How to Select an Explosion-Proof 5G LTE Router for the Chemical Industry? – In-Depth Analysis and Selection Guide

The chemical industry imposes stringent requirements on the stability and safety of industrial equipment due to the unique characteristics of its production environment—flammable and explosive gases, pervasive dust, significant temperature and humidity fluctuations, and strong electromagnetic interference. As the core hub of the Industrial Internet of Things (IIoT), the selection of an explosion-proof 5G LTE router directly impacts the reliability of data transmission, the controllability of production safety, and overall operational efficiency. This article provides a systematic solution by examining the pain points of the chemical industry, integrating technical parameters, application scenarios, and selection logic.

1. Core Challenges for 5G LTE Routers in the Chemical Industry

In scenarios such as petroleum refining, coal chemical processing, and natural gas treatment, 5G LTE routers must confront the following risks:

• Explosive Environments: Leakage of combustible substances like methane, hydrogen, and benzene can form explosive mixtures. Equipment must pass explosion-proof certifications (e.g., ATEX, IECEx, CNEx) to prevent accidents caused by electrical sparks or high temperatures.
• Extreme Operating Conditions: High temperatures (e.g., up to 80°C around reactors), low temperatures (e.g., -40°C outdoors in northern regions during winter), and high humidity (e.g., salt spray corrosion in coastal areas) threaten the lifespan of electronic components.
• Electromagnetic Interference: Strong electromagnetic fields generated by large motors and frequency converters may cause data packet loss or device restarts.
• Long-Term Operational Demands: Continuous 24/7 operation requires an MTBF (Mean Time Between Failures) of over five years, along with remote maintenance capabilities to minimize on-site downtime.

Traditional commercial routers fail to meet the demands of chemical scenarios due to their lack of explosion-proof design, weak interference resistance, and low protection ratings. In contrast, explosion-proof 5G LTE routers minimize risks through specialized material encapsulation, isolated circuit design, and redundant power supplies.

2. Key Technical Specifications for Explosion-Proof 5G LTE Routers

When selecting a router, focus on the following core parameters to ensure a balance between safety, stability, and functionality:

2.1 Explosion-Proof Certification and Protection Ratings

• Explosion-Proof Types: Prioritize intrinsically safe (Ex ia) or flameproof (Ex d) devices. Intrinsically safe models achieve inherent safety by limiting circuit energy and are suitable for Zone 0 (continuous explosive environments). Flameproof models isolate internal explosions via robust enclosures and are suitable for Zone 1 (potentially explosive environments).
• Protection Ratings: IP65 or higher ratings provide dust and water resistance for outdoor or humid workshop use. For corrosive environments, opt for 316L stainless steel enclosures or special coatings.
• Certification Standards: Domestic certification requires CNEx approval, while international compliance includes ATEX (EU) and IECEx (International Electrotechnical Commission) standards to ensure global applicability.

2.2 Network Performance and Redundancy Design

• Multi-Link Backup: Support dual-link hot standby for 5G/4G, Wi-Fi, and Ethernet, with automatic switching upon primary link failure to ensure zero data loss. For example, in remote oil well scenarios, 5G can serve as the primary link with satellite communication as backup.
• Low Latency and High Bandwidth: Applications like chemical AI monitoring and remote control require latency ≤50ms. 5G LTE routers (e.g., USR-G816) offer gigabit bandwidth to support real-time 4K video streaming.
• QoS Strategies: Prioritize bandwidth allocation for critical data (e.g., safety alarms) to prevent non-critical traffic (e.g., employee mobile internet access) from consuming resources.

2.3 Environmental Adaptability and Reliability

• Wide Temperature Range: Select industrial-grade designs operating between -40°C and 75°C to avoid capacitor failure at high temperatures or battery issues at low temperatures.
• Electromagnetic Interference Resistance: Pass IEC 61000-4 series tests to defend against ESD (electrostatic discharge), EFT (electrical fast transient), and surge interference.
• Redundant Power Supplies: Dual power inputs (DC24V/AC220V) or PoE (Power over Ethernet) prevent device offline status due to single power supply failures.

2.4 Security Protection and Remote Management

• Data Encryption: Support VPN (IPSec/L2TP/OpenVPN), MAC address binding, and firewall rules to prevent data leaks or unauthorized access.
• Remote Operations and Maintenance: Enable parameter configuration, firmware updates, and fault diagnosis via SNMP, SSH, or cloud platforms to reduce on-site maintenance costs. For instance, the USR-G816 supports the USR Cloud platform for real-time device monitoring and alert notifications.
• Physical Security: Anti-theft lock holes and device tracking prevent malicious disassembly or relocation of routers.

3. Typical Application Scenarios and Selection Recommendations in the Chemical Industry

Tailor router functionality combinations based on scenario-specific requirements:

Scenario 1: Oil and Gas Storage and Transportation Stations (Explosive Gas Environments)

• Requirements: Real-time upload of tank temperature, pressure, and liquid level data to SCADA systems, with linked alarm systems.
• Selection Priorities:
  • Intrinsically safe explosion-proof certification (Ex ia IIC T4 Ga).
  • 5G + Ethernet dual-link connectivity for uninterrupted data transmission.
  • IP67 protection rating to withstand outdoor rain exposure.
  • Support for Modbus TCP/RTU protocol conversion to ensure compatibility with legacy devices.

Scenario 2: Chemical Workshops (High Temperature, High Humidity, and Strong Corrosion)

• Requirements: Reactor temperature control and pipeline flow monitoring, requiring resistance to electromagnetic interference and salt spray corrosion.
• Selection Priorities:
  • Flameproof enclosure (Ex d IIB T4 Gb) + 316L stainless steel construction.
  • Operating temperature range of -40°C to 85°C and humidity tolerance up to 95%RH.
  • Independently isolated RS485 interfaces to prevent crosstalk.
  • Redundant power supply design to avoid restarts due to voltage fluctuations.

Scenario 3: Smart Factories (Large-Scale Device Networking)

• Requirements: Connectivity for thousands of sensors, PLCs, and cameras, necessitating high concurrent processing capabilities.
• Selection Priorities:
  • Support for 5G SA (Standalone) networking to reduce latency below 20ms.
  • Four or more gigabit Ethernet ports with VLAN support.
  • Built-in edge computing modules for data preprocessing (e.g., filtering, aggregation).
  • Open API interfaces for seamless integration with MES and ERP systems.

4. Product Case Study: USR-G816 5G LTE Router – The "All-Rounder" for Chemical Scenarios

Among numerous explosion-proof 5G LTE routers, the USR-G816 stands out as a popular choice in the chemical industry due to its "robust performance + flexible adaptability":

• Explosion-Proof and Protection: CNEx Ex d IIC T6 Gb certification, IP67 protection rating, and wide temperature operation (-40°C to 75°C) enable reliable performance in extreme environments like oil fields and refineries.
• Network Capabilities: Supports 5G/4G global compatibility, dual SIM cards with dual standby, Wi-Fi 6, and gigabit Ethernet for intelligent multi-link switching. Its built-in 5G SA module reduces latency to 15ms, meeting remote control demands.
• Security and Reliability: Combines hardware-level encryption chips with firewalls, passes IEC 61000-4-5 Level 3 surge tests, and supports remote management via the USR Cloud platform, cutting fault localization time by 80%.
• Industry Adaptability: Provides industrial protocol libraries like Modbus and OPC UA for compatibility with mainstream PLCs from Siemens and Schneider Electric. Its Python development environment supports customized functional expansions.

Application Example: A coastal refinery deployed the USR-G816 to connect tank temperature sensors and video surveillance systems. Using 5G + Wi-Fi dual-link backup, it achieved 100% reliable data transmission. The cloud platform automatically generated equipment health reports, reducing operational costs by 45%.

5. Selection Pitfall Guide: Three Common Mistakes and Countermeasures

• Mistake 1: Prioritizing Low Cost Over Authentic Explosion-Proof Certification
  • Countermeasure: Request certification numbers from suppliers and verify authenticity via official websites (e.g., CNEx.org). Prioritize brands with proven chemical industry experience.
• Mistake 2: Assuming "Explosion-Proof = Complete Safety" While Neglecting Installation Standards
  • Countermeasure: Use explosion-proof junction boxes and grounding devices with explosion-proof equipment. For intrinsically safe devices, limit cable length and distributed capacitance to avoid energy accumulation.
• Mistake 3: Overlooking Long-Term Operational Costs
  • Countermeasure: Select devices supporting remote firmware updates and log exports. Prioritize suppliers offering warranties exceeding three years and 24/7 technical support.

6. Future Trends: 5G + AI Empowering Safety Upgrades in the Chemical Industry

As 5G private networks and AI visual recognition technologies mature, explosion-proof 5G LTE routers are evolving from "data gateways" to "intelligent edge nodes":

• Predictive Maintenance: Analyze router logs and device status data to preemptively warn of failures like power supply aging or interface loosening.
• AI-Powered Safety Monitoring: Edge computing modules in routers analyze video streams in real time, automatically identifying violations (e.g., failure to wear safety helmets) and triggering alarms.
• Digital Twins: Leverage 5G's low latency to enable real-time mapping between physical devices and virtual models, optimizing production processes.

Selecting an explosion-proof 5G LTE router for the chemical industry involves balancing "safety, stability, and cost." Enterprises must prioritize core requirements like explosion-proof certification, network redundancy, and environmental adaptability based on actual scenarios, then enhance efficiency through value-added features like remote management and protocol compatibility. As 5G and the Industrial Internet deepen their integration, choosing forward-looking products like the USR-G816 will give enterprises a competitive edge in digital transformation. Safety brooks no compromise—select carefully to build a robust "digital defense line" for chemical production.