To avoid ignition failure of regenerative burner, comprehensive measures should be taken from design, operation, maintenance and monitoring. The following is a systematic solution:
1. Optimize design and selection
Match the ratio of gas to air
-Ensure that the burner design is in line with the characteristics of fuel (such as natural gas, gas, etc.), and adopt an intelligent control system with adjustable proportion to avoid ignition failure caused by unbalanced air-fuel ratio.
-Select burners with premixed or staged combustion technology to reduce local fuel enrichment/deficiency.
High quality ignition device
-Select high temperature resistant and anti-carbon ignition electrode (such as ceramic material), and ensure sufficient ignition energy (usually ≥5kV).
-Install flame detector (such as ultraviolet/ionization probe) to provide real-time feedback of ignition status, and the linkage control system will automatically retry or alarm.
2. Standardize the operation process
Maintenance of key components
-Follow the process of "blow → ignite → supply gas": Start the fan to blow the furnace (≥30 seconds), then ignite and gradually increase the gas quantity.
-Avoid direct ignition of cold furnace, and preheat the heat storage body to more than 300℃ (auxiliary heating can be achieved through bypass flue).
3. Regular maintenance and cleaning
Maintenance of key components
-Clean the carbon deposits of ignition electrodes and check the insulation performance every month; replace the aging high-voltage wire quarterly.
-Clean the gas filter and nozzle every 6 months to prevent impurity blockage; check the damage of heat storage body (ceramic ball/honeycomb body).
System calibration
-Regularly check the gas flowmeter and oxygen content analyzer to ensure accurate data; adjust control parameters (such as PID set value).
4. Environment and fuel management
Fuel quality control
-Filter moisture and particulate matter in the gas (such as installing a dryer) to avoid hydrogen sulfide corrosion of pipelines.
-Adjust the air-fuel ratio for high calorific value fuel to prevent excessive combustion temperature damage to burners.
Environmental adaptability improvement
-In low temperature or high humidity environment, heat and insulation of gas pipeline is provided to prevent the impact of condensate on combustion.
-Explosion-proof door or pressure relief device is added to deal with the risk of gas accumulation.
5. Intelligent monitoring and fault diagnosis
Real-time monitoring system
-Deploy PLC/DCS system to monitor flame status, temperature curve, pressure fluctuation and other parameters, and set abnormal threshold alarm.
-Historical data recording and analysis to predict potential faults (such as ignition delay growth may indicate electrode aging).
Emergency Plan: Install backup ignition systems or manual ignition devices; Establish a rapid shutdown-blowdown-restart procedure.
Case Study: Fault Phenomenon: Frequent engine stalling after ignition.
Cause: Partial blockage of the regenerator causing uneven airflow distribution.
Solution: Perform reverse purge on the regenerator chamber after shutdown, and replace damaged regenerators.
Through the above measures, the ignition failure rate can be significantly reduced and the system reliability can be improved. In practical application, the maintenance cycle and technical parameters should be adjusted according to specific working conditions.
