Explosion proof led luminaries: fertiliser plant safety and efficient lighting core to handle the programme

First, Explosion proof led luminaries in fertiliser factories in the fundamental application scenarios

Fertiliser factories involved in ammonia volatility, dust accumulation and high temperature and high pressure processes [such as synthetic towers, urea granulation, etc.], the security of lighting equipment, corrosion resistance, stability requirements are extremely high.

Explosion proof led luminaries are approved for explosion-proof structural design, chemical corrosion-resistant materials and intelligent temperature control system to provide safe and reliable lighting in the following core areas:

1. ammonia synthesis workshop and urea granulation area: ammonia and dust mixing is easy to form an explosive environment, explosion-proof LED lamps using Exd IIB T4 explosion-proof grade, explosion-proof cavity can withstand 150kPa explosion pressure, blocking the internal arc leakage.

2. Raw material storage and conveyor belt area: phosphorus ore, sulfur and other raw materials are prone to produce combustible dust, the lamps need to have IP66/IP67 protection level, with 316L stainless steel shell and anti-static coating [surface resistance <1×10⁹Ω], to prevent dust infiltration and static electricity accumulation.

3. Compressor group and reactor periphery: equipment vibration is frequent and the temperature is up to 80 ℃ or more, Explosion proof led luminaries using fin cooling structure + silicone filling technology to ensure that the temperature of the core device ≤ 70 ℃, with the IK10 shock-resistant lampshade, to adapt to the long-term vibration environment.

4. Wastewater treatment and emergency access: integrated lithium iron phosphate battery Explosion proof led luminaries can maintain ≥ 3 hours of lighting after a power failure, to protect personnel evacuation and repair operations.

Second, Amasly fertiliser factory choose Explosion proof led luminaries five core advantages

1. Intrinsically safe and explosion-proof performance Explosion proof led luminaries approved explosion-proof + safety-enhancing composite design, surface temperature ≤ 80 ℃ [T6 group], to effectively avoid ignition of ammonia [spontaneous combustion temperature of 630 ℃] and other flammable gases.

For example, a fertiliser plant synthesis workshop using Exd IIB T6 lamps and lanterns, the annual accident rate reduced by 55%.

2. Corrosion-resistant and long-life design shell using die-casting aluminium alloy + fluorocarbon spray coating process, approved 1000 hours of salt spray test [WF2 anticorrosion grade], adapted to the acidic gas environment;

LED light source life ≥ 100,000 hours, reduce the frequency of overhead maintenance [such as granulation tower lamps and lanterns height of 20 metres, maintenance costs reduced by 80%].

3. Energy efficient and cost improvement 150W Explosion proof led luminaries efficiency of 140 lm / W, compared with the traditional 400W metal halide lamps, illuminance increased by 35%, the annual power consumption reduced by 68%.

With an annual production capacity of 500,000 tonnes of urea plant, for example, the annual electricity cost savings of more than ¥ 300,000.

4. Intelligent control and compliance guarantee with the help of DALI dimming system and PLC linkage, according to the production time to automatically adjust the illumination [such as night inspection to 500lx, daily production to 300lx], in line with the ‘Hazardous Locations Electrical Safety Code’ mandatory requirements.

5. Environmental adaptability and multi-functional expansion of the temperature range: -40 ℃ to +80 ℃, to adapt to the northern cold and southern high temperature climate;

Optional oil mist self-cleaning coating, reduce 90% dust adhesion, reduce cleaning frequency.

Third, the technical selection and installation specifications

1. Explosion-proof grade: Exd IIB T4 [for ammonia, dust] or Exd IIC T6 [hydrogen and other high-risk gases] is preferred;

2. Optical design: asymmetric light distribution is recommended for the conveyor belt area [beam angle 120°], and wide-angle floodlight [150°] is adopted for the warehouse to improve the coverage uniformity;

3. Heat dissipation programme: fin heat dissipation + thermal conductive silicone filling, to ensure that the temperature of the drive power ≤ 70 ℃, to extend the life of the application;

4. Installation specification: lamps and lanterns spacing ≤ 8 metres, height from the ground ≥ 4 metres, to avoid direct installation in the area of easy accumulation of gas.

Fourth, application cases: a large fertiliser plant granulation tower lighting transformation

A urea granulation tower original use of high-pressure sodium lamps, annual failure rate of more than 60%, replaced with AMASLY Explosion proof led luminaries:

Average illuminance increased from 80lx to 250lx, particle quality detection efficiency increased by 30%;

Lamps approved ISO 9227 guidelines 2000 hours salt spray test, no corrosion of the shell;

Comprehensive energy consumption reduced by 62%, payback period of only 1.3 years.

FAQ: Explosion proof led luminaries common problems answer

Q1: Is special approval required for the installation of Explosion proof led luminaries in fertiliser plants?

Yes. You need to supply CNEX/PCEC explosion-proof certification, test reports, and record to the local safety supervision department before construction.

Q2: How to clean the fertiliser dust on the surface of the lamps and lanterns?

It is advocated to wipe with neutral cleaner every month and prohibit strong acid/alkali solution. Some models are equipped with nano oleophobic coating, which can reduce the cleaning frequency by 70%.

Q3: What are the guidelines for Explosion proof led luminaries decay?

The industry requires 5000 hours of light decay ≤ 5%, quality products [such as AMASLY series] 30,000 hours of light decay < 10%, to ensure long-term lighting stability.

Q4：Can I directly replace the Explosion proof led luminaries on the existing circuit cornerstone?

Need to verify the compatibility of the original line voltage [such as AC220V ± 15%], advocating the addition of surge protector to cope with power grid fluctuations.