Core Application Scenarios: Covering High-Risk Areas Across the Industry Chain

The primary risks in the petroleum chemical and natural gas industries stem from leaks of flammable media (e.g., crude oil, natural gas, refined products) and toxic/hazardous media (e.g., hydrogen sulfide, benzene derivatives). Gas detection equipment must be strategically deployed in high-risk zones of different process stages.

(1) Petroleum Chemical Industry: Refining, Chemical Production, and Storage/Transportation

1. Refinery Process Units

Refining operations (e.g., distillation, catalytic cracking, hydrocracking) involve high-temperature, high-pressure油气 separation and reactions, which can lead to leaks of gasoline vapors, diesel mists, and hydrogen sulfide (from sulfur-containing crude oil).

● Key Monitoring Points: Reactor vessels, fractionation tower bottoms (where heavier hydrocarbons accumulate), pipeline flanges/valves (frequent leak points), and pump areas (prone to mechanical seal failures).

● Equipment Configuration:

1) Catalytic combustion-type flammable gas detectors(for monitoring gasoline, diesel, and other light hydrocarbon vapors; cost-effective with fast response).

2) Electrochemical hydrogen sulfide detectors(detection limit ≤1 ppm, for sulfur-containing crude oil processing areas).

3) Infrared flammable gas detectors(resistant to sulfur poisoning, suitable for long-term operation in catalytic cracking units).

2. Chemical Production Plants

Processes like ammonia synthesis, ethylene production, and styrene polymerization involve hydrogen (H₂), carbon monoxide (CO), and benzene (C₆H₆)—all highly hazardous.

● Key Monitoring Points: Hydrogen compressor rooms (risk of hydrogen leaks), styrene reactor areas (benzene vapors are toxic and flammable), and CO-fired heater sections (CO is colorless and odorless, with lethal inhalation risks).

● Equipment Configuration:

1) Thermal conductivity hydrogen detectors(highly sensitive to hydrogen’s unique thermal conductivity, ideal for low-concentration hydrogen monitoring).

2) Photoionization detectors (PIDs)(highly sensitive to benzene and other VOCs, with detection limits in the ppb range, suitable for benzene leak detection in chemical plants).

3) Electrochemical CO detectors(precise monitoring of CO concentrations, linked to ventilation systems).

3. Storage Tanks and Loading/Unloading Areas

Tanks storing crude oil, refined products (gasoline, diesel), and liquefied petroleum gas (LPG) are major hazard sources. Leaks can form explosive mixtures.

● Key Monitoring Points: Breather valves at tank bases (1 meter below, capturing evaporating hydrocarbon vapors), loading/unloading arm connections (frequent leak points), and within fire dikes (vapor accumulation zones from liquid spills).

● Equipment Configuration:

1) Fixed flammable gas detectors (catalytic combustion/infrared types)(monitoring methane, gasoline vapors, etc.; installed 0.3–0.6 meters above ground to cover heavier-than-air hydrocarbons).

2) Interlocked control systems(detector signals trigger tank farm ventilation and emergency shutoff valves; alarms activate at ≥25% LEL to automatically halt operations).

4. Wastewater Treatment and Flare Systems

Wastewater ponds (e.g., oil-water separators, flotation tanks) release hydrogen sulfide and methane due to anaerobic decomposition of organics, while flare gas treatment towers may leak sulfur dioxide (SO₂) and nitrogen oxides (NOₓ).

● Key Monitoring Points: Below pond covers (0.3 meters above liquid level, capturing rising H₂S vapors), and at flare stack emission outlets (monitoring residual toxic gases post-treatment).

● Equipment Configuration:

1) Electrochemical H₂S/SO₂detectors (precise monitoring of toxic gases; alarm thresholds ≤10 ppm for H₂S, ≤5 ppm for SO₂).

2) Portable gas detectors(for inspection personnel entering ponds, ensuring pre-entry safety).

(2) Natural Gas Industry: Extraction, Storage/Transportation, and End-Use

The primary risks in the petroleum chemical and natural gas industries stem from leaks of flammable media (e.g., crude oil, natural gas, refined products) and toxic/hazardous media (e.g., hydrogen sulfide, benzene derivatives). Gas detection equipment must be strategically deployed in high-risk zones of different process stages.

(1) Petroleum Chemical Industry: Refining, Chemical Production, and Storage/Transportation

1. Refinery Process Units

Refining operations (e.g., distillation, catalytic cracking, hydrocracking) involve high-temperature, high-pressure油气 separation and reactions, which can lead to leaks of gasoline vapors, diesel mists, and hydrogen sulfide (from sulfur-containing crude oil).

● Key Monitoring Points: Reactor vessels, fractionation tower bottoms (where heavier hydrocarbons accumulate), pipeline flanges/valves (frequent leak points), and pump areas (prone to mechanical seal failures).

● Equipment Configuration:

1) Catalytic combustion-type flammable gas detectors(for monitoring gasoline, diesel, and other light hydrocarbon vapors; cost-effective with fast response).

2) Electrochemical hydrogen sulfide detectors(detection limit ≤1 ppm, for sulfur-containing crude oil processing areas).

3) Infrared flammable gas detectors(resistant to sulfur poisoning, suitable for long-term operation in catalytic cracking units).

2. Chemical Production Plants

Processes like ammonia synthesis, ethylene production, and styrene polymerization involve hydrogen (H₂), carbon monoxide (CO), and benzene (C₆H₆)—all highly hazardous.

● Key Monitoring Points: Hydrogen compressor rooms (risk of hydrogen leaks), styrene reactor areas (benzene vapors are toxic and flammable), and CO-fired heater sections (CO is colorless and odorless, with lethal inhalation risks).

● Equipment Configuration:

1) Thermal conductivity hydrogen detectors(highly sensitive to hydrogen’s unique thermal conductivity, ideal for low-concentration hydrogen monitoring).

2) Photoionization detectors (PIDs)(highly sensitive to benzene and other VOCs, with detection limits in the ppb range, suitable for benzene leak detection in chemical plants).

3) Electrochemical CO detectors(precise monitoring of CO concentrations, linked to ventilation systems).

3. Storage Tanks and Loading/Unloading Areas

Tanks storing crude oil, refined products (gasoline, diesel), and liquefied petroleum gas (LPG) are major hazard sources. Leaks can form explosive mixtures.

● Key Monitoring Points: Breather valves at tank bases (1 meter below, capturing evaporating hydrocarbon vapors), loading/unloading arm connections (frequent leak points), and within fire dikes (vapor accumulation zones from liquid spills).

● Equipment Configuration:

1) Fixed flammable gas detectors (catalytic combustion/infrared types)(monitoring methane, gasoline vapors, etc.; installed 0.3–0.6 meters above ground to cover heavier-than-air hydrocarbons).

2) Interlocked control systems(detector signals trigger tank farm ventilation and emergency shutoff valves; alarms activate at ≥25% LEL to automatically halt operations).

4. Wastewater Treatment and Flare Systems

Wastewater ponds (e.g., oil-water separators, flotation tanks) release hydrogen sulfide and methane due to anaerobic decomposition of organics, while flare gas treatment towers may leak sulfur dioxide (SO₂) and nitrogen oxides (NOₓ).

● Key Monitoring Points: Below pond covers (0.3 meters above liquid level, capturing rising H₂S vapors), and at flare stack emission outlets (monitoring residual toxic gases post-treatment).

● Equipment Configuration:

1) Electrochemical H₂S/SO₂detectors (precise monitoring of toxic gases; alarm thresholds ≤10 ppm for H₂S, ≤5 ppm for SO₂).

2) Portable gas detectors(for inspection personnel entering ponds, ensuring pre-entry safety).