As a high-risk industrial cluster area, chemical industrial parks need to establish an environmental safety system of "three-dimensional monitoring+intelligent control". Based on industry practice and cutting-edge technology, systematically review the core monitoring equipment and application solutions:

1. Grid based micro air station

Technical configuration:

Multi parameter integration: Built in PM2.5/PM10 (laser scattering method, accuracy ± 5%), SO ₂/NO ₂ (electrochemical method, resolution 0.1ppm), VOCs (PID photoionization, detection limit 50ppb) sensors, supporting synchronous acquisition of five meteorological parameters (temperature and humidity, air pressure, wind speed and direction).

Explosion proof design: Adopting 316L stainless steel shell (IP68 protection), certified by ATEX (Ex ia IIC T4 Ga), suitable for explosive environments in Zone 0.

Deployment strategy: Deploy at a density of 5-8 units per square kilometer, and generate a three-dimensional pollution heat map using GIS maps. Through this equipment, a petrochemical park found that the concentration of benzene series at 22:00-6:00 at night was 40% higher than that during the day. After tracing, the sealing process of tank breather valve was adjusted, and the annual VOCs emission reduction reached 80 tons.

2. Vehicle mounted navigation monitoring system

Core functions:

Quick screening: Integrated FTIR (Fourier Transform Infrared) spectrometer can simultaneously detect more than 60 volatile organic compounds (such as benzene, toluene, xylene), with a detection range of 0-2000ppm and a scanning speed of ≤ 10 seconds/time.

Accurate traceability: Combining GPS positioning with Gaussian diffusion model, the leakage source can be locked within 30 minutes (with an error of less than 50 meters). A chemical park in Jiangsu Province discovered through aerial monitoring that the concentration of propylene in the northeast corner of the park exceeded the background value by 100 times. After investigation, it was found that the waste gas was directly discharged from the flare system. After rectification, the VOCs concentration in the area decreased by 35%.

3. Infrared thermal imaging detector

Application Scenario:

Equipment leakage detection: By using infrared imaging to identify abnormal temperature rises (with an accuracy of ± 0.1 ℃) in areas such as tank breathing valves and pipeline interfaces, micro leaks of less than 0.1mm can be detected. A certain paint company used this technology to discover 12 leaks in the sealing valves of storage tanks, avoiding the volatilization of toluene with an annual leakage volume exceeding 5 tons.

Emergency response: Generate a temperature gradient map at the accident site to assist in determining the range of hazardous areas (such as the diffusion front in the event of a chlorine gas leak where the temperature drops sharply).

1. Laser spectral telemetry system

Technological breakthrough:

TDLAS Tunable Laser: Using a 1653nm wavelength laser to detect CH ₄ (detection limit 1ppm), eliminating water vapor interference through wavelength modulation spectroscopy (WMS) technology, and maintaining a measurement error of ± 2% even in environments with humidity>90%.

Long distance monitoring: The gas cloud imaging telemetry instrument can effectively monitor a radius of up to 1000 meters, identify leaks at the 10ppm level, trigger an alarm within 1 second, and generate a gas plume diffusion trajectory map.

Typical case: After deploying TDLAS gimbal at an LNG receiving station in Guangdong, the response time for natural gas leaks was shortened from 30 minutes to 1 second. In 2024, three pipeline micro leaks were successfully alerted to avoid potential explosion risks.

2. Intelligent gas sensor network

System architecture:

Multi principle fusion: electrochemical sensors (H ₂ S, Cl ₂, resolution 0.1ppm)+catalytic combustion sensors (CH ₄, 0-100% LEL)+semiconductor sensors (VOCs, detection limit 50ppb), eliminating cross interference through AI algorithms (such as reducing the false alarm rate of alcohol on PID sensors from 15% to 0.3%).

Self calibration technology: Built in standard chamber, automatically calibrated every week (deviation ≤ 3%), reducing manual maintenance frequency by 80%. After being applied in a certain petrochemical enterprise, the equipment failure rate decreased by 40%, and the annual operation and maintenance cost was saved by 1.2 million yuan.

3. Portable emergency detection equipment

Flagship product:

FID/PID dual-mode detector: supports synchronous detection of total hydrocarbons (0-10000ppm) and benzene derivatives (0-200ppm), with a response time of less than 2 seconds and a weight of less than 1.5kg. After the emergency team of a chemical park is equipped, it can complete qualitative and quantitative analysis of toxic gases at the accident site within 10 minutes.

Unmanned aerial vehicle (UAV) deployment plan: For example, the Besan UAV integrates 1-30 types of sensor modules. When flying at an altitude of 50-200 meters, it can cover a radius of 2 kilometers and achieve detection accuracy of ppb level. It is suitable for non-contact monitoring in high-risk areas (such as fire scenes).

1. Explosion proof meteorological station

Core configuration:

Full element monitoring: Ultrasonic anemometer (accuracy ± 0.1m/s), platinum resistance temperature and humidity sensor (± 0.1 ℃/± 1% RH), air pressure sensor (± 0.1hPa), supporting extended monitoring of dust concentration (0-1000mg/m ³) and combustible gas (0-100% LEL).

Intrinsic safety design: The circuit energy is limited to below 0.1mJ, and the shell is made of Hastelloy C-276 (resistant to chloride ion corrosion), with an explosion-proof rating of Ex ia IIC T4 Ga, suitable for high corrosion environments such as chlor alkali production.

Data application: A chemical industrial park combines meteorological data with gas monitoring to establish a dust warning model with wind speed>5m/s+humidity<40%. The warning accuracy reaches 85%, which is 60% lower than the false alarm rate of a single concentration threshold alarm.

2. Atmospheric stability monitoring system

Technical functions:

Vertical gradient measurement: The atmospheric stability level (A-F level) is divided by a temperature and humidity profiler (altitude 0-300 meters), providing key parameters for the Gaussian plume model to predict the diffusion range of pollutants 1-3 hours later (error<15%).

Emergency decision: When the inversion layer (stability level D) is detected, the VOCs monitoring frequency will be automatically increased to 30 seconds per time, and the mobile monitoring vehicle will be activated for encrypted inspection.

1. 3D digital twin platform

Core competencies:

Dynamic modeling: Integrating GIS maps, BIM models, and real-time monitoring data to simulate the diffusion path of toxic gas leaks (such as chlorine gas leaks, combined with wind speed and direction to predict the impact radius of up to 2.3 kilometers).

Linkage control: When the VOCs concentration in a certain storage tank area is greater than 100ppm and the wind speed is less than 2m/s, the system automatically closes the tank valve, starts the sprinkler system, and pushes evacuation instructions to the surrounding 500 meter range (response time<1 second).

2. edge computing node

Deployment value:

Data preprocessing: Outlier removal (such as automatic labeling when sensor drift>10%) and feature extraction (such as triggering an alert when kurtosis coefficient>3) are completed on the monitoring device side, with a data compression rate of 90%, reducing cloud transmission traffic costs by 40%.

Local decision: A tunnel group analyzed CO concentration and wind speed data through edge nodes. When CO>250ppm and wind speed<2m/s, the fan was started to accelerate ventilation within 1 second (increasing the air volume to 120% of the design value).

1. National standards and certification requirements

Emission limit: The "Emission Standards for Pollutants in Petrochemical Industry" (GB 31571-2015) stipulate that the VOCs concentration at the factory boundary should be ≤ 4mg/m ³, and the leakage detection frequency should be ≥ once per quarter.

Explosion proof certification: The equipment must be certified by ATEX (EU), IECEx (international), or NEPSI (China), such as the Ex ia IIC T4 Ga level of TW-FB02 explosion-proof weather station, which is applicable to Zone 0.

2. Smart supervision mode

Carbon Steward System: Integrated monitoring equipment is installed for activated carbon treatment facilities, which dynamically analyzes the saturation of activated carbon through pressure, wind speed, and temperature data, and automatically pushes replacement reminders (accuracy>95%). After application in a certain park, the efficiency of activated carbon use has been improved by 30%.

Hydrogen safety monitoring: For the hydrogen energy industry chain, PPB level laser spectroscopy detectors (with a detection limit of 10ppm) are deployed and interlocked with hydrogen refueling stations to achieve closed-loop management of H ₂ leakage warning disposal.

1. Risk control in storage tank area

Equipment combination: laser spectral telemetry instrument (monitoring radius of 1000 meters)+explosion-proof gas sensor (at the tank breathing valve)+six element meteorological station.

Effect: Through this plan, a petrochemical enterprise has shortened the detection cycle of VOCs leaks in the storage tank area from 7 days to 2 hours, resulting in an annual emission reduction of 120 tons and a corresponding carbon reduction of 360 tons of CO ₂ equivalent.

2. Safety monitoring of public utility tunnels

Technical scheme: gas cloud imaging telemeter (visual monitoring)+TDLAS PTZ (quantitative analysis)+edge computing node (local early warning).

Case: After deployment in a chemical industrial park in Zhejiang, the leakage point of the pipe gallery was located within 30 minutes (with an error of less than 10 meters), which increased the efficiency of traditional manual inspection by 20 times.

3. Emergency response system

Equipment configuration: The drone is equipped with a FID/PID detector (covering a range of 2 kilometers), a portable Fourier telemetry instrument (detecting 600 gases), and a vehicle mounted mobile laboratory (on-site GC-MS analysis).

Practical value: Through this system, a chemical industrial park in Yunnan completed the delineation of the pollution area within 10 minutes in the 2024 chlorine gas leak accident, guiding 3000 people to evacuate safely without casualties.

High risk areas: Ex ia IIC T4 Ga explosion-proof equipment, such as TW-FB02 meteorological station and TDLAS gimbal, should be prioritized around the storage tank area and reaction kettle.

Complex terrain: The mountainous chemical park adopts a combination of unmanned aerial vehicles and vehicle navigation to achieve blind spot monitoring; The coastal park uses GFRP material equipment (resistant to salt spray corrosion).

Cost optimization: Small and medium-sized enterprises can adopt a combination of "micro air stations+portable detectors", reducing initial investment by 60% and meeting daily regulatory needs.

Through the deep integration of "device intelligence+digital management", chemical industrial parks can achieve a leap from passive response to active defense. For example, the Yangtze River Chemical Industry Park has achieved a VOCs emission reduction efficiency of over 95% through the "three chain collaboration" model, and a 100% completion rate for key enterprise pollution control issues, providing a demonstration sample for the industry's green transformation. In the future, with breakthroughs in technologies such as quantum sensing and multispectral fusion, monitoring systems will continue to upgrade towards "full element perception and full process control".