Project Background

A joint venture brand automobile OEM in East China, with its painting workshop being the primary source of VOCs emissions in the manufacturing industry, was designated as a key regulatory target for LDAR (Leak Detection and Repair) by environmental protection authorities in 2024. The annual total VOCs emissions were required to decrease by more than 10% compared to 2020. The original workshop lacked an online monitoring system, failing to meet the compliance requirements of HJ 1093-2020.

Customer Pain Points

  • The VOCs (benzene/toluene/xylene) in the spray painting workshop are strong carcinogens and flammable substances, posing dual risks.
  • The original LDAR relied solely on manual inspection using handheld detectors, making it difficult to manage the records of sealing points.
  • It is required to meet the requirements of “GB 30981-2020 Limit of Harmful Substances in Industrial Building Coatings”
  • It must be integrated with the workshop MES system, binding production orders and process parameters.

URION Solutions

  • PID High-precision VOC Monitoring: 56 sets of Pioneer YQZW PID detectors (10.6 eV lamp), with a resolution of 0.01 ppm
  • Catalytic Combustion LEL Monitoring: 12 sets of catalytic combustion monitoring, with automatic solvent supply cut-off when exceeding 25% LEL
  • Solvent Recovery Monitoring: Monitoring the inlet and outlet of 8 recovery devices to verify the recovery efficiency
  • Cloud-based LDAR Account Book: All seal point IDs + detection data are managed uniformly in the cloud, in compliance with HJ 1093-2020
  • MES Integration: Monitoring data is uploaded to MES and bound to production orders
  • Warning-High Alarm-Shutdown Three-Level Linkage: Automatic shutdown when exceeding 25% LEL + Initiate spraying + Notify EHS

Implementation Effect

  • 56 sets of PID + 12 sets of catalytic combustion sensors, covering all spraying lines + paint mixing rooms + drying rooms
  • In 2025, achieve a 100% LDAR compliance rate and zero penalties from environmental regulatory authorities
  • The total emissions of VOCs have decreased by 23% compared to 2020, exceeding the target of 10% reduction.
  • After MES integration, solvent usage is precisely controlled according to orders, resulting in an average monthly savings of 8%.