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 professors and master research teams from California State University, Beijing Tsinghua University, and Taipei University, with extensive experience in energy conservation.

2012

Introduced by Nanjing Leading Talents ("

321

Plan") into China, it is now the top industrial control and energy-saving technology R&D team in China. The system can independently design and develop products that fully meet user requirements based on actual needs and site conditions.

Features

LECOS

The system is suitable for all types of gas-burning equipment. Its modular configuration and self-learning algorithm allow industrial enterprises to configure management schemes according to their specific conditions.

Key features include:

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Adaptable to different operating modes, such as multiple configurations for various applications including DCS and manual control;

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High-precision real-time parameter measurement, data acquisition, and management functions;

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User-friendly human-computer interaction;

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Self-learning fast optimization response algorithm with sensitive control to achieve the optimal air-fuel ratio;

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Integrated multiple combustion control programs and PID load regulation function;

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Monitoring and display of combustion efficiency and power;

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Threshold alarm and bypass control design ensures no disruption to production during system failures;

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Potential fault diagnosis function;

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Historical data tracing and reporting capabilities.

System Components

LECOS

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, built on high-speed computing chips, integrating parameter acquisition, response algorithms, and decision logic functions.

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

The high-precision air volume measurement module uses LEFM series anti-blocking array devices to reduce uncertainty in boiler air volume measurements.

Master control DCS and the operator application platform provide system interfaces and necessary alarm and operational guidance functions.

The Data Management Traceability and Reporting module manages, displays, stores, and exports historical and real-time data to meet industrial data application needs.

(II) LECOS Combustion Optimization Implementation

General Description:

Fast tracking of fuel and air volume control ensures sufficient combustion while reducing excess air coefficient, thus minimizing 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 reduces smoke emissions by 6.5% and lowers exhaust heat loss by about 0.6%. Current gas boiler excess air coefficients are usually above 1.2. With LECOS, efficiency improves by more than 1%, depending on working conditions.

Application Object:

Various types of gas boilers

Method of Realization:

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's electronic ratio modulation technology uses dual subsystem control logic: load automatic tracking adjustment and flue gas oxygen adjustment systems. It employs cascade adjustment and optimization algorithms for precise control.

(1) The load tracking adjustment system calculates theoretical fuel quantity based on boiler load information (steam pressure or hot water temperature), combined with flow rate data, to maintain a target value despite load disturbances. The inner loop adjusts fuel pressure and calorific value to stabilize furnace temperature.

(2) The flue gas oxygen regulation system determines theoretical air volume based on fuel quantity and sets it as the first-stage target for air valve or blast baffle adjustment. The inner loop maintains flue gas oxygen content at a set value using online oxygen monitoring.

LECOS's humanoid intelligent adjustment uses advanced self-learning algorithms, eliminating reliance on mathematical models and enabling real-time empirical-based control, offering better speed, stability, and robustness compared to traditional PID control.

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

Heating Furnace Status

The water jacket heating furnace is essential in oil and gas field operations, used for heating and gathering systems. It typically burns natural gas to heat water, which then transfers heat to oil or gas pipelines. As one of the largest self-consumption fuel equipment in oil fields, its efficiency directly impacts production efficiency, energy savings, and economic benefits.

Most oil field heating furnaces use skid-mounted water jacket furnaces with negative pressure combustion, where air is naturally drawn in through dampers, and fuel intake is adjusted manually. This method often leads to inefficiencies due to poor air-gas mixing, incomplete combustion, and excessive heat loss.

Currently, the average thermal efficiency of these furnaces is only 52%-60%, resulting in high gas consumption and increased operational costs.

LECOS System Application

LECOS aims to enhance furnace efficiency by ensuring complete fuel combustion and reducing flue gas heat loss. It automatically adjusts gas intake based on heat load and monitors flue gas oxygen content to optimize the air-fuel ratio, reducing fuel consumption and improving efficiency.

For negative pressure combustion furnaces, LECOS provides an automatic damper control module that adjusts air intake based on temperature and flue gas oxygen levels, achieving up to 5-15% natural gas savings. For positive pressure combustion furnaces, it enables automatic load tracking and combustion optimization, further saving 3-8% in gas usage.

LECOS allows modular configuration, such as selecting gas component analysis or oxygen sensors for full automation. Based on field predictions, 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. It uses nano-catalyst-coated alloy rods to create a high-frequency magnetic field that enhances fuel molecule mixing, improving combustion efficiency and reducing excess air.

The ESA device is simple to operate, requires no personnel or equipment control, and is installed before the fuel line pressure regulator and nozzle. It modifies fuel properties without adding or removing any material. A bypass pipe is installed for easy maintenance.

Water Jacket Heating Furnace Support

When used with the LECOS system, the ESA device processes fuel to improve combustion efficiency. This combination can increase efficiency by 1-3% conservatively.