Explosion proof tube light fittings in the steel mill lighting in the fundamental role and technological innovation

As a high-temperature, high-dust, high-risk industrial environment, the lighting system of the steel mill must not only meet the visual needs of high-intensity operations, but also bear the core mission of production safety.

Molten metal splash, carbon monoxide gathering, equipment vibration and other problems always threaten the stability of the lighting equipment, ordinary lamps and lanterns are very easy to become a fuse for safety accidents.

Explosion proof tube light fittings with its professional explosion-proof design, resistance to extreme environmental characteristics and long-lasting stability performance, into the steelmaking workshop, continuous casting area and gas treatment plant lighting needs.

In this paper, we will analyze the Explosion proof tube light and tubes in the steel mill application scenarios, technical advantages and selection strategy to help enterprises build a safe and efficient production environment.

First, why steel mills must be forced to use Explosion proof tube light fittings?

Steel plant environment lurks multiple safety hazards, the lighting equipment to put forward harsh challenges:

1. Explosive gas risk: converter, electric furnace operations release carbon monoxide [CO], hydrogen [H₂] concentration is easy to reach the lower limit of the explosion, ordinary lamps and lanterns sparks probably cause catastrophic accidents. 2.

2. metal dust threat: steel slag crushing, continuous casting billet cutting iron powder, zinc powder suspended in the air, when the high temperature surface is likely to burst into flames.

3. Extreme physical environment: high temperature: the temperature around the steel package exceeds 80 ℃, ordinary lamps and lanterns easily due to heat dissipation failure leading to component melting or fire;

4. vibration: mill, overhead crane operation triggered by continuous vibration to accelerate the structure of the lamps and lanterns loosening;

5. corrosion: pickling workshop sulfuric acid mist, cooling water vapor erosion of lamps and lanterns shell, triggering the risk of leakage.

Explosion proof tube light approved explosion-proof [Ex d] or composite explosion-proof [Ex de] certification, the use of fully sealed structure and impact-resistant materials, to ensure that the internal circuit sparks, high temperatures and the external hazardous environment is completely isolated.

For example, the lamp shell joint surface accuracy of 0.05mm, can block the combustible gas infiltration cavity, fundamentally eliminate the risk of explosion.

Second, the steel mill Explosion proof tube light fittings core technology advantages

1. Explosion-proof safety and structural strengthening

Explosion-proof cavity design: the shell is made of ductile iron or 316 stainless steel, approved for GB 3836.2 guideline test, and the internal explosion pressure is approved for directional release from the precision threaded joint surface.

Multiple sealing protection: Silicone seals embedded in both ends of the lamp, combined with explosion-proof stuffing box, IP68 protection level [can be 1 meter underwater for 48 hours of continuous work].

Impact resistance: Surface covered with 8mm toughened glass cover, approved IK10 impact resistance certification [20 Joule impact resistance], to resist steel slag splash.

2. Improvement of high temperature environment adaptation

Heat pipe cooling technology: built-in vacuum copper tube high-speed export LED chip heat, the surface temperature of the lamp body ≤ 65 ℃, much lower than the ignition point of dust in the steelmaking area [iron powder ignition point > 300 ℃].

Wide temperature driving power supply: It can help the stable operation in the environment from -40℃ to +120℃, avoiding strobe or light out due to the sudden change of temperature.

3. Luminous efficiency and energy saving upgrade

High color rendering light source: RA ≥ 90 LED chips accurately restore the color of molten steel (e.g. 1600℃ molten steel is bright yellow), helping the furnace worker to judge the melting status at high speed.

Intelligent dimming system: approved infrared sensors to detect personnel activities, unoccupied areas automatically switch to 30% brightness, the overall energy saving rate of 50%.

Steel plant Explosion proof tube light fittings selection and installation specifications

Third, the fundamental selection parameter guide

1. Explosion-proof level matching: gas recovery area [Zone 1]: use Ex d IIB T4 level Explosion proof tube light fittings;

2. Continuous casting workshop [Zone 2]: Ex de IIB T4 composite explosion-proof type, taking into account the gas and dust protection.

3 optical performance requirements: steel pouring area: illuminance ≥ 500 lux, color temperature 5000K cold white light; raw material yard: illuminance ≥ 200 lux, color temperature 4000K neutral light.

Fourth, the installation and maintenance of best practices

1. Explosion-proof wiring specification: armored cable is laid through galvanized steel pipe, and the junction box is filled with Ex explosion-proof mastic to prevent arc leakage.

2. Earthquake-resistant installation program: the use of magnetic base + spring shock absorber under the overhead crane track to reduce the risk of vibration caused by the lamps and lanterns fall off.

3. Cleaning and maintenance cycle: clean up the metal dust on the surface of the lampshade with anti-static brush every week; test the elasticity of the sealing ring and insulation resistance [≥100MΩ] every month; replace the driving power supply heat dissipation silicone grease every year to ensure the heat dissipation efficiency.

Fifth. Successful cases: Explosion proof tube light fittings in large-scale steelmaking enterprise applications

An annual production capacity of 10 million tons of steel enterprises in the converter workshop after upgrading the Explosion proof tube light fittings system:

Lighting-related safety accidents fell to 0, approved ISO 45001 occupational health and safety management system certification; 58% reduction in overall energy consumption, annual savings of more than 2 million yuan in electricity costs; molten steel composition testing accuracy increased by 15%, due to insufficient illumination leading to process errors reduced by 22%.

Sixth, the future momentum: Explosion proof tube light fittings and intelligent steelmaking synergistic evolution

Along with the Industrial Internet of Things [IIoT] popularization, Explosion proof tube light fittings are being given more intelligent features:

Environmental safety linkage: integrated CO sensor, gas concentration exceeds the standard trigger light strobe alarm and start the exhaust system.

Equipment status monitoring: Approved lamps and lanterns vibration sensor to collect mill operation data, early warning of mechanical failure.

Digital twin management: 3D modeling real-time display of workshop lighting energy consumption, AI algorithm to improve the light layout.

FAQ: Steel mill Explosion proof tube light fittings and lanterns common problems answer

Q1: What areas of the steel plant must use Explosion proof tube light fittings?

A: All the presence of explosive gases [such as gas area], dust [such as around the refinery] or high-temperature open flame areas need to be mandatory installation, specific reference to GB 50058 explosion-hazardous environments, design specifications for electrical installations.

Q2：Can the Explosion proof tube light fittings withstand steel splash?

A: Explosion proof tube light fittings for professional steelmaking are covered with high-temperature-resistant ceramic coating, which can withstand the impact of molten metal droplets at 1200℃ for a short period of time, but the integrity of the coating needs to be checked regularly.

Q3: Does the high humidity environment affect the explosion-proof performance?

A: Explosion proof tube light fittings conforming to IP68 guidelines can be operated for a long period of time under 100% humidity, but it is necessary to ensure that the sealing mud of the terminal box is not cracked.

Q4: Explosion proof tube light fittings maintenance costs are higher than ordinary lamps?

A: Initial investment is high 30% -50%, but with more than 50,000 hours of life and low failure rate, 3 years can be approved to save energy and reduce losses to recover the cost.