Forging Safety: End-to-End Gas Monitoring Solutions for Precious and Rare Metals

Precious metals (gold, silver, platinum, palladium) and rare metals (tungsten, molybdenum, antimony, rare earths) are the "vitamins" of modern industry, with soaring demand in semiconductors, aerospace, and new energy sectors. However, extraction, refining, and chemical experimentation often involve highly toxic, corrosive, and flammable gases.

These gases are deadly to workers and can irreversibly damage expensive metal surfaces and precision smelting equipment. Nexisense, with years of experience serving major metallurgical enterprises like Jiangxi Copper and Luoyang Molybdenum, provides a closed-loop gas safety monitoring solution from "mine entrance" to "finished product warehouse".

Threefold Risk Analysis in Precious and Rare Metals Industries

1. Highly Toxic and Corrosive Gases

• Personnel hazard: HF penetrates deeply, causing severe respiratory burns at low concentrations; Cl2 and Br2 cause strong asphyxiation.

• Asset corrosion: These acidic gases form strong acid mist with water, corroding precious metal surfaces, reducing luster and purity, causing significant economic loss.

2. Flammable Gas Threats

• During metal powder drying, hydrogen reduction, or solvent extraction, H2 or flammable vapors can accumulate in enclosed areas. Even a small static spark may trigger catastrophic explosions.

3. Oxygen Deficiency and Toxic Byproducts

• During mining or underground storage, fluctuations of SO2, CO, and O2 directly affect worker occupational health.

Nexisense Professional Product Matrix for Extreme Metallurgical Environments

SGA-500: Industrial Corrosion-Resistant Online Detector

• Explosion-proof die-cast aluminum housing, compliant with Zone 1 and Zone 2 hazardous area standards.

• Corrosion-optimized probes: custom polymer or 316L stainless steel with coating for HF, Cl2, Br2; extends sensor life in acidic mist.

• Imported sensor core for ppm and ppb-level rapid response to toxic gas leaks.

  
  

SGA-600: Portable Gas Detector

• Multiple sampling modes: diffusion, pump, and probe. Ensures air safety before entering electrolytic tanks or deep storage.

• Durable IP66 design suitable for outdoor mining and smelting workshops.

SGA-800 & SGA-900: Alarm Controller and Preprocessing System

• SGA-900 preconditions high-temperature, high-humidity, dusty samples for accurate sensor measurement and extended sensor life.

• One-button alarm integration: triggers sprays, ventilation, and emergency valve shutdown upon threshold exceedance via SGA-800.

Digital Transformation: From Monitoring to Intelligent Management

• RS485 (Modbus RTU) or 4-20mA signals integrate monitoring points into ERP or smart mining platforms.

• Asset protection: acid mist filtration activates automatically to protect finished metals.

• Occupational health tracking: digital logs of employee exposure to toxic gases.

• Safety alert tiers: micro-leak pre-warning, forced ventilation, and full evacuation.

Why Leading Metallurgical Companies Choose Nexisense

• Industry expertise: proven in top enterprises like Qinhuangdao Aluminum, Shaanxi Zinc, Jiangxi Copper.

• One-stop service: from SGA-100 modules to preprocessed systems, full-stack solutions.

• Anti-interference: selective sensors for complex metallurgical gases, minimizing false alarms.

  
  

FAQ (Frequently Asked Questions)

Q1: Why is HF detection the most challenging in precious metals?
A1: HF is highly reactive and adsorptive. Standard sensor membranes and inlets are easily corroded. Nexisense uses special anti-corrosion coatings and polished stainless steel airways to reduce HF adsorption and ensure real-time accuracy.

Q2: Is it necessary to install gas detectors in finished metal warehouses?
A2: Yes. Cl2, SO2, or acid mist can damage gold/silver surfaces. High-sensitivity SGA-500 detectors protect valuable assets by monitoring air quality.

Q3: How to integrate Nexisense devices with existing smart mining systems?
A3: Standard RS485 Modbus RTU interfaces connect seamlessly to PLC, DCS, or SCADA. Wireless options (LoRa/4G) available for remote points.

Q4: Why choose SGA-900 preprocessing in metallurgical environments?
A4: High temperature and dust in smelting can block or damage sensors. SGA-900 cools, filters, and dries sample gas, creating a "lab-level" stable environment and reducing maintenance costs.

Q5: For gases that are both toxic and flammable, which range should be prioritized?
A5: Toxic detection takes priority as occupational exposure limits (ppm) are far below explosive limits (%LEL). Dual-range technology ensures both explosion safety and micro-leak detection.

Q6: Where is probe sampling of SGA-600 mainly used?
A6: Detecting gaps, flanges, deep mines, or extraction tanks without approaching leaks, ensuring precise explosion and toxicity monitoring.

Q7: What is the OEM advantage of SGA-700 sensor modules?
A7: Embedded directly in equipment with preloaded calibration data and standardized output, plug-and-play replacement like a USB drive, simplifying maintenance.

Q8: How to choose protection grade in acid-leaching processes in zinc/copper operations?
A8: Use IP66+ devices with Nexisense anti-corrosion probe covers to avoid acid damage to sensors.

Conclusion

Precious and rare metals are critical to the economy; production safety and asset protection are equally important. Nexisense provides industrial-grade precision solutions for toxic and corrosive gases, from labs to extreme smelting conditions, offering one-stop gas detection for safe and sustainable metallurgical operations.