Case Background

Mining and metallurgy are high-risk heavy industries. Mining covers underground mines, open-pit mines, roadway excavation, mining support, tailings ponds and other operation scenarios. The metallurgical industry includes complete processes such as blast furnace, converter, coke oven, sintering, gas purification, non-ferrous metal smelting, pickling and desulfurization. Both industries feature confined and complex operating environments with heavy dust, drastic temperature and humidity fluctuations and severe equipment working conditions. Various flammable, explosive, toxic and harmful gases are continuously generated during production. Subject to strict national codes including Mine Safety Regulations, Metallurgical Gas Safety Regulations and the Eight Steel Safety Rules, the industries have strong demand for gas safety monitoring. The core requirements are as follows:

1.1 Mandatory Monitoring of Multiple Hazardous Gases with Severe Accident Risks
During underground mining, coal seams and surrounding rock continuously release gas (methane), carbon monoxide, hydrogen sulfide, sulfur dioxide and other gases. Oxygen deficiency and excessive gas accumulation tend to occur in underground confined spaces, which may easily trigger gas explosion, coal dust explosion and personnel poisoning or suffocation, constituting the top safety hazard in mines. The whole metallurgical production relies on gas systems. Gas leakage and high-concentration carbon monoxide are likely to occur in blast furnaces, converters, gas holders and pipe valve groups. Meanwhile, smelting, pickling and desulfurization processes produce toxic and corrosive gases such as ammonia, nitrogen oxides, chlorine and hydrogen fluoride. Leakage may lead to mass personnel poisoning, equipment corrosion and damage, fire and explosion accidents with sudden and destructive risks.

1.2 Adaptation Requirements for Severe and Special Working Conditions
Underground mine environments are characterized by heavy dust, high humidity, confined spaces, uneven ventilation, long roadways and severe signal blockage. Equipment is vulnerable to falling rocks and mechanical impact. Metallurgical workshops are exposed to long-term heat radiation, sharp temperature differences, heavy dust, acid-alkali corrosion and dense steel structure interference. Conventional general gas detectors suffer from sensor drift, accuracy degradation, signal interruption and shell corrosion damage, failing to operate stably for a long time. Specialized detection equipment with high explosion-proof rating, high protection, corrosion resistance, anti-interference performance and support for complex signal transmission is urgently required.

1.3 Full-scenario Safety Control Requirements
Mining and metallurgical operations fall into two categories: permanent monitoring in fixed zones and temporary monitoring for dynamic operations. Fixed high-risk areas such as underground roadways, mining faces, metallurgical gas holders and blast furnace platforms require 24-hour uninterrupted online monitoring. Dynamic operations including roadway inspection, confined space work, equipment maintenance, temporary underground construction and metallurgical furnace emergency repair require operators to carry portable detectors to monitor gas concentration and oxygen content in real time, eliminating blind and illegal operations and removing safety blind spots in dynamic activities.

1.4 Compliance Supervision and Data Traceability Requirements
In accordance with mandatory national standards including Safety Regulations for Metal and Nonmetal Mines, Safety Code for Gas of Industrial Enterprises (GB 6222-2025), judgment criteria for major mine hazards and the Eight Steel Safety Rules, gas detectors must be fully deployed in underground mines and gas-related metallurgical areas to realize 24-hour monitoring, over-limit alarm and data retention and traceability. Connection with intelligent mine safety supervision platforms and metallurgical safety production supervision systems is required to meet the demands of government-enterprise data reporting, compliance inspection and hazard traceability. Traditional manual inspection and paper recording result in fragmented and untraceable data, which cannot satisfy standardized compliance management.

1.5 Intelligent Early Warning and Linked Disposal Requirements
Most areas in underground mines and metallurgical workshops have no permanent on-site personnel. Traditional single alarm modes suffer from delayed warning and passive response. The industry needs intelligent systems with real-time monitoring, multi-level early warning, remote push, ventilation equipment linkage and power-off interlock functions to realize advance warning and automatic disposal when gas exceeds limits, preventing serious accidents caused by delayed response and transforming safety management from passive disposal to active prevention.

Taizhi Solutions

This solution is deeply tailored to the exclusive working conditions and safety specifications of the mining and metallurgical industries. Targeting core pain points such as underground gas accumulation, toxic gas buildup, metallurgical gas leakage and corrosive gas exceeding limits, it builds a closed-loop gas safety monitoring system integrating explosion-proof fixed online monitoring, portable mobile detection and industrial IoT intelligent cloud platform. It fully covers full scenarios of mining excavation, roadway operation, underground construction, metallurgical smelting, gas storage and transportation, and tail gas treatment. The system realizes real-time gas concentration collection, multi-level over-limit early warning, intelligent equipment linkage, full data traceability and closed-loop hazard management, comprehensively ensuring production safety in mining and metallurgical operations.

2.1 Overall ArchitectureThe solution adopts an integrated three-layer architecture optimized for long-distance transmission in mine roadways and signal interference in metallurgical steel structure environments, delivering stable operation and comprehensive management:

• Terminal Perception Layer: Mine-certified explosion-proof fixed gas detectors, portable multi-gas detectors and regional alarm controllers are deployed at key locations including mining working faces, roadways, return airways, underground pump houses, blast furnaces, converters, gas holders, valve groups, pickling workshops and confined spaces. The system accurately monitors major hazardous gases such as methane, carbon monoxide, hydrogen sulfide, oxygen, ammonia and nitrogen oxides. With outstanding dust resistance, corrosion resistance, impact resistance and anti-electromagnetic interference performance, the equipment fully adapts to harsh industrial conditions.

• Data Transmission Layer: It supports multiple transmission methods including industrial wired RS485, LoRa spread spectrum wireless and 4G/5G. Optimized for roadway signal shielding and metallurgical steel structure interference, the system features strong penetration and low packet loss rate, supporting ultra-long-distance stable transmission. It synchronously uploads real-time monitoring data, equipment status and alarm information to the cloud platform without data omission or delay.

• Platform Management Layer: A dedicated intelligent gas monitoring cloud platform for mining and metallurgy is developed, integrating real-time data display, concentration curve analysis, multi-level alarm push, ventilation equipment linkage, automatic fault diagnosis, historical data traceability, automatic report generation and hierarchical authority management. Supporting multi-terminal remote management via PC and mobile phones, the platform can seamlessly connect with enterprise smart mine, smart metallurgy safety systems and government supervision platforms.

2.2 Scenario-based Deployment LogicFixed detectors are deployed in batches in unattended high-risk areas to achieve 7×24-hour uninterrupted online monitoring, linked with on-site ventilators, power-off interlock devices and audible and visual alarms. For dynamic scenarios such as daily inspection, temporary underground operation, equipment maintenance and confined space construction, portable detectors are equipped to support pre-operation detection, real-time monitoring during operation and post-operation re-inspection. All terminal data are uniformly aggregated on the platform to realize unified monitoring, early warning and disposal of full-area risks.

2.3 Core Advantages of the SolutionFully compliant with exclusive industry standards, the equipment holds qualified explosion-proof certificates for both mining and metallurgical scenarios. Featuring excellent dust resistance, corrosion resistance and anti-interference capability, the solution solves typical industry pain points including weak roadway signals, harsh workshop conditions and monitoring blind zones. It realizes a full closed-loop management of “monitoring – early warning – linkage – maintenance – traceability” with high intelligence, effectively reducing manual operation and maintenance costs, preventing major safety accidents and fully meeting industry compliance and supervision requirements.

Impl. Results

3.1 Full-coverage Blind-spot-free Monitoring to Precisely Avoid Hidden Safety Hazards
Adopting the combined mode of "fixed-point permanent monitoring + full-coverage mobile inspection", the system covers high-risk blind zones including underground mine roadways, mining faces, return airways, blind roadways, as well as metallurgical blast furnace platforms, gas pipe interlayers, confined spaces and tail gas treatment areas. Equipped with high-precision industrial sensors, the devices deliver high detection accuracy and fast response, accurately capturing trace gas leakage and abnormal concentration changes. It predicts hazards such as gas accumulation, gas leakage and excessive toxic gas in advance, thoroughly solving missed, delayed and false detections caused by traditional manual patrols and preventing explosion, poisoning and suffocation accidents at the source.

3.2 Multi-level Intelligent Linkage for Efficient Closed-loop Emergency Disposal
The system establishes a three-level warning mechanism consisting of on-site audible and visual alarms, platform pop-up alerts, and remote push via mobile APP and SMS. Alarms are triggered within seconds once gas concentration exceeds thresholds. For mining scenarios, underground ventilators can be automatically activated and production equipment interlocked for power cut to quickly dilute accumulated gas and prevent explosions triggered by equipment sparks. For metallurgical scenarios, sprinklers, exhaust fans and emergency shut-off devices can be linked to rapidly block the spread of coal gas and toxic gases. Managers receive real-time warning notifications and arrange rapid disposal, greatly shortening emergency response time to quickly eliminate hazards.

3.3 Full Data Traceability for Standardized Implementation of Compliance Management
The platform automatically retains all monitoring data, alarm records, inspection tracks and equipment maintenance records 24 hours a day. Data can be stored long-term, remains tamper-proof and is available for query and export at any time. It fully complies with safety supervision codes for mining and metallurgy and hazard judgment requirements of the Eight Steel Safety Rules, facilitating inspections by safety authorities and special mine safety audits. The system automatically generates daily, monthly and hazard analysis reports to replace traditional manual paper ledgers and realize standardized, digital and traceable safety management.

3.4 Stable Equipment Adaptation to Harsh Working Conditions with Greatly Reduced O&M Costs
All terminal devices have obtained mining and industrial explosion-proof certifications. Featuring high dustproof, waterproof, anti-corrosion, impact-resistant and anti-electromagnetic interference performance, they can operate stably for a long time under extreme conditions such as high humidity and heavy dust in underground mines, high temperature, corrosion and strong vibration interference in metallurgical workshops with an extremely low failure rate. Meanwhile, the platform supports automatic equipment fault diagnosis and sensor drift early warning to achieve precise maintenance, reduce manual inspection frequency and equipment replacement costs, and guarantee stable operation throughout the year.

3.5 Remote Intelligent Control to Improve Overall Operational Efficiency
Managers do not need on-site duty. They can obtain real-time information on full-area gas concentration, equipment operating status and on-site safety situation through the cloud platform to realize remote visual management. In addition, big data analysis accurately locates high-incidence points of gas anomalies in mines and weak leakage sections of metallurgical pipelines, providing data support for equipment maintenance, process optimization and ventilation system adjustment, and effectively improving the efficiency of production, operation and safety control.

Solution Value

4.1 Safety Value: Build Intrinsic Safety Barriers and Eliminate Major Accidents
Through full-area real-time monitoring, accurate early warning and intelligent equipment linkage, the solution prevents major safety accidents such as mine gas explosions, underground personnel poisoning and suffocation, and metallurgical gas leakage explosions and toxic gas poisoning at the source. It fully protects the life safety of frontline workers and ensures stable operation of plant equipment and production systems, avoiding heavy losses including casualties, equipment damage and full production shutdown caused by accidents, and consolidating the intrinsic safety bottom line of enterprises.

4.2 Compliance Value: Adapt to Industry Special Specifications and Avoid Compliance Risks
The solution fully complies with specialized regulations including the Safety Regulations for Metal and Nonmetal Mines, Safety Code for Gas of Industrial Enterprises (GB 6222-2025), the Eight Steel Safety Rules and judgment standards for major mine hazards. It realizes full monitoring coverage of high-risk areas, traceable data, linked early warnings and standardized ledgers, making up enterprise compliance deficiencies. It effectively avoids compliance risks such as safety supervision penalties, production suspension rectification, qualification downgrade and project restrictions, and ensures regular compliant production.

4.3 Efficiency Value: Reduce Costs and Upgrade Digital Safety Management
The intelligent monitoring system replaces labor-intensive manual inspection and paper-based ledger statistics, greatly reducing labor investment and operation and maintenance costs. Supported by accurate data, it optimizes mine ventilation scheduling and metallurgical equipment maintenance plans, reduces ineffective maintenance, gas loss and equipment failure rates, simplifies safety management processes, and promotes the upgrading of safety management from traditional manual control to digital, intelligent and refined management for mining and metallurgical enterprises.

4.4 Production Value: Ensure Stable Continuous Production and Improve Operational Benefits
The system timely identifies and eliminates gas safety hazards, avoiding temporary shutdowns and rectification caused by excessive gas concentration and hidden dangers. It ensures continuous and stable operation of the entire mining and metallurgical production process. Meanwhile, it precisely controls the leakage and emission of toxic and harmful gases, reducing raw material consumption and equipment corrosion loss, and effectively improving overall production and operational efficiency.

4.5 Environmental Value: Control Exhaust Emissions and Implement Green Production
It enables real-time monitoring of metallurgical waste gas such as nitrogen oxides, ammonia and sulfides, as well as harmful gas leakage and emissions in mining sites. It effectively identifies unorganized emission risks, supports precise waste gas pollution control, meets environmental emission standards, avoids environmental penalties, and achieves coordinated development of safe production and green manufacturing.

Equip. Intro

This solution’s supporting equipment strictly follows special standards for mining and metallurgical industries, and has obtained certifications for mining explosion protection, industrial explosion protection, high protection and anti-corrosion performance, specially adapted to harsh working conditions of the industries. The core equipment falls into three categories: fixed online monitoring devices, portable detection devices and intelligent management platform. The specific parameters and functions are as follows:

5.1 Mining / Metallurgical Explosion-proof Fixed Gas Detector As the core monitoring device for fixed high-risk areas, it is specially applied to underground mining faces, roadways and return airways in mines, as well as blast furnaces, converters, gas holders, valve groups, pickling and desulfurization workshops in metallurgical plants. Equipped with imported high-precision electrochemical and infrared sensor chips, it accurately detects gases including methane, carbon monoxide, hydrogen sulfide, oxygen, ammonia and nitrogen oxides with detection error ≤±3% and response time ≤30s. It holds Ex d IIC T6 explosion-proof certificate and IP66/IP67 high protection rating. Its shell is made of anti-corrosion and wear-resistant material, featuring high and low temperature resistance, dust and corrosion resistance, mechanical impact resistance and electromagnetic interference resistance. Supporting dual transmission modes of RS485 and LoRa wireless communication with strong signal penetration, it adapts to complex signal environments of underground roadways and steel-structure workshops. With automatic zero calibration and self-diagnosis functions, it operates stably 7×24 hours and can directly link with ventilators, power-off interlock devices and shut-off valves.

5.2 Multi-parameter Portable Gas Detector Specially designed for dynamic operation scenarios in mining and metallurgy, the lightweight, explosion-proof and drop-resistant device is suitable for underground inspection, confined space operation, equipment maintenance, furnace emergency repair and temporary construction. It supports simultaneous 4-in-1 or 6-in-1 multi-gas detection, covering core measurement requirements for oxygen, flammable gas, carbon monoxide, hydrogen sulfide, ammonia and sulfur dioxide, enabling full-dimensional hazard investigation without equipment replacement. Equipped with a high-definition backlit display for clear reading in low-light environments, it delivers triple audible, visual and vibration alarms for accurate warning under noisy and dim working conditions. The device supports data storage, export and wireless transmission to record measurement data and inspection tracks. With long battery life and dustproof, waterproof and drop-resistant properties, it meets the requirements of high-frequency mobile detection operations.

5.3 Industrial Gas Alarm Controller As the core device for centralized on-site regional management, it receives signals from multiple fixed detectors in batches and displays gas concentration data by working zones, satisfying independent management demands for zoned mine roadways and separate metallurgical workshops. It supports local data storage, over-limit alarm, fault prompt and linkage output, and allows customized zone alarm thresholds. Built with power-off protection, it can run independently and retain data under network disconnection and power failure, ensuring uninterrupted monitoring and early warning and stable local on-site control.

5.4 Intelligent Gas Monitoring Cloud Platform for Mining and Metallurgy Serving as the core intelligent management carrier of the solution, the platform fully supports data access from all terminal devices of mining and metallurgy. Its core functions include real-time data monitoring, gas concentration curve analysis, multi-level alarm push, equipment fault early warning, ventilation equipment linkage control, historical data traceability, automatic report generation and hierarchical permission management. It supports remote access via Web portal and mobile APP for multiple roles including plant managers, underground dispatchers and safety supervisors. Cloud data is stored permanently and remains tamper-proof to fully meet industry compliance and traceability requirements. It can seamlessly connect with smart mine, smart metallurgy management systems and government safety supervision platforms, helping enterprises realize digital closed-loop management of gas safety.