High-Temperature Industrial Source Online Monitoring System

In industrial production, high-temperature processes such as furnaces, ovens, flue gas pipelines, and boilers are indispensable. These environments often involve high-temperature gas emissions, many of which are flammable, explosive, or toxic. Without effective monitoring, they can cause fires, explosions, environmental pollution, and health hazards. With increasingly strict environmental regulations, enterprises urgently need reliable online monitoring technology to manage these risks. Nexisense's high-temperature industrial source online monitoring system provides a comprehensive solution for real-time gas detection, automatic alarms, and data compliance management.

Gas Risks and the Necessity of Monitoring in High-Temperature Environments

High-temperature industrial processes often exceed several hundred degrees Celsius. Typical hazardous gases include methane, propane, and other combustible hydrocarbons, as well as toxic gases such as carbon monoxide, hydrogen sulfide, and nitrogen oxides. At high temperatures, these gases become less stable, more reactive, and easier to reach the lower explosive limit (LEL).

For example, combustible gases escaping from high-temperature steel furnaces may cause flash fires, and residual hydrogen sulfide in boiler flue gas pipelines poses corrosion and health risks. Reports indicate that high-temperature gas-related accidents account for a significant portion of industrial safety incidents. Implementing online monitoring allows early intervention when abnormal concentrations occur, preventing minor risks from escalating into major disasters.

Nexisense emphasizes preventive monitoring through high-temperature-resistant design, ensuring stable operation under extreme conditions while supporting multi-gas parameter monitoring, covering the full spectrum from combustible gas warnings to pollution source emissions.

Nexisense SGA-500 Series High-Temperature Combustible Gas Detectors

For common combustible gases in high-temperature furnaces and ovens, the SGA-500 series is the preferred solution. Equipped with high-temperature extension lines, it withstands up to 250℃, allowing direct sampling near heat sources without additional cooling.

The detector uses imported high-precision sensors, supports diffusion or pump sampling, and provides fast and accurate response. When concentrations exceed preset alarm thresholds (e.g., 20% LEL warning, 50% LEL alarm), it immediately triggers audible and visual alarms and can activate ventilation or cut off fuel supply. This instant response is crucial for continuous high-temperature production lines, effectively reducing explosion risks.

Additionally, the SGA-500 supports 4-20mA and RS485 outputs for PLC or DCS integration, enabling remote monitoring. Many steel and chemical plants report reduced high-temperature inspection frequency and improved operational efficiency after deploying this system.

High-Temperature Probe Rods in Flue Gas and Boiler Monitoring

Not all high-temperature monitoring is limited to combustible gases. Flue gas pipelines and boilers often require monitoring of multiple pollutants such as SO₂, NOx, and CO. Nexisense high-temperature probes withstand up to 800℃, allowing direct sampling from hot flues or furnace chambers without compromising sensor accuracy.

The probes use special alloys and insulation to prevent condensation or reaction losses during transmission. For single-gas monitoring, they can be paired with the SGA-500 series; for multi-parameter monitoring, they integrate into online pollution source systems to measure temperature, pressure, flow, and gas composition simultaneously.

Probes are often installed at chimney inlets or boiler outlets, ensuring representative data, helping enterprises comply with standards like HJ/T 75, and avoiding over-limit emissions fines.

Integration and Expansion of Online Pollution Monitoring Systems

The Nexisense system is an upgraded solution, capable of handling multiple gas parameters. Using high-temperature probes for sampling and multi-channel analysis modules, it supports VOCs, acidic gases, heavy metal vapors, and complex components.

The system is flexible: a basic version monitors a single boiler, while an extended version covers entire plant emissions. Data can be transmitted wirelessly or wired in real-time to environmental platforms or control rooms, enabling hourly and daily averages and trend analysis.

Built-in intelligent algorithms predict anomalies based on historical data, such as pipe blockage or incomplete combustion, supporting process optimization and energy efficiency improvements.

Accessories for High-Humidity and High-Dust Environments

High temperatures often come with high humidity (steam condensation) and dust (particle deposition), which can affect sampling accuracy. Nexisense provides specialized accessories:

• High humidity: Efficient dust filters combined with drying tubes, supporting direct sampling up to 99% RH. Tubes quickly remove moisture to prevent sensor condensation.

• High dust: Dual dust filters remove particles above 1μm. Dual-layer design extends filter life and reduces maintenance frequency.

Accessories are modular and customizable. For example, high-humidity accessories are critical after wet desulfurization, while high-dust filters are essential at pulverized coal boiler outlets. These designs ensure long-term reliability under harsh conditions.

Practical Benefits of Implementing Nexisense Systems

• Enhanced safety: real-time warnings reduce high-temperature gas hazards, ensuring safer work in hot zones.

• Environmental compliance: accurate emission data prevent penalties and support emission trading.

• Operational optimization: data-driven adjustments to fuel and ventilation reduce energy consumption.

• Case study: a large chemical plant reduced annual over-limit emissions to zero and saved over 20% in maintenance costs. Remote diagnostics and auto-calibration minimize on-site interventions.

  
  

Frequently Asked Questions (FAQ)

1. How does the high-temperature probe withstand 800℃? Integrated cooling channels and insulation gradually reduce gas temperature to sensor-safe levels (<50℃) while preserving sample integrity and avoiding condensation loss.

2. Which combustible gases does SGA-500 detect? Methane, ethane, propane, butane, hydrogen, alcohols, customizable per process gas; range from 0-100% LEL to specific ppm.

3. How does the system handle multi-gas simultaneous monitoring? Multi-channel design with independent sensors per channel, parallel monitoring of NOx, SO₂, CO, O₂, ensuring synchronized data.

4. Drying tube lifespan in high humidity? Typically replaced every 3-6 months depending on humidity and flow. Spare tubes recommended; system self-checks drying efficiency.

5. How is data uploaded to environmental platforms? Supports HJ 212 or custom interfaces, real-time encrypted upload to local environmental bureaus, with local backup for audit and historical queries.

6. Maintenance of dual dust filters in high-dust areas? Check outer filter weekly; replace inner filter quarterly. Optional pressure sensors alert for clogging.

7. Impact on boiler efficiency? Monitoring O₂ and CO allows calculation of excess air ratio, guiding combustion adjustments, improving thermal efficiency by 5%-10%.

8. Does installation require shutdown? Usually can be done online during scheduled maintenance; professional team ensures minimal disruption.

Conclusion

The high-temperature industrial source online monitoring system is essential for safety and environmental management in industrial hot zones. Nexisense provides SGA-500 detectors, 800℃ probes, multi-parameter systems, and high-humidity/dust accessories, covering the full chain from sampling to analysis, warning, and linkage. These technologies protect production lines while supporting green transformation and cost control. Enterprises are encouraged to evaluate site conditions and implement professional monitoring solutions to support sustainable development.