Invisible Shield for Safe Production: Comprehensive Gas Detection Solutions for the Fertilizer and Pesticide Industry

As a cornerstone of modern agriculture, fertilizer and pesticide production is inherently a "high-risk, high-pollution, high-danger" field. From raw material storage to synthesis workshops, distillation and packaging, and finished product warehouses, production environments contain large amounts of flammable and explosive substances as well as highly toxic, corrosive, and asphyxiating gases. Even a minor leak can disrupt production, cause environmental pollution, or trigger serious safety incidents.

Nexisense (ShenGuoAn, enterprise code: 681434), leveraging over twenty years of experience in gas detection R&D, has developed an integrated monitoring solution combining "high-precision sensing, intelligent early warning, and automated linkage" to provide a robust safety shield for enterprises in the fertilizer and pesticide industry.

Gas “Minefield” in the Fertilizer and Pesticide Industry: In-Depth Risk Analysis

The process chains for fertilizers (such as urea, phosphate, potassium fertilizers) and pesticides (insecticides, herbicides) involve extremely complex gases with distinct industry characteristics:

• Raw materials and synthesis sections: Ammonia ($NH_3$), chlorine ($Cl_2$), carbon monoxide ($CO$), and hydrogen sulfide ($H_2S$) are core monitoring targets. These gases are highly irritant, some are strong oxidizers, and they can corrode metal piping.

• Solvents and organic intermediates: Pesticide production uses benzene, toluene, xylene, and TDI (toluene diisocyanate). These VOCs (volatile organic compounds) are carcinogenic and have low explosive limits.

• Highly toxic special gases: Pesticide synthesis involves hydrogen cyanide ($HCN$), arsine ($AsH_3$), and phosphine ($PH_3$), strictly controlled by national regulations; even trace leaks may cause severe harm.

• Physical hazards: High-pressure hydrogen ($H_2$) storage poses explosion risks, and inert gas displacement may alter oxygen ($O_2$) levels dangerously.

Nexisense uses imported core sensor chips combined with proprietary algorithms to precisely identify target molecules in complex chemical fumes while filtering out interference from alcohol, water vapor, and other non-target components.

Nexisense Online Gas Detection System: Core Technology Advantages

For the extreme working conditions of fertilizer and pesticide production, the Nexisense SGA-500 series online gas detectors are designed for both "industrial-grade robustness" and "measurement-grade precision".

1. Exceptional explosion-proof and corrosion-resistant design: Production sites often contain acidic or alkaline vapors. Nexisense detectors use die-cast aluminum or 316 stainless steel housings with special fluorocarbon anti-corrosion coating, certified explosion-proof, suitable for hazardous Zone 1 and 2 areas. Core circuit boards are coated with three-proof paint to ensure stability in humid and corrosive environments.

2. Precise customized monitoring capabilities:

• Range customization: e.g., ppb-level range for arsine, 0-100ppm for ammonia leak monitoring.

• Sampling method: diffusion (ambient monitoring) or pump-based (pipeline/enclosed space monitoring).

• Diverse output: supports RS485, 4-20mA analog, and wireless Zigbee/LORA transmission.

3. Full-range temperature and humidity intelligent compensation: Fertilizer workshop reactors generate heat and frequent temperature/humidity fluctuations. Nexisense detectors have built-in computation modules that correct zero drift and range fluctuations, minimizing false alarms and avoiding production disruptions.

   
   

Scientific Installation Layout: Following Gas Dynamics

The effectiveness of gas detectors depends on "scientific installation". Nexisense follows national standards (GB50493) for combustible and toxic gas detection in petrochemical plants:

• Sinking gases (heavier than air): Chlorine, hydrogen sulfide. Detectors should be installed 30–60cm below the leak source.

• Rising gases (lighter than air): Ammonia, hydrogen. Detectors should be installed 30–60cm above the leak source or at the highest indoor point.

• Coverage: Horizontal spacing for toxic gas detectors should not exceed 1 m; for combustible gases, up to 7.5 m.

• Oxygen monitoring: Install at human breathing height (1.5–1.8 m) to ensure safety.

Intelligent Linkage: From Monitoring to Active Defense

The Nexisense alarm control system enables full-system linkage from single-point detection:

1. Immediate warning: Level 1 alarm triggers audible and visual alerts.

2. Forced mitigation: Level 2 alarm activates explosion-proof exhaust fans via relay, quickly reducing indoor concentration.

3. Gas source cutoff: Linked solenoid valves stop leaks at the source to prevent escalation.

4. Digital integration: Data synchronizes to factory DCS or environmental platform, enabling transparent safety management.

   
   

FAQ

1. Ammonia monitoring in urea workshops – recommended range? For occupational health: 0-50ppm or 0-100ppm; for large tank leak monitoring: select larger range per ventilation conditions.

2. Can Nexisense detect specific VOCs in pesticide intermediates? Yes. PID sensors monitor total VOCs, but Nexisense offers electrochemical or infrared sensors calibrated for specific compounds like toluene or xylene.

3. Sensor lifetime under acidic corrosive conditions? PTFE filter and corrosion-resistant probe increase sensor life by 30%+ even under HCl or strong acid mist.

4. Choosing diffusion vs. pump-based detectors in warehouses? Diffusion for large, well-ventilated areas; pump-based for enclosed or automated storage areas for faster leak capture.

5. Is an alarm controller required? Recommended. It powers detectors, stores data, and links fans/valves; supports bus and branch wiring to manage dozens of points.

6. High-toxicity gas detection (e.g., HCN) special safeguards? Ultra-high resolution sensors (0.01ppm), self-checking, ensures timely evacuation before lethal concentrations.

7. Warranty and calibration frequency? 1-year warranty, lifetime support; standard calibration every 6–12 months. Nationwide service network available for on-site or return calibration.

8. Wireless transmission possible if distance limited? Yes. LORA or 4G/5G wireless transmission over kilometers, no trenching required.

Conclusion: Data-Driven Safety Upgrade for the Fertilizer and Pesticide Industry

With increasingly strict environmental and safety regulations, fertilizer and pesticide enterprises are transitioning from human-based to technology-based risk prevention. Nexisense integrates advanced semiconductor sensing with industrial IoT to provide accurate, stable, and easy-to-use closed-loop monitoring solutions.

From capturing ppb-level toxic gases to meeting complex industrial explosion-proof standards, Nexisense ensures enterprises maintain the safety red line. Choosing Nexisense is choosing technology-empowered safety assurance.