High-Temperature Gas Detection Solutions: Nexisense Ensures Industrial Safety and Stability

High-temperature environments are ubiquitous in industrial fields, including metallurgical furnaces, chemical reactors, glass melting furnaces, ceramic sintering kilns, waste incinerators, as well as exhaust ducts and chimneys. These processes release hot gases, including combustible gases (methane, hydrogen), ammonia (NH₃), hydrogen sulfide (H₂S), carbon dioxide (CO₂), oxygen (O₂), nitric oxide (NO), chlorine (Cl₂), hydrogen fluoride (HF), hydrogen cyanide (HCN), arsine (AsH₃), toluene diisocyanate (TDI), benzene compounds, acetone, formic acid, and other volatile gases. High temperatures accelerate gas diffusion, reactions, or accumulation, and leaks may cause explosions, corrosion, poisoning, or environmental hazards, threatening personnel safety and equipment integrity.

National standards such as GB/T 15501 "Technical Requirements for Air Quality Monitoring Instruments" and AQ 3053 "Technical Specifications for Gas Detection and Alarm Devices in High-Temperature Workplaces" require specialized detection systems in high-temperature areas for continuous monitoring, early warning, and emergency response. Nexisense provides single- to multiparameter high-temperature detection solutions, helping enterprises establish effective protection in furnace chambers, flue ducts, and exhaust systems to ensure efficient and compliant production.

High-Temperature Gas Risks and Monitoring Challenges

• Temperature interference: Environments of 200–800℃ can cause conventional sensors to fail, drift, or be damaged.

• Complex gas mixtures: Coexistence of multiple gases, e.g., CO₂/O₂/NO in incinerators, HF/HCN/AsH₃ with particulates in chimneys.

• Rapid diffusion: High temperature accelerates gas evaporation and flow, leaving little reaction time.

• Harsh conditions: High dust, humidity, corrosiveness; equipment must resist heat, corrosion, and blockage.

Effective monitoring ensures safety compliance and optimizes processes, such as adjusting O₂/CO₂ for combustion efficiency or detecting H₂S/NO to prevent corrosion. Real-time data reduces downtime, increases energy efficiency, and meets environmental standards.

Selecting High-Temperature Gas Detection Equipment

• Temperature resistance: Sensors/probes withstand 250–800℃ with extended cables or cooled sampling.

• Gas types and ranges: Combustible gases 0–100% LEL; toxic gases like Cl₂/HF/NH₃ 0–10/50 ppm; multiparameter systems cover gases, particulates, temperature, and humidity.

• Sampling method: Remote probe in hot zone, main unit at ambient; pumped sampling with dust removal and cooling.

• Reliability: Original sensors + temp/humidity compensation, explosion-proof Ex d IIC T6 Gb, IP65+.

• Integration: 4-20mA/RS485 Modbus RTU output, wireless transmission, HJ212 protocol for PLC/DCS/environmental platform.

Core Products of Nexisense

SGA-500 Series High-Temperature Gas Detector
Split design, sensor probe withstands 250℃, 80cm extension cable for direct monitoring of combustible gases in hot zones. 24V power, ready-to-use, real-time concentration display, automatic alarm on threshold exceedance. Advantages: suitable for high-temperature furnaces/ovens, response<10s; compatible with controllers or PLC/DCS for integrated systems; high stability and low error for continuous operation.

High-Temperature Sampling Probes and Online Monitoring Systems

SGA-GWTG probes withstand 800℃, with fixed threads and filters, directly mounted in chimneys/exhaust ducts. Sample gas is pumped, dust removed, and cooled before entering the detector chamber. Single-gas monitoring combines probe+pump+detector; multiparameter SGA-900 integrates six gases + PM2.5/PM10 + temperature/humidity, supports data storage, curve display, and wireless transmission to environmental platforms. Features: suitable for flue multiparameter monitoring (NH₃/H₂S/CO₂/NO/Cl₂/HF); built-in pretreatment prevents blockage, ensuring accuracy.

Additional extensions include mini air monitoring stations (for ambient air quality), portable inspection instruments (daily checks), and smart sensor modules (integration development).

Installation and Application Guidelines

• Probe placement: Insert 1/3–2/3 into furnace or duct center, avoid dead zones; secure with threaded mount for sealing.

• Main unit placement: Ambient temperature zone, connected by extension cable.

• Sampling treatment: Pumped with dust removal and cooling modules, prevents condensation/blockage.

• Cabling: Shielded cables to S+/V+/V- terminals; wireless modules for remote points.

• Calibration and maintenance: Regular zero/span calibration using standard gas; check filters.

These guidelines ensure stable system operation at high temperatures with rapid leak response.

Typical Applications

• Metallurgical furnaces: monitor combustible gases/CO₂/O₂ for combustion optimization.

• Chemical reactors: detect NH₃/Cl₂/HF at high temperatures, prevent corrosion and leaks.

• Incinerator chimneys: multiparameter monitoring for HCN/AsH₃/NO, ensuring compliant emissions.

• Glass/ceramic sintering: mini stations evaluate volatile gas diffusion at plant boundaries.

  
  

FAQ

1. Which gases does the SGA-500 high-temperature detector support and maximum temperature? Combustible gases (0–100% LEL), NH₃ (0–100 ppm), H₂S (0–50 ppm), CO₂ (0–5% VOL), O₂ (0–30% VOL), NO (0–100 ppm), Cl₂ (0–20 ppm), HF (0–10 ppm), HCN (0–50 ppm), AsH₃ (0–5 ppm), TDI (0–1 ppm), benzene compounds/acetone/formic acid (0–100 ppm). Probe withstands 250℃.

2. How to install high-temperature sampling probes in chimneys/exhaust ducts? Temperature requirements? SGA-GWTG probe withstands 800℃, installed via threaded mount into 1/3–2/3 duct center, with filter; sample gas pumped, cooled, dust removed before entering chamber; flow >5 m/s recommended; professional survey ensures sealing.

3. How does the system meet environmental networking and data transmission requirements? Supports HJ212 protocol, minute-level upload of concentration, converted values, and operational parameters (T/P/flow) to environmental platform; RS485 Modbus RTU/4-20mA output; optional LoRa/4G wireless for remote monitoring.

4. Sensor lifespan in high-temperature environments and calibration period? IR/catalytic sensors 3–5 years, electrochemical 2–3 years; built-in lifespan prediction; functional check every 6 months, zero/span calibration every 12 months; pre-cooling extends lifespan; self-diagnosis alerts maintenance.

5. How is the split design applied in high-temperature furnaces? Installation tips? Probe inserted into furnace (250℃), main unit outside, connected by 80 cm extension; select uniform airflow zone, avoid vibration/dust; shielded cables; clean probe regularly for response<10s.

6. How does the SGA-900 online system handle multiparameter high-temperature gases? Integrates six gases + PM2.5/PM10 + T/H, pumped via probe, multistage pretreatment (dust/humidity/cooling) into module; curve display, storage; controller linkage for ventilation/valve shutdown on exceedance; wireless for remote chimneys.

7. Special design for highly toxic gases (AsH₃/HCN) in high temperature? Corrosion-resistant probe/piping (PTFE/Hastelloy), electrochemical sensors (0–5/50 ppm, response<60s), enhanced pretreatment for humidity/corrosion, graded alarms for micro-leak detection.

8. How to obtain product selection manuals, case studies, or quotations? Submit high-temperature parameters (T/gas types/points) and process description; team responds within 24h. Provide manuals (temperature charts, explosion certificates, installation drawings), typical cases, 3D models; standard products 1–3 workdays, multiparameter custom systems 5–10 workdays.

Conclusion: Nexisense Empowers Safety in High-Temperature Environments

High-temperature gas monitoring is critical for industrial safety. Nexisense provides heat-resistant probes, high-precision sensors, and multiparameter systems to deliver reliable, stable detection in furnaces and chimneys. Monitoring combustible and toxic volatile gases helps enterprises prevent risks and optimize operations. Contact Nexisense for customized solutions, on-site surveys, and technical support. Industrial efficiency starts with safety monitoring.