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The ZF-4 gas furnace condition monitoring and optimization system is an advanced control device designed to enhance the efficiency of automatic gas production processes. This innovative system has demonstrated remarkable energy-saving and pollution-reduction effects in real-world applications, delivering substantial economic benefits. Its wide-ranging applicability makes it a valuable tool across industries such as nitrogen fertilizer production, synthetic ammonia manufacturing, city gas supply, industrial gas generation, glassmaking, and ceramics.
As petroleum resources become increasingly scarce, the coal chemical industry is gradually replacing petrochemicals. In China, most coal gasification technologies still rely on intermittent fixed-bed methods. However, for many years, operators have lacked real-time insights into the conditions inside gasifier furnaces. Decisions were often based on visual observations and experience, leading to inefficiencies and at least 5% of raw coal being wasted.
The ZF-4 system addresses this challenge by utilizing signals collected from the ZF test system installed on the gas generator. It applies principles such as pulsation theory, Fahrenheit field theory, and passive radar positioning technology to monitor instantaneous changes in furnace conditions. These data are then displayed on a host computer, providing operators with critical information for decision-making. With full visibility of furnace conditions, the system enables closed-loop tuning, ensuring stable, high-output, and low-consumption operation over extended periods—ultimately achieving energy savings and reducing environmental impact.
Practical implementation of the ZF-4 system has shown impressive results. The gas generation rate per furnace has increased by an average of 23.2%, while coal consumption per ton of amino resin has dropped by 9.9%. Additionally, the steam decomposition rate has improved by 9.9% on average, highlighting its effectiveness.
Anhui Sanyuan Industrial Automation Equipment Co., Ltd. is a rapidly growing private high-tech enterprise in China’s chemical automation sector. Specializing in automation control technologies for petroleum, chemical, and power production, the company collaborates closely with top universities and research institutes across the country. Combining education, research, and industry, it focuses on chemical automation engineering and integrated mechanical-electrical projects.
The company's flagship product, the ZF-4 gas furnace monitoring and optimization system, has been successfully deployed in over 20 provinces and cities, including Hebei and Chongqing. It has brought significant economic returns to nearly 300 fertilizer manufacturers and has received widespread praise from users for its performance and reliability.