As the global steel industry accelerates its transition toward green and low-carbon operations, Pulverized Coal Injection (PCI) has emerged as a critical process for reducing fuel ratios and enhancing energy efficiency. Ensuring the stability and safety of this system is paramount.
FPI delivers intelligent safety monitoring solutions tailored for the PCI stage. Leveraging advanced laser analysis technology, we establish a robust “safety perimeter” to ensure process continuity and superior asset protection in iron-making.
Industry Challenges: Hidden Fire and Explosion Risks
During coal preparation and transportation within the PCI system, heat accumulation can lead to coal oxidation and the generation of Carbon Monoxide (CO). Without reliable monitoring, this thermal buildup may trigger spontaneous combustion or catastrophic explosions, threatening personnel safety and incurring significant downtime costs.
In extreme environments characterized by high temperature, pressure, and heavy dust load, traditional monitoring methods often fall short due to response latency and excessive maintenance requirements.
The FPI Solution: A Holistic Approach to Precision Safety
Based on the operational logic of PCI systems, FPI has engineered a monitoring strategy centered on the LGA-4100 series in-situ laser gas analyzer, providing real-time insights at three critical nodes:
Coal Mill Inlet: The First Line of Defense Against Deflagration
Monitoring CO and O₂ at the pulverizer inlet ensures that the drying medium (such as hot blast or flue gas) is properly inerted before contacting the coal. Precise O₂ monitoring is essential to prevent spontaneous combustion during the high-temperature grinding process, while real-time CO detection provides a critical baseline for gas quality. Leveraging second-level response times, this dual-parameter monitoring solution sensitively captures fluctuations in gas concentrations, providing accurate and real-time data as a core reference for operational safety.
LGA-4100 In-situ Laser Gas Analyzer
Applications：Iron & Steel, Oil refinery, Fine-chemical, Semi-conductor
Bag Filter Outlet: Closed-Loop Control and Safety Gateway
Monitoring CO and O₂ concentrations at the outlet duct is vital for process safety. As a fire-prone area with extreme dust density, rigorous O₂ analysis verifies atmospheric safety to prevent the formation of explosive environments. Simultaneously, precise CO detection provides immediate feedback on abnormal oxidation or smoldering within the filter bags. This data-rich feedback empowers enterprises to continuously optimize ventilation efficiency and safety margins across the PCI system.
LGA-4100 In-situ Laser Gas Analyzer
Applications：Iron & Steel, Oil refinery, Fine-chemical, Semi-conductor
Coal Bunker: Eliminating Spontaneous Combustion Risks in Storage
Focused on CO and O₂ monitoring at the bunker top, this solution effectively verifies the efficiency of nitrogen inertization while capturing signals of smoldering that are otherwise invisible. By identifying early-stage oxidation through trace-level CO detection alongside O₂ analytics, the system provides a vital early warning to operators, ensuring the inherent safety of storage facilities before an incident escalates.
LGA-4100 In-situ Laser Gas Analyzer
Applications：Iron & Steel, Oil refinery, Fine-chemical, Semi-conductor
Core Advantages: Empowering Precision Manufacturing via Laser Technology
Intrinsic Safety: Utilizing TDLAS (Tunable Diode Laser Absorption Spectroscopy) technology, the system remains immune to background gas interference, capturing minute concentration changes for high-fidelity early warnings.
Resilience in Extremes: Engineered for high-dust and high-vibration environments, the LGA-4100 features a rugged probe design and self-cleaning capabilities, eliminating the clogging issues common in traditional extractive sampling systems.
Low Maintenance, High Availability: With no moving parts and non-contact measurement, the solution significantly reduces spare parts costs and ensures 24/7 operational uptime for high-intensity production environments.
FPI is dedicated to empowering steel enterprises with data-driven precision manufacturing through digital and intelligent sensing technologies. This PCI monitoring solution is a cornerstone of our comprehensive blast furnace portfolio, helping the global industry balance high-output demands with uncompromising safety for a sustainable future.
