Industry: Metallurgical industry

Comprehensive Monitoring Solution for Carbon Monoxide in Steel Metallurgy Steelmaking Workshops

CO monitoring in steel-making workshop: high-temperature dust-proof enclosure + centralized monitoring screen + three-level linkage alarm

Industry Pain Points

The steel metallurgical workshop is a high-risk area for CO, with blast furnace gas CO concentrations reaching up to 25-30%, converter gas 60-70%, and coke oven gas 6-8%. Any leakage poses a fatal risk within minutes. Additionally, the workshop operates under high temperatures (molten iron at over 1500°C), strong electromagnetic interference (continuous casting billet heating), high dust concentrations (5-30 mg/m³), and long distribution distances (steelmaking workshops often span up to 200 meters). Traditional detectors either frequently produce false alarms or have significant blind spots at critical nodes (gas pressure stations, gas holders, converter fronts, continuous casting main control). Once a gas pipeline network leak triggers production shutdown, the single loss can exceed one million yuan. The risk of employee casualties is classified as a national-level control object according to GB 6222

Solution Overview

URION provides an integrated monitoring solution for key nodes such as steelmaking, converters, continuous casting, gas cabinets, gas pressurization stations, gas mixing stations, and coking, featuring a three-network separation of "blast furnace gas area + converter gas area + coke oven gas area" and multi-component coverage of CO, LEL, O2, and H2S. Key technologies include a high-temperature dustproof enclosure (IP66 / temperature resistance up to 70°C), an infrared CO sensor (unaffected by temperature rise and humidity drift), dual explosion-proof certification (Ex d IIB T4), 4G/5G private network backhaul, and DCS-linked emergency stop (interlock valve response time < 3 seconds). The deployment density follows GB 50493-2019 and GB 6222-2005 standards, with a 7.5m radius for leakage sources and a 15m radius for permanent areas. Key positions (gas distribution station, converter operation room) are individually protected. Optional features include CO satellite monitoring for gas emission towers, accompanied by intelligent inspection PDA and a three-level alarm platform.

## Recommended Configuration Matrix

– **Blast Furnace Gas Area**: Fixed infrared CO detector (range 0-1000 ppm + 0-100% LEL) + explosion-proof portable 4-in-1 (CO/LEL/O2/H2S) for routine inspection
– **Converter gas area**: High-temperature CO + LEL integrated probe (temperature-resistant to 80°C) + large data dashboard + DCS interlock
– **Gas Mixing Station / Pressurization Station**: Fixed multi-point sampling pump-aspirated analyzer + pressure interlock emergency stop + SMS alarm
– **Continuous casting workshop**: Ceiling-mounted distributed probes (to avoid radiant heat from molten steel) + dynamic compensation

## Implementation Essentials

1. The detector is calibrated with 200 ppm CO standard gas every three months, and the coke oven area is calibrated monthly due to significant H2S interference
2. The alarm threshold values are set according to GBZ 2.1: pre-alarm PC-TWA × 0.5 = 10 ppm; high alarm PC-STEL = 30 ppm; interlock shutdown IDLH = 1500 ppm
3. It must be equipped with an explosion-proof rating of EX d IIB T4, compliant with GB 3836-2021
4. Interlocking logic with PLC: Ultra-high alarm → automatically open the corresponding gas shut-off valve + initiate emergency ventilation + send SMS notification to the shift leader

## Regulatory Basis

– GB 6222-2005 “Safety Regulations for Industrial Enterprise Gas”
– GBZ 2.1-2019 PC-TWA 20 mg/m³（17 ppm）
– GB 50058-2014 Electrical Apparatus for Explosive Gas Atmospheres
– GB 50493-2019 Design Standard for Detection and Alarm Systems

## Applicable Customers

Steel groups (Baowu / Ansteel / Hebei Iron & Steel / Shagang / Shougang / Baotou Steel / Panzhihua Iron & Steel), independent coking plants, ferroalloy plants, non-ferrous metallurgy (copper smelting / lead-zinc smelting).

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