Ensuring environmental and worker safety in steel production operations is a top priority across the industry. Facilities rely on blast furnace, coke oven, and Linz-Donawitz (LD) gases as part of the production process. Because carbon monoxide (CO) is a primary component of these gases, even small leaks can create serious safety risks, environmental concerns, and operational losses.

Identifying the source of a gas leak can be challenging. These gases are invisible to the naked eye, and leaks may develop gradually or shift with changing airflow conditions. Traditional detection methods, such as portable gas detectors or fixed monitoring systems, can indicate the presence of gas, but often cannot quickly pinpoint the exact source—delaying corrective action and increasing risk. 

Optical Gas Imaging (OGI) cameras, such as the Flir G346, provide a different approach. Using a specially filtered thermal detector, OGI cameras visualize carbon monoxide and other gases in real time. This allows operators to scan large areas quickly, identify leak sources from a safe distance, and perform inspections without interrupting production. 

The Flir G346 OGI camera for Carbon Monoxide (CO) detection

Stopping Carbon Monoxide Leaks Before They Become Safety Incidents

Steel manufacturing environments present multiple potential leak points—from casting operations to furnace fuel systems. Because these systems are interconnected and often operate under changing conditions, leaks can be difficult to isolate using traditional inspection methods alone.

Optical gas imaging enables operators to investigate suspected leak areas more effectively. For example, when a leak is suspected near a casting or control area, inspection teams can use an OGI camera to scan gas lines, valves, and surrounding infrastructure. This allows them to visualize gas movement and quickly identify leaks at components such as flange joints or connections—without relying solely on indirect measurements.

7 ROI-Driven Use Cases for Optical Gas Imaging in Steel Manufacturing

1. Faster Leak Detection and Reduced Downtime

In large facilities, locating a single CO leak can take significant time using conventional methods. With OGI, operators can scan wide areas in minutes and pinpoint leak sources in real time. This reduces troubleshooting time and allows maintenance teams to act faster—minimizing production disruption and unplanned downtime. 

OGI image of CO leak

2. Improved Worker Safety Through Remote Inspection

Traditional leak detection often requires personnel to enter potentially hazardous environments. OGI cameras enable non-contact inspection from a safe distance, allowing operators to detect leaks while remaining outside gas exposure zones. This significantly reduces risk to personnel during inspection activities. 

OGI image of leakage through a support line

3. More Efficient Inspection of Blast Furnace Systems

Blast furnaces and associated components, such as tuyeres and gas lines, are common sources of CO leakage. OGI allows inspectors to scan these areas quickly and safely, identifying leaks across multiple components without needing to physically access each point.

Once leaks are identified, repairs can be verified through follow-up imaging, helping ensure issues are fully resolved and reducing repeat maintenance efforts.

OGI image of leaking tuyer

4. Pinpointing Leak Sources in Fuel Systems and Hot Strip Mills

In hot strip mill operations and furnace fuel systems, fixed CO monitors may indicate elevated gas levels but cannot always identify the source. OGI provides visual confirmation of leaks at pipe joints, connections, and fuel delivery systems, enabling faster and more targeted repairs.

This reduces time spent isolating issues and helps prevent the accumulation of hazardous gas near critical equipment.

Image of pipe leaking carbon monoxide

5. Increased Inspection Coverage and Productivity

Large steel facilities may contain thousands of potential leak points. OGI allows inspectors to scan extensive areas quickly—often covering far more components in a single shift compared to traditional methods. 

This increased productivity helps teams move from reactive leak response to more proactive inspection workflows.

OGI image of leaking caster

6. Reduced Product Loss and Energy Waste

In many steel plants, process gases are recovered and reused for power generation or reheating furnaces. Undetected leaks can result in significant loss of valuable gas.

By identifying leaks earlier and enabling faster repairs, OGI helps reduce these losses—improving overall energy efficiency and contributing to measurable cost savings. 

Large leak area using high sensitivity mode (HSM)

7. Support for Compliance and Environmental Goals

Steel manufacturers operate under increasing pressure to reduce emissions and demonstrate compliance with environmental regulations. OGI provides visual documentation of leaks and repairs, supporting inspection records and emissions management programs.

By enabling more effective monitoring, OGI helps companies strengthen their environmental performance and align with evolving regulatory expectations.

OGI image of CO leak

Conclusion

Optical gas imaging is becoming an essential tool for carbon monoxide detection in steel manufacturing. By enabling real-time visualization of gas leaks, OGI cameras such as the Flir G346 allow operators to detect issues earlier, respond faster, and improve both safety and operational efficiency.

From faster leak detection to reduced downtime and improved compliance, OGI provides a clear return on investment. By integrating OGI into inspection workflows, steel manufacturers can move from reactive maintenance to proactive detection—helping protect workers, conserve resources, and maintain continuous production.

Want to learn more about OGI for carbon monoxide detection?

Get in touch with our team or explore the Flir G346 camera.

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