Data Acquisition & IoT Solution for Coke Oven Dust Removal Equipment

Against the backdrop of tightening global environmental regulations and the accelerated digital transformation of heavy industries, the iron and steel, coking, and related sectors are facing unprecedented pressure to address air pollution. Coke ovens generate complex flue gas containing coke powder, coal dust, sulfides, and other harmful substances, characterized by high temperature and strong corrosiveness. International standards increasingly mandate ultra-low emission levels (e.g., particulate matter limits as low as 10mg/m³), pushing coking enterprises to upgrade their dust removal equipment monitoring, data traceability, and intelligent management capabilities.
However, traditional equipment management systems fall short of meeting these modern demands. Dust removal units typically operate independently, relying heavily on labor-intensive manual inspections that are inefficient and error-prone. Without real-time monitoring, equipment failures and emission exceedances often go undetected, threatening production safety and environmental compliance. To tackle these challenges, WideIOT offers a comprehensive data acquisition and IoT solution built on its Industrial Intelligent Gateway, empowering coking enterprises to achieve digital and intelligent management of dust removal systems.

Key Industry Pain Points

1. Low Management EfficiencyDust removal equipment is widely distributed and operates in standalone mode, lacking unified data collection mechanisms. Critical parameters such as equipment status, operation time, flue gas temperature, and emission concentration are recorded and reported manually, leading to heavy workloads, low efficiency, and high error rates.
2. Delayed Fault ResponseReal-time remote monitoring of equipment operation and emission data is unavailable. Failures, abnormal operations, and emission exceedances cannot be detected promptly, compromising dust removal efficiency and production safety. Slow on-site emergency responses further exacerbate the impact of such incidents.
3. Underutilized Data AssetsCollected operational data is not systematically managed or analyzed, failing to support dust removal process optimization, predictive maintenance, and environmental regulatory compliance. This hinders enterprises from achieving refined environmental management and cost reduction goals.

WideIOT’s Integrated IoT Solution

WideIOT’s solution centers on the Industrial Intelligent Gateway, which connects to DCS (Distributed Control Systems) or PLC (Programmable Logic Controllers) of coke oven dust removal systems. The gateway collects real-time data on equipment status, process parameters, and flue gas emissions, then transmits the data to factory monitoring and management platforms via 5G/4G/WiFi/Ethernet networks. This enables remote monitoring, intelligent alerts, data analytics, and remote control functions, providing data-driven decision support for the digital transformation of dust removal systems.

Core Functions

1. Comprehensive Data Acquisition

The WideIOT Industrial Intelligent Gateway is compatible with communication protocols of PLCs, DCSs, instruments, and sensors, and supports multiple network access methods including 5G, 4G, WiFi, and Ethernet. It captures a full range of critical data, such as fan current, dust differential pressure, particulate concentration, temperature, and valve status, laying a solid data foundation for system monitoring.

2. Edge Computing Capabilities

Equipped with a built-in edge computing engine, the gateway supports intelligent data collection, filtering, alarm calculation, threshold-triggered sampling, formula-based computation, and grouping strategies. It performs real-time cleaning and integration of raw data at the edge, significantly improving data transmission efficiency and system response speed while reducing cloud computing loads.

3. Multi-Platform Integration

The solution seamlessly integrates with the WideIOT Cloud Platform, as well as third-party IoT platforms (e.g., Azure IoT,AWS IOT, Huawei Cloud IoT), enterprise self-built platforms, and MES (Manufacturing Execution Systems). 

4. Intelligent Alarm & Notification

The system automatically identifies equipment faults and emission exceedances based on preset rules, and sends real-time alerts via WeChat, SMS, or email. It generates alarm statistics reports, enabling managers to quickly locate issues and take corrective actions, minimizing downtime and environmental risks.

5. Remote Control & Operation

Authorized personnel can monitor dust removal equipment through computer and mobile terminals, viewing configuration dashboards and data reports in real time. They can also remotely control equipment operations, such as starting/stopping fans and switching valves, enhancing emergency response capabilities and management flexibility without on-site visits.

6. Data-Driven Analytics & Optimization

By analyzing equipment operation and emission data, the solution provides insights into operational efficiency, fault distribution, and alarm frequency. These insights support process optimization, predictive maintenance scheduling, and environmental compliance management, helping enterprises maximize the value of their data assets.

Core Benefits for Global Clients

• Enhanced Environmental Compliance: Achieve real-time monitoring of emission data and meet strict ultra-low emission standards, reducing the risk of regulatory penalties and enhancing corporate ESG (Environmental, Social, and Governance) performance.
• Reduced Operational Costs: Eliminate labor-intensive manual inspections, lower maintenance costs, and minimize production downtime caused by equipment failures.
• Improved Management Efficiency: Realize centralized, remote management of distributed dust removal equipment, enabling rapid decision-making and agile response to operational issues.
• Sustainable Production: Support process optimization and resource recycling (e.g., recovered dust can be reused in coal blending processes), driving green and sustainable development in the coking industry.

Global Applicability & Value

WideIOT’s solution is designed to adapt to diverse industrial environments and regulatory frameworks worldwide. Its compatibility with international communication standards and third-party platforms ensures seamless integration into existing enterprise systems, making it suitable for iron and steel, coking, and heavy chemical enterprises across Asia, Europe, and the Americas.
As global environmental requirements continue to rise, WideIOT’s data acquisition and IoT solution empowers coking enterprises to transform their dust removal operations from passive compliance to proactive, intelligent management. Partner with WideIOT to build a green, efficient, and sustainable production system, and gain a competitive edge in the global market.