In-Situ Tunable Diode Laser (TDL) Process Gas Analyzer for Oxygen Monitoring in Coal-to-Liquid Process

The Background: Addressing Energy Demand Through Coal-to-Liquid Conversion

With the continuous growth of energy demand, coal-to-liquid (CTL) has emerged as a significant energy conversion method worldwide. In China, the energy resource structure is characterized by abundant coal, limited oil, and scarce natural gas. To leverage the country's coal resources and convert them into oil products, a coal chemical enterprise in Ningxia, China, has launched a 4 million tons per year coal indirect liquefaction project. This is the world's largest single chemical project with a one-time investment scale. The coal-to-liquid process offers a new avenue for utilizing coal resources, reducing dependence on oil, and promoting economic development. However, this process also presents several challenges.

The Challenge: Ensuring production safety while maximizing production efficiency

For such large-scale coal-to-liquid project, the critical challenges are how to ensure production safety and improve production efficiency as much as possible. Coal and oxygen are the primary reactants in the coal-to-liquid process. Under high temperature and pressure, coal is converted into syngas (carbon monoxide and hydrogen). Then, syngas undergoes Fischer-Tropsch synthesis with the help of a catalyst, producing synthetic oil that contains hydrocarbons, oxygenates, and water. As hydrocarbons are flammable and explosive, reacting with oxygen could lead to explosions. Therefore, maintaining a safe operational environment throughout the coal-to-liquid process is essential to prevent potential hazards.

In addition to safety, optimizing production efficiency is another critical factor. Oxygen concentration is one of the key parameters that directly affects gasification efficiency—the higher the oxygen concentration, the faster the reaction. However, excessively high oxygen concentration may cause over-oxidation, leading to the formation of carbon dioxide and water, which in turn reduces the amount of effective gas produced and negatively impacts production efficiency. Controlling these variables is essential for optimizing the conversion process and maximizing overall production efficiency.

Therefore, online monitoring of oxygen content in the coal-to-liquid process is a key technical requirement for ensuring both safety and efficiency. To address these challenges, the coal chemical enterprise in Ningxia decided to implement a new set of online oxygen analysis instruments for real-time monitoring and control of oxygen content in the coal-to-liquid process.

The Approach: Cubic Instruments comprehensive Tunable Diode Laser (TDL) gas analysis solution providing exceptional accuracy in oxygen content monitoring

Cubic Instruments, a leading manufacturer of smart gas sensors and advanced gas analyzers, provides a comprehensive Tunable Diode Laser (TDL) gas analysis solution for this large-scale coal-to-liquid project in Ningxia. The solution consists of four parts: sampling unit, preprocessing unit, control unit, and analysis unit.

Above four parts work together to form Cubic Instruments comprehensive Tunable Diode Laser (TDL) gas analysis solution, guaranteeing safe and efficient operation in the coal-to-liquid process.

Throughout the solution, Cubic Instruments In-situ Tunable Diode Laser (TDL) Process Gas Analyzer GasTDL-3100 serves as the key analytical component responsible for precise oxygen measurement. While the sampling, preprocessing, and control units ensure a stable gas sample for analysis, GasTDL-3100 accurately measures oxygen concentration in the gas sample in real-time. GasTDL-3100 enables operators to effectively monitor and promptly adjust oxygen concentration to ensure process safety and efficiency.

To fulfill the pivotal function, GasTDL-3100 is designed with advanced features that ensure exceptional performance and reliability. Based on Tunable Diode Laser Absorption Spectroscopy (TDLAS) technology, GasTDL-3100 has high selectivity for oxygen, ensuring no cross-interference from background gases in the coal-to-liquid process. The in-situ design enables GasTDL-3100 to perform measurements directly, with a response time as fast as 1 second, allowing operators to react promptly to unforeseen circumstances. Besides, GasTDL-3100 has an oxygen measurement accuracy of up to ±1% FS, enabling operators to precisely maintain oxygen concentrations within safe limits. Beyond its core performance, GasTDL-3100 also has the characteristics of high security (Exd II CT6 certified explosion-proof capability), simple operation, easy maintenance, and long lifetime. All these outstanding performances make GasTDL-3100 an excellent choice for online monitoring of oxygen content in the coal-to-liquid process.

The Result: Providing crucial data support for safe and efficient production, driving sustainable industry development

The comprehensive Tunable Diode Laser (TDL) gas analysis solution provided by Cubic Instruments for Ningxia’s coal-to-liquid project has enabled operators to monitor the oxygen content in real time and upload the data to the central control system for recording. This gas analysis solution provides crucial data support for safe and efficient production, addressing the project's challenges. Cubic Instruments looks forward to driving the implementation of more projects, contributing to the sustainable development of the industry, and supporting global efforts towards clean energy and environmental protection.

Why Cubic Instruments: World’s leading gas sensor and gas analyzer manufacturer with over 20 years of experience

As a leading manufacturer of smart gas sensors and advanced gas analyzers, Cubic Instruments has developed a variety of cutting-edge gas analysis technologies through years of technical expertise, including Non-dispersive Infrared (NDIR), Ultraviolet Differential Absorption Spectroscopy (UV-DOAS), Non Dispersive (NDUV), Tunable Diode Laser Absorption Spectroscopy (TDLAS), Laser Raman (LRD), Light Scattering (LSD), Thermal Conductivity (TCD), Electrochemical (ECD), and Ultrasonic technologies. Leveraging these outstanding technologies, Cubic Instruments' comprehensive gas analysis solutions are widely applied in environmental monitoring, process gas monitoring, automobile exhaust emission testing, smart metering and so on. With over 20 years of extensive experience, stringent quality control, and a global perspective, Cubic Instruments will continue to deepen its expertise in the gas analysis industry and contribute to global efforts in sustainable development.

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