Study on Quasi-Open Microwave Cavity Sensor Measuring Pulverized Coal Mass Concentration in Primary Air Pipe

Pulverized coal mass concentration in the primary air pipe is one of the essential parameters for promoting furnace combustion efficiency. However, attaining accurate, real-time, and online detection for pulverized coal mass concentration remains challenging due to factors such as large pipe diameter and high flow rate. This study introduces a quasi-open microwave resonant cavity sensor. The principle and model were analyzed using the perturbation method, and the design and optimization were conducted with the simulation. A prototype and its test system were constructed, and the test results demonstrated good agreement between the simulations and experiments. The simulation revealed that the resonant frequency decreased monotonically from 861 to 644 MHz as mass concentration increased within 20%~80%, resulting in a change of about 3.62 MHz/1% under static mixture. The resonant frequency showed a drop from 21 MHz to 9 MHz with an increase in mass concentration under pulverized coal flow. Prediction models were developed and validated, showing the absolute values of the relative errors to be within 4% under operational scenarios. Additionally, the impact of the sensor on pulverized coal flow was evaluated, and it was found that the sensor structure had minimal impact on the flow in terms of velocity and the distribution of continuous flow. Finally, the long-term stability was assessed by examining the wear of the antennas and barriers. With inner barriers experiencing up to 2/3<i>d</i> wear, the resonant frequency drift ratio remained below 1.5%, corresponding to a mass concentration deviation of less than 3.2%.