LED explosion proof lamp in steel plant lighting in the fundamental role and intelligent lighting program

First, the core challenges of the steel plant lighting environment: why must choose LED explosion proof lamp?

As a typical high-temperature, high-dust, flammable and explosive environment, steel mills put forward stringent requirements for lighting equipment. Ordinary lamps and lanterns in the steelmaking furnace, rolling area and other high-risk scenarios are prone to cause explosions or failures, and LED explosion proof lamp by virtue of its professional design, into the production safety and efficiency of the core equipment.

1. Steel plant four tough challenges

Explosive gases and dust: coking workshop gas [containing methane, hydrogen], rolling area metal dust [such as zinc, magnesium]; there is an explosion risk.

Extreme high temperature environment: the temperature around the steelmaking furnace can reach more than 80 ℃, conventional lamps and lanterns are easy due to high temperature, resulting in material melting or circuit failure.

Chemical corrosion and mechanical shock: acid mist, alkali mist corrosion of lamps and lanterns shell, metal splash, heavy equipment vibration easy to cause structural damage.

Continuous operation and energy-efficient pressure: steel mills need 24-hour continuous lighting, traditional light sources with high energy consumption and frequent maintenance, increasing operating costs.

2. LED explosion proof lamp core advantages

Explosion-proof safety design: Explosion-proof [Ex d] or dust-proof [Ex tD] structure, approved by GB 3836, ATEX certification, effectively isolate the internal arc and the external hazardous environment, eliminating the risk of explosion.

High temperature and corrosion resistance: 316 stainless steel shell with ceramic heat dissipation technology, resistant to extreme temperatures of -40 ℃ ~ +150 ℃, the surface of the fluorocarbon spraying process to resist acid and alkali corrosion.

Energy efficient and long life: LED LED explosion proof lamp luminous efficiency > 140lm / W, life expectancy of more than 60,000 hours, compared with high-pressure sodium lamp energy saving 70%, reduce the frequency of maintenance of high-temperature areas.

Second, LED explosion proof lamp in the steel mill core application scenarios and get the job done program

1 steel furnace and continuous casting area

Demand pain points: high temperature radiation [> 80 ℃], steel splash, gas leakage risk.

Solution: choose Ex d IIB T3 LED explosion proof lamp [surface temperature ≤ 200 ℃], power 150W-300W, color temperature 5000K, temperature resistance ≥ 150 ℃.

Add a metal protective net to prevent steel slag splash damage to the lampshade, lamps and lanterns spacing 4-5 meters, illuminance ≥ 200lux.

2. Rolling mill and hot rolling mill

Risk characteristics: metal dust accumulation, frequent vibration of heavy equipment. Technical solutions: Ex tD A21 IP65 dust explosion-proof certified lamps and lanterns, surface temperature <dust cloud ignition temperature 2/3 [such as aluminum powder <288 ℃]. Seismic structure design [seismic performance ≥ 20G], internal spring damping bracket, to adapt to the mill vibration environment.

3. Coking plant and gas purification area

Special requirements: methane/hydrogen gas mixture, hydrogen sulfide corrosion. Recommended configuration: Ex d IIC T4 LED explosion proof lamp [T4 group surface temperature ≤ 135 ° C], with stainless steel explosion-proof junction box, explosion-proof surface gap <0.15 mm. emergency lighting module with the help of the mains power failure ≥ 120 minutes, to protect the gas leakage emergency treatment lighting.

4. Raw material yard and transportation channel

Functional requirements: a wide range of coverage, dustproof and waterproof. Technical solutions: 80W LED explosion-proof floodlights, with batwing light distribution design, covering a radius of 15 meters, illuminance ≥ 100lux. IP68 protection level, resistant to rain and snow wash and dust intrusion, reducing the frequency of cleaning and maintenance.

Thrid, steel plant explosion-proof light selection four core indicators

1. Explosion-proof grade accurate matching

Gas / dust classification: gas explosion-proof: IIC class [hydrogen], IIB class [ethylene]; dust explosion-proof: IIIA [metal dust]. Temperature group: T1 [≤ 450 ℃] to T6 [≤ 85 ℃], steelmaking furnace periphery needs at least T3 group [≤ 200 ℃].

2. High temperature and heat dissipation design

Heat dissipation technology: heat pipe cooling + ceramic substrate to ensure that the LED junction temperature <85 ℃, light decay rate <5% / 10,000 hours. Material selection: 310S stainless steel for high-temperature area [1100℃], die-cast aluminum for regular area [150℃].

3. Intelligent control and energy efficiency management

Dimming strategy: automatically switch 100%/50% brightness according to production shifts, energy saving more than 40%. Internet of Things integration: Approved 4G/5G module real-time monitoring of the status of the lamps and lanterns, abnormal data pushed to the central control system.

Fourth, LED explosion proof lamp installation and long-term maintenance strategy

1. Professional installation specifications

Seal processing: cable inlet using double rubber seals + explosion-proof glands [specifications M20 × 1.5], explosion-proof surface coated with 650 ℃ high-temperature grease. Layout improvement: High temperature area lamps and lanterns are ≥1.5 meters away from the heat source to avoid heat radiation accelerating aging.

2. Periodic maintenance program

Monthly inspection: Clean the radiator dust, check whether the protective net is deformed, and replace the lampshade if the light transmission rate decreases >20%. Annual inspection: use the explosion-proof parameter tester to verify the explosion-proof gap, insulation resistance >5MΩ [hot and humid environment needs to be >2MΩ].

3. Intelligent operation and maintenance upgrade

Digital twin platform: 3D modeling of workshop lighting system, AI prediction of lamp life, accurate management of spare parts inventory, AR remote assistance: maintenance personnel approve AR glasses to obtain real-time guidelines to reduce downtime.

Fifth. Future Momentum: Intelligent and Green Technology Driving Steel Mill Lighting Innovation

DC micro-grid power supply: photovoltaic + energy storage system with DC24V LED explosion proof lamp, reduce cable loss, improve the reliability of emergency power supply.

UV-C disinfection integration: LED explosion proof lamp built-in 275nm UV module, in the raw material yard synchronization of the implementation of the illumination and air disinfection.

LiFi optical communication: in the combustible area instead of radio communication, LED explosion proof lamp integrated LiFi module, to enhance the safety of data transmission.

Conclusion

Steel plant lighting safety is to protect the production efficiency and workers’ life cornerstone, LED explosion proof lamp approved explosion-proof, high-temperature resistant, intelligent features, into a high-risk environment lighting guardian.

As a professional service provider in the field of industrial lighting, Amasly Lighting supplies LED explosion proof lamp for steel mills to handle the whole scenario, covering explosion-proof certification, customized heat dissipation design to intelligent operation and maintenance management, helping enterprises to implement safe, efficient and sustainable production intentions.

Get customized explosion-proof lighting solutions for steel mills → Amasly Lighting