Online Monitor

1. Product Overview

 

The industrial online gas monitor is a complete set of 24/7 uninterrupted continuous online gas concentration monitoring equipment developed for industrial waste gas emission and hazardous gas leakage working conditions. It integrates sampling pretreatment unit, core analysis host, intelligent data transmission and alarm linkage modules, suitable for various harsh working conditions such as chemical industry, environmental protection, lithium battery, pharmaceutical, coating and sewage treatment.

 

Equipped with multiple mature detection sensor technologies, it can accurately quantitatively detect flammable gas, toxic and harmful gas, VOC organic waste gas, boiler flue gas components, acid waste gas and other media. The integrated stainless steel cabinet is dust-proof, waterproof, corrosion-resistant and optional explosion-proof, which can operate stably for a long time in high-temperature, high-humidity, dusty, acid-alkali steam and flammable & explosive high-risk workshops.

 

The instrument collects real-time gas concentration data and automatically triggers local sound and light alarms when the measured value exceeds the limit. It transmits data to factory PLC central control system, environmental online monitoring platform and DCS control system through 4-20mA analog signal and RS485 digital communication, realizing online supervision of waste gas emission and real-time early warning of hazardous chemical leakage. It helps enterprises meet the acceptance standards of environmental online monitoring and safety production supervision, and control risks such as poisoning, explosion and environmental penalties caused by excessive waste gas and gas leakage from the source.

 

2. Core Composition & Structural Description

 

The complete online gas monitoring system is integrated into a stainless steel protective cabinet, divided into three core units:

 

2.1 Sample Pretreatment Unit

 

The integrated sampling pretreatment module (top probe assembly in the picture) is matched on the top of the equipment, including sampling filtration, condensation dehydration, dust interception, voltage stabilization and heat tracing pipeline components.

 

- Automatically filter dust, oil and water vapor in flue gas and process gas to avoid impurities entering the core analysis unit and damaging sensors;

- Optional heat tracing anti-condensation pipeline for high-temperature flue gas working conditions to prevent water-soluble gas from dissolving in condensed water and causing distorted detection data;

- Pressure stabilizing buffer structure stabilizes inlet gas flow to ensure constant gas velocity entering the analyzer and consistent stable detection values.

 

2.2 Analysis Main Unit (Core Detection Cabinet)

 

The whole machine is a closed cabinet made of thickened stainless steel with a visible observation window on the front, built-in core sensors, main control circuit board, operation display screen and alarm driving module:

 

1. Optional Multi-Technology Detection Sensors

Five mainstream detection technologies can be selected according to measured gas: electrochemical sensor, catalytic combustion sensor, NDIR infrared spectrum detection, TDLAS laser tunable diode absorption spectrum, PID photoionization detection.

- Electrochemistry: Accurate detection of trace toxic gases such as ammonia, hydrogen sulfide, carbon monoxide, chlorine and ozone;

- Catalytic combustion: Detection of lower explosion limit of flammable gases such as methane, ethanol, acetone and liquefied gas;

- Infrared/TDLAS laser: Anti-interference against water vapor and dust, high-precision detection of flue gas components such as CO, CO₂, NOₓ and SO₂, suitable for high-temperature and high-humidity flue gas;

- PID photoionization: Low-range accurate detection of VOC volatile organic waste gas, suitable for coating, printing and lithium battery workshops.

2. Intelligent Operation & Display Panel

The liquid crystal display screen is built in the cabinet viewing window, which displays real-time gas concentration, equipment operating status, temperature & humidity, fault codes and historical alarm records synchronously. It supports local key calibration, custom alarm threshold, zero point and range calibration operation.

3. Local Sound & Light Alarm Module

Built-in alarm drive circuit will automatically trigger sound and light alarm when concentration exceeds limit or equipment fails, reminding staff to dispose of leakage or excessive waste gas on site quickly.

 

2.3 Data Transmission Communication Module

 

Dual standard industrial signal output interfaces are integrated, which can connect to factory automation system without additional conversion equipment:

 

1. 4-20mA analog signal: Linearly corresponding to gas concentration, directly connected to PLC and DCS control cabinet;

2. RS485 Modbus-RTU digital bus: Long-distance transmission of concentration, equipment status and fault data, docking with environmental online moDual standard industrial signal output interfaces are integrated, which can connect to factory automation system without additional conversion equipment:

 

1. 4-20mA analog signal: Linearly corresponding to gas concentration, directly connected to PLC and DCS control cabinet;

2. RS485 Modbus-RTU digital bus: Long-distance transmission of concentration, equipment status and fault data, docking with environmental online monitoring platform and upper computer monitoring system, supporting remote data access and parameter modification.

 

3. Core Working Principle

 

1. Gas Sampling & Pretreatment

The measured gas in process pipelines, reactors and waste gas chimneys is sucked into the pretreatment unit through sampling pipelines to complete dust removal, dehydration, voltage stabilization and cooling treatment. After filtering impurities, clean, constant temperature and constant pressure standard gas to be measured is output.

2. High-Precision Concentration Analysis

Clean gas enters the core analysis chamber. The corresponding sensor converts gas concentration into standard electrical signals according to photoelectric/electrochemical reaction characteristics of gas molecules. The main control chip calculates in real time and the LCD screen synchronously displays accurate values.

3. Over-Limit Alarm Judgment

Two levels of high/low alarm thresholds can be customized in the system, which compare the measured concentration with the set threshold in real time. Sound and light alarm will be activated immediately once concentration exceeds the limit.

4. Remote Data Upload & Linkage

Real-time concentration data is output outward through 4-20mA and RS485 synchronously. The central control system can link waste gas treatment equipment, exhaust fans and emergency shut-off valves according to monitoring values to realize automatic control.

5. Automatic Equipment Self-Diagnosis

The whole machine is equipped with real-time self-check program, which automatically monitors intake flow, sensor loss, power supply and communication status. It actively reports fault codes when blockage, sensor failure or circuit interruption occurs, avoiding safety blind spots caused by monitoring failure.

 

4. Core Product Advantages

 

4.1 Compatible with Multiple Detection Technologies, Covering All Types of Gas Detection Requirements

 

The sensor module can be replaced flexibly on one equipment, covering detection of flammable gas, toxic inorganic gas, VOC organic waste gas, boiler flue gas NOₓ/SO₂/CO and other media. One set of equipment meets two major demands: safety production leakage monitoring and environmental waste gas emission online monitoring, reducing equipment procurement cost.

 

4.2 Integrated Pretreatment System, Adapted to Harsh Industrial Working Conditions

 

Standard complete dust removal and dehydration pretreatment module can be directly connected to waste gas pipelines with high temperature, high humidity, much dust and oil steam, avoiding water vapor and dust corroding core sensors, greatly extending instrument service life and reducing frequent maintenance and sensor replacement frequency.

 

4.3 24/7 Continuous Unattended Online Monitoring

 

The whole machine supports uninterrupted stable operation all year round without manual inspection. It has built-in automatic fault reminder and data storage function, which can retain historical concentration and alarm records to meet the traceability requirements of environmental supervision data.

 

4.4 Dual-Route Industrial Standard Signal Output, Adapted to Automated Factories

 

Equipped with both 4-20mA analog quantity and RS485 digital communication, compatible with most industrial PLC, DCS and environmental online monitoring platforms, supporting remote data monitoring and equipment linkage control, perfectly matching modern intelligent chemical and environmental protection production lines.

 

4.5 Stainless Steel Anti-Corrosion Whole Machine, Optional Explosion-Proof Custom Version

 

The main cabinet of the equipment is made of 304 stainless steel, acid & alkali resistant, anti-corrosion, dust-proof and waterproof. Explosion-proof complete machine can be customized for flammable and explosive workshops, suitable for Zone 1 and Zone 2 explosion-proof hazardous areas such as chemical industry, lithium battery and hazardous chemical warehouses.

 

4.6 High Detection Precision & Strong Anti-Interference Ability

 

Infrared and TDLAS laser detection technologies are free from cross-interference of water vapor, dust and coexisting gases. Stable and accurate measurement can be realized for trace leakage of low concentration and low emission waste gas, with small data drift and no frequent calibration required for long-term use, bringing simple operation and maintenance.

 

4.7 Meet Dual Acceptance Standards of Environmental Protection & Safety Supervision

 

The detection data of the equipment can be directly uploaded to the government environmental online monitoring platform, with complete detection and calibration reports and full supporting qualification documents, smoothly passing the acceptance of pollutant discharge permit online monitoring and enterprise safety production fire inspection.

 

5. Main Application Industries & Monitoring Scenarios

 

1. Chemical Manufacturing Industry

Fine chemical reactors, organic solvent tank farms, waste gas collection pipelines and hazardous chemical warehouses, monitoring leakage of methanol, toluene, hydrogen sulfide, ammonia, flammable solvents and process tail gas emission.

2. Environmental Protection Waste Gas Treatment Industry

Boiler flue gas, outlet of RCO/RTO catalytic combustion equipment, sewage station waste gas, waste incineration tail gas, detecting emission indicators such as SO₂, NOₓ, CO, VOC and hydrogen sulfide to meet online monitoring requirements of pollutant discharge.

3. New Energy Lithium Battery Industry

Coating, liquid injection and formation workshops, electrolyte warehouses, monitoring VOC volatilization of NMP and organic solvents. Explosion-proof models are applicable to high-risk lithium battery production environments.

4. Pharmaceutical & Biotech Manufacturing Industry

API synthesis workshops, extraction sections and fermentation waste gas pipelines, monitoring volatile toxic organic gases such as ethanol and formaldehyde.

5. Coating, Printing & Furniture Industry

Spray booths, ink blending workshops and baking room waste gas outlets, real-time monitoring of VOC concentration to control operating efficiency of waste gas treatment equipment.

6. Petroleum & Gas Industry

Oil & gas pump houses, liquefied gas storage tanks and gas boiler rooms, monitoring leakage of flammable gases such as natural gas and liquefied petroleum gas.

7. Other Scenarios

Laboratory waste gas, chemical fertilizer plant tail gas, printing and dyeing workshop waste gas, ammonia refrigeration machine rooms of cold storage, metallurgical smelting flue gas monitoring, etc.

 

6. Optional Custom Configurations

 

1. Customized detection technologies: Electrochemistry, catalytic combustion, NDIR infrared, TDLAS laser, PID photoionization sensors available on demand;

2. Working condition upgrade: Explosion-proof complete machine, high-temperature heat tracing sampling pipeline, high anti-corrosion PTFE pipeline, extended pipeline sampling probe;

3. Transmission function expansion: 4G wireless remote transmission module, LORA wireless communication, local data storage recorder;

4. Complete supporting accessories: Front dust filter sampling probe, heat tracing insulation pipeline, explosion-proof junction box, on-site sound and light alarm;

5. Cabinet upgrade: 316L thickened stainless steel anti-corrosion cabinet, outdoor rain and sun protection cabinet.