Bitoba LECOS combustion optimization system for oil and petrochemical heating furnaces

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one

LECOS

System brief

development team

LECOS

The gas combustion optimization system was developed by a team of professors and master researchers from California State University, Beijing Tsinghua University, and Taipei University, with extensive experience in energy-saving technologies.

2012

Introduced by Nanjing Leading Talents ("

321

Plan"), the system became one of the top industrial control and energy-saving technology research teams in China. It is capable of independently designing and developing products that meet specific user needs and on-site conditions.

Features

LECOS

The system is suitable for various types of gas and combustion equipment. Its modular configuration and self-learning algorithm allow industrial enterprises to customize management schemes based on their own conditions.

Key features include:

â—† Adaptability to different operating modes, such as multiple configurations for different applications, DCS, manual control, etc.

â—† High-precision real-time parameter measurement, data acquisition, and management functions.

â—† User-friendly human-computer interaction.

â—† Fast self-learning optimization algorithm for sensitive control and achieving the optimal air-fuel ratio.

â—† Integrated multiple combustion control programs and PID load regulation function.

â—† Monitoring and display of combustion efficiency and power.

â—† Threshold alarm and bypass control design to ensure no production impact during system failures.

â—† Fault diagnosis capability.

â—† Historical data tracing and reporting functions.

System Components

LECOS

The system includes a host module, combustion equipment operation parameter monitoring module, high-precision air volume measurement module, remote sensing module, master control DCS, operator application platform module, and data management traceability and reporting modules.

The host module is the core of the system, based on high-speed computing chips, integrating parameter acquisition, response algorithms, and decision logic functions.

The combustion equipment parameter module is equipped with high-precision sensors for air volume, duct pressure, temperature, fuel metering, flue gas temperature, and composition monitoring, tailored to user requirements.

The high-precision air volume measurement module uses LEFM series anti-blocking array devices to solve air volume measurement uncertainty issues in boilers.

The master control DCS and operator application platform provide system interfaces with operational management systems and necessary alarm and guidance functions.

The data management and reporting module handles, displays, stores, and exports historical and real-time data to meet industrial data application needs.

(II) LECOS Combustion Optimization Implementation

General Description:

The system precisely controls fuel and air flow based on load, ensuring sufficient combustion while reducing excess air coefficient, thereby lowering exhaust heat loss and improving furnace efficiency.

Expected Goals:

Achieve an excess air coefficient of 1.05 for boilers. A reduction of 0.1 in the excess air ratio can lower smoke emissions by 6.5% and reduce exhaust heat loss by about 0.6%. Current gas boiler excess air coefficients are typically above 1.2. With LECOS, efficiency improves by more than 1%, depending on working conditions.

Application Object:

Various types of gas boilers.

Method to Realize:

LECOS Control Box (microprocessor board) + peripheral equipment (gas analyzer, zirconia oxygen sensor, gas/air flow meter, pressure and temperature sensors, fast-response actuator).

Functional Elements:

Electronic ratio modulation technology + humanoid intelligent adjustment (self-learning).

Adjustment Logic (Main):

LECOS uses dual subsystem control logic, including load tracking and flue gas oxygen adjustment systems, with cascade optimization algorithms for precise control.

(1) Load tracking system: Outer loop calculates theoretical fuel quantity using boiler load information (steam pressure or hot water temperature), combined with flow rate data, to maintain a target value. Inner loop adjusts fuel based on calorific value and pressure.

(2) Flue gas oxygen regulation system: Outer loop determines theoretical air volume based on fuel quantity, serving as the first-stage target for air valve adjustment. Inner loop adjusts oxygen content to maintain set values.

LECOS's humanoid intelligent adjustment uses advanced self-learning algorithms, offering better speed, stability, and robustness compared to traditional PID control. It analyzes operational data to determine optimal control behavior.

(III) Application of LECOS System in Oil and Gas Field Water Jacket Heating Furnace

Heating Furnace Status

Water jacket heating furnaces are essential in oil and gas fields, used for heating and gathering systems. Typically fueled by natural gas, they heat water to transfer heat to oil or gas. They are among the largest fuel-consuming equipment in oil fields, with efficiency directly impacting production efficiency and economic benefits.

Most oil field heating furnaces use skid-mounted water jackets with negative pressure combustion, where air is manually adjusted via dampers. Fuel intake is controlled by valves, targeting oil pressure before and after the heating tube. This method leads to inefficiencies due to poor air-gas mixing and inconsistent flame temperatures.

Poor combustion results in low radiation intensity, reduced heat transfer efficiency, and potential corrosion from condensate. Excess air increases heat loss and fuel consumption, especially at low loads.

Current thermal efficiency averages 52%-60%, leading to high gas consumption and increased production costs.

LECOS System Application

LECOS aims to improve furnace efficiency by ensuring complete fuel combustion and reducing flue gas heat loss. It automatically adjusts gas intake based on temperature and monitors flue gas oxygen content to optimize air-fuel ratios.

For negative pressure combustion furnaces, LECOS supports automatic damper control, adjusting gas demand and air volume based on flue gas oxygen content. This reduces excess air to 5%, saving 5-15% natural gas. It also enables positive pressure combustion by adding a blower.

For positive pressure combustion furnaces, LECOS uses PID control and gas analysis to achieve automatic load tracking and combustion optimization, improving efficiency by 3-8%.

LECOS allows modular configuration, such as selecting gas component analysis for automatic control or oxygen sensors for air-fuel ratio control. The system has a payback period of 6-8 months.

(4) ECOS Gas Energy Saver for LECOS System

ESA Gas Energy Saver Description

LECOS supports the ESA multi-pole fuel environmental protection energy saver, developed by ACME in the U.S. It uses nano-catalyst-coated alloy rods to create a high-frequency magnetic field, refining fuel molecules to enhance gas-air mixing, improve combustion efficiency, and reduce excess air.

ESA is easy to operate, requires no personnel or equipment control, and is installed before the fuel pressure reducing valve and nozzle. It changes only the physical properties of the fuel, with a bypass pipe for maintenance.

Water Jacket Heating Furnace Support

When used with LECOS’s automatic control system, ESA further enhances combustion efficiency. Based on conservative estimates, it can increase gas savings by 1-3%.