Application of Industrial Methane Gas Detector in Coking Plant Gas Leak Detection

Coking plants, as a critical part of coal chemical processing, produce large amounts of coke oven gas during production. Coke oven gas contains high concentrations of combustible components. Any leakage not only poses a threat to human safety but can also trigger fire or explosion. Therefore, installing a professional industrial methane gas detector is essential for ensuring production safety.

Overview of Coke Oven Gas and Risks

Coking Process

Coking is the process where organic matter or coal undergoes carbonization and expansion at high temperatures. In petroleum processing, coking is used for the thermal cracking of heavy oils (e.g., vacuum residue, cracked residue, asphalt), generating gas, liquid fuel, and petroleum coke. Main coking types include delayed coking, batch coking, chamber coking, fluid coking, and flexible coking.

Coking plants use coal as raw material to extract gas through high-temperature pyrolysis, while producing saccharides, tar, asphalt, and chemical raw materials. The remaining by-product is coke.

Gas Leak Risks

Coke oven gas mainly consists of methane (CH4), a high-calorific combustible gas:

• Inhalation Risk: Excessive inhalation can lead to respiratory failure and suffocation, potentially fatal.

• Fire and Explosion Risk: The explosion limit of methane is 5%-36%; exposure to flames can trigger fire or explosion, with ignition temperature around 500-600°C.

• Property Damage: High-concentration leaks can damage equipment, pipelines, and production facilities, causing economic losses.

Due to the complex environment and frequent gas leaks, professional monitoring tools are essential for safety in coking plants.

Features of Nexisense SGA-501 Industrial Methane Gas Detector

To address the risks of coke oven gas leaks, Nexisense developed the SGA-501 industrial methane gas detector, providing a reliable solution.

Core Advantages

• Real-time Online Monitoring: Continuously monitors gas concentrations and triggers alerts immediately upon anomalies.

• Audible and Visual Alarm: Automatically triggers alarms above 85dB when limits are exceeded, with customizable three-stage alarm points and one-button mute.

• Signal Transmission: 4-20mA current or RS485 digital output can connect to PLC, DCS, DDC, and other control systems.

• Industrial Explosion-Proof Design: Aluminum alloy housing, durable, compliant with GB50493-2009 standards, certified CPA type-approved and national explosion-proof certification.

• High Accuracy and Stability: Imported chip, 32-bit nano-processor, and 24-bit high-resolution ADC ensure long-term stable data.

  
  

• Multi-language Interface: Supports Simplified Chinese, English, and Traditional Chinese.

• Temperature and Humidity Compensation: Three-point full-scale compensation ensures accurate monitoring.

• Data Management: Large storage capacity, with wired or wireless export/print options for analysis and record-keeping.

Deployment Plan for Gas Safety Monitoring in Coking Plants

• Key Area Placement: Install sensors near coke ovens, gas pipelines, and storage tanks.

• Real-time Data Collection: Transmit data from SGA-501 to DCS or PLC for centralized monitoring.

• Automatic Interlock: Exceeding gas concentration triggers relays to ventilate or shut down equipment to reduce risk.

• Regular Calibration and Maintenance: Modular design reduces maintenance complexity, ensuring long-term monitoring accuracy.

Practical Applications

• Large Coking Plants: Install SGA-501 near coke ovens and gas storage areas to monitor methane concentration in real time and reduce leak risks.

• Small to Medium Coking Plants: Integrate sensors with PLC for centralized monitoring and remote alarm to prevent potential fire or explosion.

• Energy and Chemical Research Labs: Provide accurate methane data for optimizing safety control and production efficiency..

  
  

Technical Principles

• Gas Sampling and Signal Processing: The sensor detects methane concentration, amplifies, filters, and processes signals with smart algorithms.

• Temperature and Humidity Compensation: Full-scale three-point compensation ensures accurate data in varying environments.

• Standardized Output: Analog 0-5V or TTL digital signals directly connect to control systems.

• Alarm and Interlock Control: Audible/visual alarms and relay linkage enable automated safety protection.

FAQ

1. Which gases can the SGA-501 detect? Mainly methane (CH4) and other high-calorific combustible gases.

2. Does the product require frequent calibration? Modular design allows long-term use after one calibration without repeated adjustment.

3. What are the data output options? 4-20mA current or RS485 digital output for PLC, DCS, DDC systems.

4. Applicable scenarios? Coking plants, gas storage, energy chemical plants, industrial safety monitoring.

5. Is the product explosion-proof? Yes, industrial-grade aluminum alloy housing, compliant with GB50493-2009.

6. Is installation complex? Modular design, compact and easy to install in complex environments.

7. Can remote monitoring be implemented? Sensor signals connect to control systems for centralized and remote monitoring.

8. How is the alarm configured? Supports three-stage alarm points; exceeding the limit triggers audible/visual alarms with relay interlock or mute option.

Conclusion

Gas leaks in coking plants are high-risk events affecting personnel and property. Installing the Nexisense SGA-501 industrial methane gas detector enables real-time monitoring, audible/visual alarms, remote data transmission, and automated interlock, significantly reducing gas leak risks. Its high accuracy, stability, and explosion-proof design allow coking plants to balance safety and efficiency while providing reliable gas safety management. Intelligent monitoring and scientific management maximize employee safety and minimize accidents, ensuring a safe and stable production environment.