mainly triatomic gases (H₂O, CO₂), with a high radiation coefficient, increasing thermal efficiency by over 30%. Industrial Applications of Rigid Flames.

Dual Benefits of Energy Saving and Environmental Protection: Fuel consumption is reduced by 50%-70%, and baking time is shortened by 30%. Nitrogen oxide (NOx) emissions are reduced by 70%.

Extended Technical Principles: Pure oxygen combustion eliminates nitrogen interference (nitrogen accounts for 78% of traditional air), reduces flue gas heat loss (approximately 30% of kiln energy consumption), and prevents the formation of harmful pollutants from nitrogen and oxygen at high temperatures.

Zhengzhou Zhongwei Environmental Protection Equipment Co., Ltd. ZWHB-FY-150/150 high-efficiency oxygen-enriched (pure oxygen) burner. The front end of the burner nozzle uses castable refractory material to prevent damage to the nozzle and ignition device from excessively high flames or temperatures, protecting the nozzle and piping from being damaged by the heat of the ladle.

This burner has the following characteristics:

• High flame temperature and high thermal radiation intensity;
• Accelerates combustion speed, promotes complete fuel combustion, especially for low calorific value fuels such as blast furnace gas.
• Lowers the ignition temperature of the fuel and reduces the combustion time;
• Increases heat utilization efficiency;
• Lowers the excess air coefficient, reduces the amount of flue gas after combustion, and reduces heat loss;
• Lowers the nitrogen oxide content in the flue gas to meet environmental requirements.

Ignition Method:

The ignition device uses a pilot flame, which is ignited automatically. It is equipped with a manual valve and a pneumatic shut-off valve for the ignition gas. This function utilizes electronic control equipment to ensure the reliability and safety of ignition, greatly reducing the labor intensity and potential safety risks for operators.

The automatic/manual control system provides operators with greater flexibility. This system allows for seamless switching between automatic and manual modes to meet different production needs or emergency situations.

Note: Because blast furnace gas is a low calorific value gas, with a calorific value of approximately 700-800 kcal, direct ignition is difficult. Therefore, the pilot flame requires a high calorific value gas, such as natural gas, liquefied petroleum gas, or high calorific value gas. A high-energy ignition gun is used to ignite the pilot flame burner first. After stable combustion, the main gas burner is automatically switched, thus improving the success rate of igniting low calorific value gas.

Flame Detection

The system is equipped with an explosion-proof flame detection probe, installed on a fixed bracket, with the probe directly aimed at the pure oxygen burner flame position. The flame detection probe has high sensitivity and good selectivity for all flames emitting in the ultraviolet spectral range. The flame detection probe transmits the detected signal to the control system in real time, forming a flameout protection safety circuit.

Temperature Measurement System:

The temperature measurement design uses infrared temperature measurement equipment. The control system receives signals from the temperature equipment and displays them on the touch screen, performing temperature control logic calculations. Temperature thermocouples can also be installed on the cover according to specific operating conditions for temperature measurement.

Real-time monitoring of the bottom refractory temperature of the ladle, adjusting the heating curve based on the refractory temperature to achieve better energy-saving effects. Baking curve records and abnormal alarm records can be queried.

Gas Pipeline Configuration

The main gas pipeline extends to the rotating arm of the ladle baking device and connects to the rotating shaft, with the burner branch pipelines arranged on the ladle cover. The gas pipeline connects to the main gas supply pipeline, and after upstream filtration, it is delivered to the interfaces of each baking device. The gas pipeline is equipped with manual valves, blind valves, pneumatic shut-off valves, and regulating valves. According to on-site feedback, manual valves and shut-off valves can be used normally, but the shut-off valves do not have switch signal feedback.

Leakage alarm devices should be installed within the installation range of the gas pipeline valve group for real-time detection. When the system has an alarm fault, the gas source can be immediately cut off to ensure safe operation.

Combustion Air Pipeline Configuration

Oxygen-enriched baking devices use an oxygen-enriched baking device and require a combustion air blower. The combustion air pipeline is equipped with an oxygen-air mixing device. Pure oxygen baking devices only need to be connected to the oxygen pipeline.

Oxygen Pipeline Configuration

The oxygen pipeline configuration is an important part of the molten iron ladle baking device, and its design and layout directly affect baking efficiency and safety. The following is a detailed analysis of the oxygen pipeline configuration:

Oxygen Source: The oxygen pipeline usually connects to the main oxygen station to ensure an adequate supply of oxygen.

Main Accessory Installation: In the oxygen pipeline, flow meters, manual valves, pressure reducing valves, regulating valves, pressure transmitters, vent valves, shut-off valves, and check valves are installed in sequence. The installation order and location of these devices are crucial for ensuring the safe transportation and use of oxygen.

Material: The oxygen pipelines are all made of 304 stainless steel and are degreased to ensure oxygen purity and prevent contamination and ensure safe use.

Compressed Air Pipeline:

Compressed air provides power for pneumatic regulating valves and pneumatic shut-off valves. The pipe diameter is DN15, with a flow rate of 0.25m ³ /min and a pressure of 0.4-0.6 MPa.

Electrical Control System Functions:

The electrical control part of the combustion control system is designed as an on-site explosion-proof floor-standing control cabinet, used to centrally connect various detection devices and actuators on site. This system uses a high-performance programmable logic controller, Siemens PLC, to achieve real-time data interaction with on-site equipment and supports real-time monitoring, remote control, and report generation.

Zhongwei Company's control cabinet design includes the following functions, and the electrical control system mainly consists of the following modules:

• Cover position control, responsible for controlling the up and down flipping of the cover;
• Ignition control, using electronic control equipment to ensure the reliability and safety of ignition;
• Flame monitoring, real-time monitoring of the presence and intensity of the flame through a flame detection probe, and providing corresponding operating signals;
• Instrument measurement and display, responsible for collecting key parameters such as system pressure, flow rate, and temperature, and displaying them in real time on the control cabinet;
• Auxiliary air blower control, using a variable frequency drive (VFD) to control the start and stop and speed of the blower to adapt to different combustion needs;
• Oxygen flow control, real-time monitoring and adjustment of the oxygen flow into the combustion chamber through a mass flow meter to ensure combustion efficiency;
• Fuel gas flow control, precisely controlling the proportional flow of fuel gas to meet the needs of specific combustion processes.

In terms of combustion control, the PLC acts as the control unit, and through high-speed data processing and complex control algorithms, it achieves precise control of the combustion process. The PLC is responsible for receiving signals from the flame detection system and adjusting the flow rate of fuel gas, oxygen, and air according to these signals to maintain a stable combustion state. At the same time, the PLC can also optimize the combustion process based on the real-time data provided by the instrument measurement system, improve combustion efficiency, and reduce emissions.

In addition, the PLC can also communicate with the variable frequency drive of the auxiliary air blower, dynamically adjusting the speed of the blower according to the combustion needs, thereby controlling the supply of combustion air. This closed-loop control system can ensure the stability and economy of the combustion process while reducing energy consumption.

Description of the state under different baking modes (remarks, the baking oven is designed with three auxiliary combustion modes: oxygen-enriched, full oxygen, and air):

During air baking, the oxygen supply is closed, and the oxygen required for combustion is provided by the auxiliary air blower.

During oxygen-enriched baking, the oxygen switch is interlocked with the blower and gas state. When the blower malfunctions or the air pressure is too low, oxygen enrichment will not be performed. When gas leaks or the pressure is too low, the oxygen will automatically shut off.

During pure oxygen baking, it has a preset oxygen-fuel ratio automatic adjustment function. When the oxygen-fuel ratio is out of balance, it has an alarm and automatic cut-off function.

Safety Interlock System ：

Fuel gas pressure protection system: A pressure transmitter is installed on the fuel gas pipeline to monitor the fuel gas pressure in the pipeline in real time. When the inlet pressure is detected to be lower than the set lower limit, the system will automatically trigger the emergency shut-off valve of the gas supply to close, preventing equipment failure or safety risks caused by insufficient fuel gas supply.

Oxygen-fuel ratio imbalance alarm: The oxygen-fuel ratio must be controlled stably. If the oxygen-fuel ratio control deviation is too large, a micro-explosion may occur. The oxygen-fuel ratio is monitored and controlled in real time throughout the baking process.

Flameout protection interlock: The system has a flameout protection function, and the combustion state is monitored in real time through a flame detector. Once a flameout occurs due to system fluctuations or other external factors, the control system will immediately start the interlock control sequence, send a signal to the corresponding valve actuator, and achieve rapid closure to prevent gas leakage and potential reignition risks.

Overtemperature alarm system: Temperature sensors are deployed at key temperature measurement points to monitor the operating temperature of the system. If the temperature detected by the sensor exceeds the preset safety threshold, the system will activate the audio-visual alarm device and start the emergency response program to protect the equipment from overheating damage and ensure the safety of the operators.

Leakage detection and alarm system: High-sensitivity combustible gas detection probes are arranged in the fuel gas equipment installation area. These probes can detect the concentration of combustible gas in the environment and start the interlock action when the preset alarm threshold is reached. The system will issue an alarm signal and cut off the gas source through control logic to reduce the risk of fire or explosion. In addition, the system can also be equipped with emergency ventilation and exhaust devices to further ensure area safety.

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