The Role of CO Analysis in Cement and Steel Production
Carbon monoxide (CO) is a critical indicator in high-temperature industrial processes like cement and steel production. It’s not just a byproduct — it’s a signal. A signal of combustion efficiency, safety, and environmental compliance. Yet, it’s often misunderstood or poorly measured due to limitations in legacy sensor technologies.
In this article, we explore why accurate, real-time CO analysis matters in cement kilns and steel furnaces — and how laser-based technology is changing the game.
Why CO Matters in Cement and Steel Plants
Cement and steel production both rely on intense thermal processes where fuels like coal, petcoke, and natural gas are burned at high temperatures. In these environments, carbon monoxide forms when combustion is incomplete — usually due to poor air-fuel mixing, fluctuating temperatures, or insufficient oxygen supply.
That makes CO a real-time indicator of:
Combustion efficiency
Safety risks like explosive atmospheres
Environmental compliance with emissions regulations
Failing to detect rising CO levels early can lead to equipment damage, production loss, or even plant shutdowns.
Cement: CO Signals Kiln Stability
In cement manufacturing, CO analysis is used to monitor combustion in the rotary kiln and preheater tower. When fuel doesn’t fully combust, CO levels rise — often a sign of:
Kiln feed build-up
Air leakage
Flame instability
Real-time CO readings help operators optimize air-fuel ratios, reduce energy consumption, and prevent ring formations or blockages, which are costly to resolve.
Steel: CO Reflects Furnace Health
In the steel industry — especially in blast furnaces and basic oxygen furnaces (BOFs) — CO is a direct product of carbon reacting with oxygen. Measuring it helps:
Track process performance
Adjust fuel injection rates
Prevent explosions in enclosed ducts or off-gas systems
CO levels are also vital in coke oven gas systems, where undetected leaks can create hazardous working environments.
Why Traditional CO Sensors Fall Short
Most older CO analyzers rely on electrochemical cells or infrared (NDIR) detectors. While common, they’re often:
Slow to respond
Susceptible to drift
Prone to fouling in dusty, high-temperature environments
In cement and steel plants, that’s a problem. Conditions are harsh. Dust, temperature swings, and corrosive gases all degrade sensor performance — making frequent maintenance and sensor replacement necessary.
Laser-Based CO Analysis with TDLAS
Tunable Diode Laser Absorption Spectroscopy (TDLAS) offers a more reliable solution. Beamonics’ TDLAS-based CO analyzers are designed to handle tough environments with:
Fast, real-time response (sub-second updates)
No contact with process gas
Zero sensor drift
Low maintenance
TDLAS systems are also ideal for cross-stack or in-situ installation, making them perfect for large ducts, kilns, or furnace exhaust streams.
CO is more than just a pollutant — it’s a real-time process signal. In cement and steel production, accurately measuring CO helps you stay efficient, stay compliant, and stay safe.
At Beamonics, we help heavy industries implement reliable, maintenance-free CO analysis using the power of TDLAS. If you’re still relying on outdated sensor tech, it’s time to make the switch.
Want to upgrade your CO monitoring system?
Contact us to learn how our laser-based analyzers can help you optimize operations in cement or steel production.
