Next-Gen Gas Sensors Will Redefine Industrial Safety

An industrial gas sensor could provide a crucial warning that tells someone their life is in danger and to evacuate immediately. Such hardware is critical in industrial environments, especially since gases are often a necessary component of production processes. Placing the appropriate sensors strategically throughout an area is an essential safety measure—outlined in various standards and regulations—that protects workers in many sectors today. (In the process industries, for example, ISA/IEC 61511 defines functional safety performance levels for safety instrumented systems.)

What are some examples of next-generation sensors that can alert people once gas amounts reach toxic levels?

Developing a sensor for continuous monitoring

A tricky reality of gas sensor use is that conditions can quickly change. Gathering readings only a few times an hour may not be frequent enough. It is far better to take them more often, giving people a more accurate picture of their surroundings. That is why researchers at MIT developed a gas sensor for industrial or domestic use that works continuously.

They focused on a material called a metal-organic framework that can reliably detect tiny gas traces. However, rapid performance degradation is its downside, and it occurs due to material saturation. To counteract that issue, they combined the metal-organic framework with a more durable polymer that is easier to process but less sensitive to gas.

The group worked with the polymers in a liquid form and the metal-organic framework in a powdered state, carefully mixing the two and depositing the resultant substance on a substrate, creating a thin coating. It maintained its baseline performance within a 5%-10% margin after 100 detection cycles, indicating its potential to remain dependable over the long term.

Although these sensor experiments involved nitrogen dioxide, the researchers believe they could adapt the setup to monitor for most toxic gases. Additionally, the formula could be particularly easy to integrate into existing settings. For example, people might apply coatings to exhaust pipes or chimneys, eliminating the need to mount sensors on walls or deal with other limiting factors.

The next step is to see how this innovation works in real-life environments. The associated results could show the commercial potential.

Maintaining safety and quality during welding activities

Welding is a widely used manufacturing technique that has become essential for joining materials. People choose from several main methods for their specific applications. They must also select the appropriate shielding gas, which forms a barrier around the weld, protecting it from potential defects. Earth’s air contains 78% nitrogen in addition to various other gases that could contaminate the weld zone, but shielding gases prevent that complication.

The quantity and concentration of shielding gases depend on the type chosen. However, many industrial welding facilities have sensors to monitor the environment. Although these settings have ventilation systems that move the gases away from the welder’s breathing zone, those additions must stay well-maintained to retain their effectiveness. Gas monitors in welding shops are important for keeping workers safe and ensuring gases are at or below safe levels.

The type of sensor chosen depends on factors such as the number of welding stations, the hazardous gases used, the room’s airflow patterns and active air current sources. In addition to improving staff safety, a gas sensor in a welding shop enhances quality. Fortunately, manufacturers offer innovative models to support demanding needs.

One example is a portable option that measures and analyzes the gas blends used in welding. The resultant information allows employees to check for contamination and verify that they use the suitable types and amounts of gases for their desired applications. More than 150,000 worldwide locations currently use such technologies.

Making hydrogen fuel adoption a safer prospect

Some organizations are exploring the opportunities associated with hydrogen fuel cells. Hydrogen is appealing because it does not emit pollutants during combustion or production. However, one of the challenges restricting widespread usage is this gas becomes explosive when mixed with air.

Designing an industrial gas sensor to keep the hydrogen levels low enough to prevent explosions would be a critical step in encouraging people to consider hydrogen for various applications, knowing they can do so safely. In one example, Dutch and Swedish researchers collaborated to design an optical device for detecting hydrogen.

It consists of several metal nanoparticles placed at an optimal distance based on the recommendations of an artificial intelligence tool. This highly precise approach paid off since the sensor picks up changes in hydrogen concentration a few hundred-thousandths of a percent small.

The process also revealed the sensor performed better with specific nanoparticle arrangements than with random ones. That change made this innovation more sensitive than previously developed hydrogen detectors of the same style.

This team verified that their sensor was the first to detect hydrogen optically in the parts-per-billion range. That excellent sensitivity gives teams ample warning, allowing them to detect leaks or other abnormalities before catastrophes strike. The group also created the sensor to have audible and visual alerts of elevated hydrogen concentrations, ensuring people will notice the notifications and act promptly.

Developments such as this new sensor should convince industrial leaders that improvements are underway to make hydrogen usage safe. Estimates suggest the hydrogen fuel cell’s market worth will surpass 130 billion USD by 2030. Progress such as what these researchers achieved could further expand adoption.

Creating a flexible, wearable sensor

Sometimes, the most practical choice is to have a person have an industrial gas sensor attached directly to them, mainly if they must perform risky duties. Researchers have demonstrated the possibilities by building a wearable nitrogen dioxide sensor individuals can attach to their clothing or skin.

It detects gas concentrations in a person’s breath or sweat, depending on how they apply the sensor. Although similar designs exist, this one’s breathability is a notable differentiator. The researchers clarified that making it porous would prevent moisture buildup that could cause skin irritation. They specifically developed the sensor to detect nitrogen dioxide and said patients with chronic obstructive pulmonary disease could benefit from using it because that gas can worsen the condition.

However, they said it would be possible to tweak it to broaden the scope to sense other gases, making it appropriate for use in industrial or military applications. Sensors such as this one that are comfortable to wear and versatile enough to fit numerous applications should have a bright future, especially as decision-makers explore options that prioritize safety and are comfortable to use without limiting productivity.

Industrial gas sensor innovations improve safety

These compelling examples show how researchers and manufacturers have made substantial progress in developing highly sensitive gas sensors for use in various industrial environments. This work and similar efforts go a long way toward maintaining and enhancing workplace safety.

This feature originally appeared on ISA Interchange.