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The ZF-4 gas furnace condition monitoring and optimization system is a cutting-edge control device designed to enhance the efficiency of automatic gas production processes. This advanced system has demonstrated remarkable energy-saving and pollution-reduction effects in real-world applications, delivering substantial economic benefits. Its versatile technology is applicable across various industries, including nitrogen fertilizer production, synthetic ammonia manufacturing, city gas supply, industrial gas generation, glassmaking, and ceramic production.
As petroleum resources continue to deplete, the petrochemical industry is gradually being replaced by coal-based chemical processes. In China, most coal gasification technologies rely on intermittent fixed-bed systems. However, for many years, operators have lacked real-time insights into the internal conditions of gasifier furnaces. Traditionally, furnace status was judged based on visual observations and operator experience, leading to at least 5% of raw coal being wasted due to inefficiencies.
The ZF-4 system overcomes this challenge by utilizing signals collected from the ZF test system installed on the gas generator. It applies pulsation theory, Fahrenheit field theory, and passive radar positioning technology to detect real-time changes in furnace conditions. These data are then displayed on a host computer, providing operators with critical information for optimal decision-making. By fully monitoring furnace conditions, the system enables closed-loop tuning of the gasifier, ensuring stable, high-output, and low-consumption operation over extended periods, ultimately achieving energy savings and reducing environmental impact.
Practical application of the ZF-4 system has shown impressive results: the gas generation rate per furnace increased by an average of 23.2%, coal consumption per ton of amino resin decreased by 9.9%, and the steam decomposition rate improved by 9.9% on average. These outcomes highlight the system’s effectiveness in improving process efficiency and sustainability.
Anhui Sanyuan Industrial Automation Equipment Co., Ltd. is a rapidly growing private high-tech enterprise in China's chemical automation sector. The company specializes in developing automation control technologies for petroleum, chemical, and power production processes. It collaborates closely with top universities and research institutes across China, combining industry, education, and research to drive innovation. The company focuses on chemical automation engineering and integrated mechanical-electrical projects.
Its flagship product, the ZF-4 gas furnace monitoring and optimization system, has been widely adopted across more than 20 provinces, cities, and autonomous regions, including Hebei and Chongqing. Since its market launch, it has brought significant economic returns to nearly 300 chemical fertilizer manufacturers. The system has received widespread praise from users for its reliability, performance, and tangible benefits.