Gas analyzer for dry/dusty kilns
BACKGROUND OF THE INVENTION 
     This invention relates to gas analyzing systems and more particularly to such systems which may be used to analyze samples of gas drawn from dry and dusty environments, such as lime kilns. 
     One problem with prior gas analysis systems used to analyze the gases in a hot, dry and dusty environment, such as lime kiln, is that the systems became inaccurate, over time, as their probe lines became clogged with dust. Prior systems, because their lines were clogged, had a slower response time. Inaccuracies also arose because of the adverse effect of &#34;tramp&#34; air, which is air that flows into the kiln through seal leaks, incompletely closed doors and other accidental causes. Such tramp air may have a disproportionate effect on measurements made by the system especially those involving oxygen. 
     One type of previously disclosed gas monitoring system is shown in the inventor&#39;s prior U.S. Pat. No. 4,094,187 (&#39;187 patent) entitled &#34;Stack Gas Analyzing System With Calibrating/Sampling Feature&#34;, incorporated by reference herein. In U.S. Pat. No. 4,094,187 patent it is explained that &#34;real-time&#34; gas analyzer uses pipes to convey the gas to a nearby analyzer to permit their immediate analysis and the adjustment of process parameters based upon that analysis. Such rapid adjustments may prevent the exhaust of unacceptable levels of pollutants, and may prevent injury to the kiln and/or associated equipment. In U.S. Pat. No. 4,094,187 patent the calibration gases are supplied to the analyzers through the same gas path used by the samples of the effluent. 
     OBJECTIVES AND FEATURES OF THE INVENTION 
     It is an objective of the present invention to provide a gas monitoring system for dry, dusty and hot environments such as lime kilns, which system will be relatively accurate to permit more accurate control of the fuel/air ratio in order to conserve fuel and maintain an efficient and safe operation of the kiln&#39;s boiler. 
     It is a further objective of the present invention to provide such a monitoring system which tests itself for accuracy using commercially available span gases, i.e., commercially available calibration gases. 
     It is a further objective of the present invention to provide such a monitoring system which will monitor oxygen (O 2 ) combustible gases (methane, etc.), carbon monoxide (CO) and carbon dioxide (CO 2 ). 
     It is a further objective of the present invention to provide such a monitoring system which is relatively fast in the time required for its self-calibration, for example, less than two minutes, in order to use relatively less of its span gases for calibration. 
     It is a further objective of the present invention to provide such a monitoring system which will be fully automatic in operation, under microprocessor control, so that its calibration, blanking and purging will be automatically commenced, controlled and terminated without attention from an operator. 
     It is a further objective of the present invention to provide such a monitoring system which is designed to help prevent the entry of dust, along with the gas to be sampled, into the monitoring system, so that the sample which is tested may be relatively &#34;unconditioned&#34;, i.e., not cleaned prior to analysis. 
     It is a further objective of the present invention to provide such a monitoring system which will not be adversely affected in the accuracy of its measurements by the presence of hydrogen sulfide or humidity in the sample. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, a system for real-time analysis of effluent gas is provided. The system includes a probe which extends relatively far into the kiln; for example, it extends 14 feet, to avoid the adverse effect on the measurement of &#34;tramp&#34; air, i.e., extraneous air which may leak into the kiln. The effluent gas to be analyzed is hot and moist. A sample is taken, through the probe and the moisture and heat removed by cooling the sample. Some of the gas sample, now at room temperature (70° F.) is pumped into an oxygen analyzer. Other portions of the dried gas sample are pumped to other analyzers. Preferably the &#34;span gases&#34;, i.e., the commercially obtained gases used for calibration of the system, are nitrogen, oxygen and methane, depending on the connected analyzers. 
     The probe is mounted at the end of a probe support which is an elongated support pipe. The gas sample is obtained through an isolation tube which leads to the probe chamber and which is pointed for sample flow opposite in direction to the flow of gas. Two pipes, suspended within the support pipe, are connected to the probe chamber. One of the pipes carries a tube through which the effluent gas samples are drawn and the second pipe carries air to purge the probe chamber and the calibration span gases. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objectives and features of the present invention will be apparent from the following detailed description, which should be taken in conjunction with the accompanying drawings. 
     In the drawings: 
     FIG. 1 is a block diagram of the gas analyzing system of the present invention; 
     FIG. 2 is a side view, partly in section, of the probe for use in the system of FIG. 1; 
     FIG. 3 is a cross-sectional view, taken along line A--A of FIG. 2, looking in the direction of the arrows; and 
     FIG. 4 is a side view of the free end of the probe. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in FIG. 1, the effluent gas analyzing system of the present invention is for analyzing gases in a dry dusty environment, such as that found in a lime kiln 1. The gases that are desired to be tested are oxygen (O 2 ), methane (combustibles), carbon dioxide and carbon monoxide. 
     The stack probe 2, shown in detail in FIG. 2, extends into the kiln 1. The dusty flue gases within kiln 1 flow in the direction of arrow 4. The sample 6 is taken through the isolation tube 5, which points for sample flow 6 in the opposite direction from flow 4. The sample 6 passes into the interior of the probe chamber 3. 
     The direction and size of the isolation tube 5 prevents the pulsations in pressure in the effluent gas flow from affecting the gas pressure within the probe chamber 3. This isolation from the effect of pulsation permits a low flow of &#34;span&#34; gases, i.e., calibration gas, during the calibration cycle. The amount of flow of span gas may be regulated so that it is slightly in excess of the sampling rate (the rate of flow of the gas sample). 
     The change in direction of 180°, of the flow of sample 6 from the flow 4, prevents the heavier dust particles from entering the probe chamber 3 with the sample. That change in direction effectively separates the heavier particles, which are carried past the isolation tube 5 due to their higher inertial energy. The probe chamber 3 is mounted on the end of the pipe 12. The pipe 12 leads through control valve 13a to a source of atmospheric purge air 13. 
     An unconditioned sample of the gases from within kiln 1 is pumped from probe chamber 3 through filter 8 and exhausted through tube 14, which tube is carried within the pipe 12. The sample passes through sample pump 17 to the conditioning system. The conditioning system includes scrubber 18. From scrubber 18 the gas can be passed through cooler 19, to remove its moisture. The gas sample, when it exits from cooler 18, is at room temperature (70° F.), or lower. The gas is then pumped and divided so that portions are pumped to oxygen (O 2 ) analyzer 15a and to three other analyzers. The three analyzers are analyzer 15b for combustibles (methane), analyzer 15c for carbon monoxide (CO) and analyzer 15d for carbon dioxide. 
     A second pipe 20, with a blocking valve 20b, within and leading from probe chamber 3, leads to the source of the calibration gases 21. That source 21 consists of standard compressed calibration gases (span gases) which, for example, are oxygen 21a, methane 21b, carbon dioxide 21c, and carbon monoxide 21d. The calibration gases, in pressurized cylinders, are controlled by the respective valves 22a, 22b, 22c and 22d. 
     Preferably the valves, such as 22a-22d, and the exhaust pipe are electrically operated and controlled from a digital micro-processor flow control computer 25. The lines 25a-25e  leading to and from computer 25, are electrical control lines. Only representative electrical control lines are shown, for the purpose of clarity of the illustration. However, preferably all the valves are electrically controlled by the controller 25. 
     Preferably, the control computer 25 operates valve 13a once an hour, to purge the filter 8 of the probe chamber 3 with air to clean the filter. The entire unit is preferably calibrated once a day, automatically by the control computer 25. Such calibration may take from 2-5 minutes, and tests have shown that a calibration period of 21/2 minutes is satisfactory. 
     A tube 23 leads from the pipe 12 to the calibration gases 21. The control valve 23a is normally closed but is opened to permit the flow of calibration gases through pipe 12 and into the probe chamber 3. This will put the entire probe system under positive gas pressure in order to test for air in-flow leaks. Such leaks, unless detected and halted, would result in inaccurate measurements. 
     The source of pressurized air 24, which is connected to tube 20 through control valve 24a, is used as a secondary air purge. The secondary air purge preferably is automatically cycled so that the air from air source 24 may clear out dust from the probe chamber 3. The secondary air, along with the dust, will be expelled through the isolation tube 5. 
     The problem of tramp air, i.e., leakage of air into the sample system, is especially serious when the oxygen analyzer is used, as even small air leaks can lead to inaccurate oxygen measurements. The alternative calibration mode is used to detect such leaks. In the alternative calibration mode, the valve 23a is opened and the calibration gases from compression sources 21a-21d pass through pipe 12 and the filter 8 into the probe chamber 3. The gas pressurizes the sample system and any leaks may be detected. 
     As shown in FIGS. 2 and 3, the isolation tube 5, which is preferably a 1/2-inch pipe, is attached near the free end of the probe chamber 3. The pipe 20 is preferably a 1/4-inch (diameter) pipe and is connected so that its exit orifice 20a is within the probe chamber 3. The tube 14 consists of a 3/8-inch tubing inside of a 1/2-inch pipe. The pipe 12 ends 2 inches before the probe chamber. The 1/2-inch pipe (of tube 14) has its exit orifice within filter 8 and the tube 14 lies almost entirely within the pipe 12. Preferably pipe 12 is a 1-inch pipe. The pipe 12 is centered within the support pipe 30 by strap metal supports 31. Each support 31 has two legs 31a and 31b. The support 31 is welded to the pipe 12. A single support 31 is within the support pipe 30 to hold the pipe 12. The support pipe 30 extends along the entire length of the probe until the rear face of the probe chamber and, at its opposite end, extends through the dust chamber wall into the kiln proper. Alternatively, the support pipe 30 may be mounted on a blind flange fixed to a kiln wall. The probe chamber 3 is supported by the tube 20, tube 14 and pipe 30; the main support for the probe chamber being the tube 14. Preferably the support pipe 30 is a 6-inch (diameter) pipe.