Case of Online Monitoring of Carbon Monoxide in Kilns of Building Materials Enterprises: Upgrading Safety Production from Numerous Hidden Dangers to Intelligent Control

Release time:2025-11-05

Source:A real case of skyeaglee

A chemical enterprise generates waste gas containing volatile organic compounds (VOCs) during production, which needs to be discharged through a chimney pipeline. In order to grasp the concentration of VOCs in the waste gas in real time and ensure that the emission meets environmental protection standards, the enterprise has installed an online gas pretreatment device.

The sampling probe of the device goes deep into the chimney pipeline to collect the waste gas. After the gas is subjected to dust removal, dehumidification and other treatments by the pretreatment system, it is transmitted to the monitoring instrument. The staff can intuitively see the VOCs concentration value through the instrument screen. For example, a certain monitoring showed that the concentration was 4.4 ppm, which was within the normal emission range. The application of this device enables the enterprise to realize the real-time monitoring of waste gas emission, helps it meet environmental protection requirements, and also provides reliable data support for the supervision of environmental protection departments.

 

 

Case Background: "Safety Blind Spots" and "Efficiency Bottlenecks" in Kiln Production

The enterprise's core production line consists of two large building materials kilns. Carbon monoxide is continuously generated during fuel combustion and process reactions. Previously, the enterprise managed CO concentration through manual regular inspection + offline detection:
  • In terms of safety, data lagged by several hours. In case of a sudden concentration increase, on-site personnel could hardly evacuate in time. There were multiple equipment failures triggered by excessive CO concentration, and even near-miss safety accidents.
  • In terms of production, it was impossible to grasp the real-time relationship between concentration changes and combustion efficiency. Process adjustments could only be made based on experience, resulting in fuel waste and large fluctuations in product quality.

 

Breaking the Dilemma: Precision Attack with Customized Online Monitoring System

Aiming at the complex working conditions of high temperature, high humidity, and heavy dust in the kiln, we have created a full-process online gas pretreatment monitoring system for it, solving CO monitoring problems in the entire link from "sampling - purification - detection - early warning".
 

Step 1: Purification Journey of "Dirty Sample Gas" from Flue to Gas Path

The sample gas in the kiln flue is mixed with dust and water vapor, which will seriously interfere with data if detected directly. After the sample gas is extracted from the flue by the sampling pump, it first passes through a precision filter to intercept dust. Then, through a dual-stage electronic condensation dehumidification system, the dew point of the gas is stably controlled at 4°C, completely eliminating the impact of high humidity. Finally, the gas-water separator + exhaust (water) pump automatically drains free water and residual impurities, allowing "clean" sample gas to enter the detection link.
 

Step 2: Real-time Sentinel in Hazardous Areas

In the explosion-proof area next to the kiln, we installed an explosion-proof gas detector. It has passed EU CE and ROHS certifications and can work stably in hazardous areas Zone 1 and Zone 2. It displays CO concentration in real time and transmits data to the central control room simultaneously with 4~20mA analog signals and RS485 digital signals. Once the concentration approaches the safety threshold, the instrument immediately triggers an audible and visual alarm and sends a linkage warning signal to the central control room.

Step 3: Data-Driven "Process Optimization"

The flowmeter supporting the system precisely controls the gas intake of the sample gas, ensuring the stability and reliability of detection data. These real-time data are not only the guardian of the "safety red line" but also the "optimization guide" for the production process. By analyzing the relationship between CO concentration changes and combustion parameters, the enterprise can precisely adjust fuel supply, achieving an 8% reduction in fuel consumption and a 5% improvement in product qualification rate.

Results: Two-Way Pursuit of Safety and Production

  • Safety Dimension: From "post-event traceability" to "pre-event early warning", no safety accidents caused by abnormal CO concentration have occurred since the system was put into use, and the sense of security of on-site personnel has been significantly improved.
  • Production Dimension: From "experience-based exploration" to "data-driven decision-making", the efficiency of process adjustment has increased by more than 30%, and both energy consumption costs and product defect rates have decreased.
  • Management Dimension: The historical data reports generated by the system provide a quantitative basis for equipment operation and maintenance and process iteration, promoting the transformation of enterprise management to "intelligent and refined".

A chemical enterprise generates waste gas containing volatile organic compounds (VOCs) during production, which needs to be discharged through a chimney pipeline. In order to grasp the concentration of VOCs in the waste gas in real time and ensure that the emission meets environmental protection standards, the enterprise has installed an online gas pretreatment device.

The sampling probe of the device goes deep into the chimney pipeline to collect the waste gas. After the gas is subjected to dust removal, dehumidification and other treatments by the pretreatment system, it is transmitted to the monitoring instrument. The staff can intuitively see the VOCs concentration value through the instrument screen. For example, a certain monitoring showed that the concentration was 4.4 ppm, which was within the normal emission range. The application of this device enables the enterprise to realize the real-time monitoring of waste gas emission, helps it meet environmental protection requirements, and also provides reliable data support for the supervision of environmental protection departments.

 

 

Case Background: "Safety Blind Spots" and "Efficiency Bottlenecks" in Kiln Production

The enterprise's core production line consists of two large building materials kilns. Carbon monoxide is continuously generated during fuel combustion and process reactions. Previously, the enterprise managed CO concentration through manual regular inspection + offline detection:
  • In terms of safety, data lagged by several hours. In case of a sudden concentration increase, on-site personnel could hardly evacuate in time. There were multiple equipment failures triggered by excessive CO concentration, and even near-miss safety accidents.
  • In terms of production, it was impossible to grasp the real-time relationship between concentration changes and combustion efficiency. Process adjustments could only be made based on experience, resulting in fuel waste and large fluctuations in product quality.

 

Breaking the Dilemma: Precision Attack with Customized Online Monitoring System

Aiming at the complex working conditions of high temperature, high humidity, and heavy dust in the kiln, we have created a full-process online gas pretreatment monitoring system for it, solving CO monitoring problems in the entire link from "sampling - purification - detection - early warning".
 

Step 1: Purification Journey of "Dirty Sample Gas" from Flue to Gas Path

The sample gas in the kiln flue is mixed with dust and water vapor, which will seriously interfere with data if detected directly. After the sample gas is extracted from the flue by the sampling pump, it first passes through a precision filter to intercept dust. Then, through a dual-stage electronic condensation dehumidification system, the dew point of the gas is stably controlled at 4°C, completely eliminating the impact of high humidity. Finally, the gas-water separator + exhaust (water) pump automatically drains free water and residual impurities, allowing "clean" sample gas to enter the detection link.
 

Step 2: Real-time Sentinel in Hazardous Areas

In the explosion-proof area next to the kiln, we installed an explosion-proof gas detector. It has passed EU CE and ROHS certifications and can work stably in hazardous areas Zone 1 and Zone 2. It displays CO concentration in real time and transmits data to the central control room simultaneously with 4~20mA analog signals and RS485 digital signals. Once the concentration approaches the safety threshold, the instrument immediately triggers an audible and visual alarm and sends a linkage warning signal to the central control room.

Step 3: Data-Driven "Process Optimization"

The flowmeter supporting the system precisely controls the gas intake of the sample gas, ensuring the stability and reliability of detection data. These real-time data are not only the guardian of the "safety red line" but also the "optimization guide" for the production process. By analyzing the relationship between CO concentration changes and combustion parameters, the enterprise can precisely adjust fuel supply, achieving an 8% reduction in fuel consumption and a 5% improvement in product qualification rate.

Results: Two-Way Pursuit of Safety and Production

  • Safety Dimension: From "post-event traceability" to "pre-event early warning", no safety accidents caused by abnormal CO concentration have occurred since the system was put into use, and the sense of security of on-site personnel has been significantly improved.
  • Production Dimension: From "experience-based exploration" to "data-driven decision-making", the efficiency of process adjustment has increased by more than 30%, and both energy consumption costs and product defect rates have decreased.
  • Management Dimension: The historical data reports generated by the system provide a quantitative basis for equipment operation and maintenance and process iteration, promoting the transformation of enterprise management to "intelligent and refined".