行业：机械制造

Comprehensive gas safety monitoring solution for machinery manufacturing

行业痛点

机械制造覆盖整车厂 / 重型机械 / 精密机加 / 模具 / 焊接装配，气体风险特征是"工艺粉尘 + VOC 喷涂 + 局部明火"复合：① **焊接车间**：氩弧 / CO2 焊烟（含 NOx + CO + 锰 + 铬等），员工密集长期暴露呼吸道损伤；② **喷涂 / 涂装线**：VOC（甲苯 / 二甲苯 / 醋酸丁酯）+ 固化烤炉 LEL，近年某汽车主机厂喷涂车间 VOC 整改投入数千万元；③ **铸造车间**：高温 CO + SO2（焦炭燃烧）+ 粉尘（金属粉尘有爆炸下限）；④ **热处理车间**：渗碳 / 渗氮 / 淬火 — CO（保护气）+ NH3（渗氮）+ CH4（载气）；⑤ **机加切削液**：水基切削液长期使用产生细菌 → 内毒素 + 异味；⑥ **环保监管**：HJ 1093 排放标准 + LDAR 法定 + 厂界恶臭 + 园区监管，机械制造业是 VOC 排放第二大源（占全国 12%），监管严格。

方案概述

优锐安机械制造方案覆盖焊接 / 喷涂 / 铸造 / 热处理 / 装配 5 大工艺：① **焊接车间**：分布式 CO + NOx + 烟尘 + 局部排风状态联测，与移动焊烟净化器联动；② **喷涂 / 涂装线**：VOC PID 在线监测 + 固化炉 LEL × 25% 联锁切气 + 烤炉烟道 RTO（蓄热式焚烧）入口 / 出口浓度（监测 RTO 处理效率 ≥ 95%）；③ **铸造车间**：CO + SO2 + 粉尘 + 高温保护探头（耐温 80℃）；④ **热处理车间**：CO + NH3 + CH4 多组分 + 炉门联锁；⑤ **机加切削液车间**：内毒素 + VOC + 风量监测；⑥ **厂界 + 烟囱排放（环保合规）**：HJ 1093 烟气连续监测系统 CEMS（VOC + 颗粒物 + NOx + SO2）+ 厂界恶臭 4 个监测站，数据直连生态环境局监管平台。

## Key Monitoring Nodes (By Process)

### Welding Workshop
– CO 0-200 ppm + NOx（NO + NO2）
– PM2.5 + PM10 (welding fume)
– Distributed probes: 1 probe per welding position + linkage with the air volume of a mobile welding fume extractor

### Spraying / Coating Line
– **Spray Booth**: VOC PID 0-1000 ppm (toluene / xylene / butyl acetate) + LEL
– **Leveling / Drying**: VOC + Temperature
– **Curing oven**: LEL × 25% high alarm → shut off main gas valve; CO incomplete combustion + O2 combustion monitoring
– **RTO regenerative thermal oxidizer**: inlet + outlet VOC concentration (calculated treatment efficiency = 100% × (inlet – outlet) / inlet, ≥ 95% compliance)
– **Workshop main exhaust outlet**: Continuous Emission Monitoring System (CEMS) for flue gas (VOC + particulate matter + NOx + SO2)

### Foundry workshop
– Cupola / Furnace: CO + SO2 (coke combustion)
– Pouring / Sand Removal: Dust (explosive metal dust → explosion-proof grade Ex d IIIB / IIIC) + CO
– Sand processing: dust + VOC (resin sand)

### Heat treatment workshop
– Carburizing / Nitriding / Quenching Furnaces: Multi-component detection of CO, NH3, and CH4
– Furnace door interlock: CO + LEL detection must meet the standard before opening the door
– Atmosphere furnace: H2 + CO + N2 flow rate + concentration monitoring

### Machining / Assembly (Low Risk)
– Cutting fluid mist + endotoxin
– Local VOC (cleaning agent usage)

## Key Technical Specifications

– Explosion-proof: Ex d IIB T4 (spray coating / baking oven) + Ex d IIIC (cast metal dust)
– Protection: IP65 (high dust in workshop + cutting fluid splash)
– Range: VOC PID 0-1000 ppm (PPB level sensitivity) + LEL 0-100%
– Response time: T90 < 30 seconds (PID) - Operating temperature: -20℃ ~ +60℃ (workshop) + 80℃ (high temperature casting) - Communication: Modbus + Profinet (interface with workshop PLC / SCADA) - CEMS flue gas online monitoring: certified by CCEP / CMC (issued by the Ministry of Environmental Protection) ## Implementation Key 1. **VOC + RTO treatment efficiency compliance**: The core of strict environmental management requires monitoring of both inlet and outlet concentrations to demonstrate a treatment efficiency of ≥ 95% (GB 16297 + HJ 733) 2. **LDAR statutory leak detection**: Conduct PID inspections on flange, valve, and pump sealing points four times a year. Any reading exceeding 500 ppm indicates a leak 3. **Integrated welding fume purification**: Increase in CO + NOx → Automatically increase the air volume of the welding fume purifier 4. **Casting dust explosion protection**: The lower explosion limit of metal dust accumulation is much lower than that of gas (aluminum powder 30g/m³), requiring independent explosion-proof IIIC level + anti-static grounding 5. **Data-linked environmental monitoring platform**: CEMS data is automatically reported to the local environmental protection bureau every minute, and in case of exceeding standards, an automatic SMS notification will be sent to the factory manager + a warning of potential fines ## Regulatory Basis - HJ 1093-2020 "Continuous Monitoring System for Pollution Source Flue Gas" - HJ 733-2014 "Control of Volatile Organic Compound (VOC) Emissions from Leaks and Open Liquid Surfaces" - HJ 1131-2020 "Technical Guidelines for Leak Detection and Repair (LDAR) of Volatile Organic Compounds in Industrial Enterprises" - GB 16297-1996 Integrated Emission Standard of Air Pollutants - GB 50058 Electrical Apparatus for Explosive Gas Atmospheres - GB 50493 Detection and Alarm Design - GBZ 2.1 Limits (Welding Fume / Cutting Fluid Mist PC-TWA) ## Applicable Customers Vehicle manufacturers (FAW / SAIC / BYD / Geely / Great Wall / Changan / NIO / Ideal / XPeng / Tesla China); components + molds (Huayu / Fuyao / Tuopu / Sanhua); construction machinery (XCMG / SANY / Zoomlion / LiuGong / Shantui); heavy machinery (Shanghai Blower Works / Harbin Electric / Shanghai Electric); shipbuilding (Waigaoqiao Shipbuilding / Jiangnan Shipbuilding / Hudong-Zhonghua); machining + mold SMEs (industrial clusters in Jiangsu, Zhejiang, Guangdong, and Shandong).