The metallurgical and smelting industry is a foundational pillar of the national economy, covering core sectors including steel and non-ferrous metal smelting, providing critical support for industrial manufacturing and the real economy. The full smelting production chain comprises key processes such as coking, sintering, blast furnace ironmaking, converter/electric furnace steelmaking, heating furnace rolling and coal gas recovery & utilization. Operations run under complex harsh conditions: high temperature, high pressure, heavy dust and strong corrosion, generating massive byproduct gases including blast furnace gas, converter gas and coke oven gas, alongside complex multi-component gases such as carbon monoxide, hydrogen, sulfur dioxide, nitrogen oxides and oxygen. Gas composition fluctuates drastically, posing great difficulties for monitoring and control.
The industry is currently undergoing transformation toward green low-carbon, intelligent, efficient and safely controllable production, accompanied by increasingly stringent safety and environmental supervision. Traditional extensive gas monitoring models can no longer match industrial development demands:
1. Precision of process gas composition directly governs smelting reaction efficiency, product quality and energy consumption. Inaccurate gas component control results in raw material waste, excessive energy usage and low finished product yield.
2. Leakage or excessive concentration of toxic, hazardous, flammable and explosive gases easily trigger severe safety incidents including poisoning, fire and explosion. Non-compliant waste gas emissions led to regulatory penalties that hinder long-term corporate development. In addition, traditional gas analyzers suffer from delayed response, weak anti-interference performance, high maintenance costs and limited capacity for simultaneous multi-component detection, failing to meet the demand for all-weather, high-precision, stable and reliable on-line monitoring at smelting sites.
Metallurgical enterprises are primarily large steel mills, whose primary process medium is coal gas. Gas analysis systems deployed focus mainly on measuring CO, CO₂, H₂ and O₂. Steel plants operate numerous coal-fired furnaces generating various coal gases requiring analysis, including blast furnace gas, converter gas, coke oven gas, as well as gas holder, coal powder silo and heat treatment furnace atmospheres.
Gas media in steel plants feature higher dust and moisture content compared with chemical industry working fluids. Blast furnace top gas presents particularly harsh operating conditions, while coke oven gas contains problematic tar. Common tar removal methods include water washing and steam decoking, with customized pretreatment systems varying across manufacturers.
Nearly every steel mill is equipped with supporting air separation units fitted with multiple analytical instruments for high-purity gas testing. Such systems contain a large number of analyzers yet adopt relatively simple pretreatment units due to clean gas media.
In summary, cabinet-type gas analysis systems dominate the metallurgical sector, while standalone analysis shelters are rarely used. Integrated analysis systems for blast furnace gas and coke oven gas represent the primary technical integration challenges of this industry.
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