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Industrial Safety with Electrochemical Gas Sensors

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Industrial Safety Gas Detection Using Solid Polymer Electrochemical Gas Sensors: Reliable Monitoring Solutions

What is Industrial Safety Gas Detection with Electrochemical Gas Sensors?

Industrial safety involves protecting people, equipment, and the environment from potential harm in workplace settings. In the context of ‘industrial safety gas detection’, this means identifying and mitigating risks associated with the release of hazardous gases from gas bottles, tubing, valve manifold boxes, or machinery.
Gas leaks pose significant threats, including severe harm to personnel, damage to equipment (e.g., corrosion from toxic gases), and environmental hazards. Additionally, many industrial gases are flammable, self-igniting, or explosive, making early detection critical to preventing catastrophic events.

Electrochemical sensors are valued for their high sensitivity, accuracy, and ability to detect low gas concentrations, making them suitable for industrial safety applications.

What are the typical applications for industrial safety applications?

  • Petrochemical Industry: Monitoring flammable and toxic gases in refineries, chemical plants, and storage facilities to prevent accidents.
  • Mining: Detecting methane, carbon monoxide, and other gases to prevent explosions and ensure the safety of miners.
  • Manufacturing: Ensuring the safety of workers in facilities where hazardous chemicals are produced or handled, gas sensors help protect workers from exposure to toxic gases.
  • Warehousing: Identifying leaks of flammable or toxic gases from stored materials to prevent fires or exposure.
  • Pharmaceutical and Laboratory Settings: Detecting gases like ammonia or hydrogen chloride used in synthesis or research processes.
  • Food and Beverage Industry: Monitoring carbon dioxide levels in breweries, soft drink plants, or cold storage to ensure safe working conditions.
  • Power Generation: Detecting hydrogen leaks in turbine systems or toxic emissions from power plants to ensure operational safety.

Why Use Solid Polymer Electrochemical Gas Sensors?

  • Accuracy and Precision: Capable of detecting low concentrations of toxic gases like carbon monoxide, chlorine, or hydrogen sulfide.
  • Cost-Effective: Affordable compared to alternative technologies like infrared or semiconductor sensors.
  • Compact Design: Small, lightweight, and easy to integrate into portable or fixed detection systems.
  • Durability: Reliable in harsh industrial environments with proper maintenance.

Effective gas detection systems, powered by technologies like electrochemical sensors, are indispensable for maintaining industrial safety. They help mitigate risks, ensure compliance with safety regulations, and foster a secure working environment for everyone involved.

Which Gases need to be monitored in industrial safety applications?

Toxic gases: Carbon Monoxide (CO), Hydrogen Sulfide (H2S), Ammonia (NH3), Sulfur Dioxide (SO2), Nitrogen Dioxide (NO2), Total Volatile Organic Compounds (TVOC), Formaldehyde (HCHO)


Corrosive Gases: Hydrogen Chloride (HCl), Hydrogen Fluoride (HF), Chlorine (Cl2), Fluorine (F2), Chlorine Dioxide (ClO2), Ozone (O3)


Combustible Gases: Hydrogen (H2)

What are the Advantages of EC Sense Industrial Safety Gas Sensor Products?

  • Lower detectable limit of 1 ppb ; 1 µg/m³
  • Fast response time

Gas Sensor Features:

  • Small size
  • Long lifetime > 3 years
  • No warm-up time required
  • No zero line drift

Gas Sensor Module Features:

  • Detects gas, temperature and humidity
  • Digital signal UART (TTL 3.3 V) or I2C output
  • Low power consumption and sleep mode (suitable for battery and IoT applications)
  • Wide temperature range of -40 °C to +55 °C

Which Solutions can EC Sense offer for Life Safety Applications?

Product LineFeatures
ES1 / ES4 / EC4 – Gas SensorsFor portable and fixed gas detection solutions
TB420 – Analog Gas Sensor ModuleWith intrinsic safety certification and standard 4-20 mA output
StoxPro – Smart Gas Sensor DeviceSmall size with IP66 rating and intrinsic safety certification, with RS485 and 4-20 mA output, sensor service lifetime testing

Which Technology makes EC Sense Sensors special?

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The EC Sense solid polymer electrochemical technology is a revolutionary innovation in the field of electrochemical detection. This technology is based on the principle of electrochemical catalytic reaction, detecting the output signals of the electrochemical reactions of different gases and accurately measuring the gas concentration through the signal. The sensor is composed of three electrodes in contact with the electrolyte. A typical electrode consists of a large surface area of noble metal and other materials. The electrode, electrolyte and the surrounding air are in contact and the gas diffuses into the working electrode. Here the gas will be oxidized, this causes a current, which is proportional to the gas concentration.

Industrial Safety with Electrochemical Gas Sensors

New Posts, Industry

Controlling the Air Quality inside and outside of animal farms is important for the health of the animals, the health of the farm workers, for the surrounding neighborhood and environment and finally for the quality of our food and therefore also for the health of the end consumer.
Therefore, EC Sense has developed a reliable Long Life Ammonia Sensor Device, ECtox, which can measure continuously high background ammonia gas concentrations in the air.
Why is Air Quality for Animals important?

The meat consumption has risen steadily in recent years. There is already a large industry that breeds such “meat” at top speed.
A chicken’s life is only 8 weeks long. A pig’s life on a small farm is about a year long; in an industrial farm it is only 120 days. In order to maximize profit, the population in an industrial animal breeding facility is constantly raised. This increases the risk that this population will be affected by diseases.

What is the Cause of the Pollution?

The pollution is caused by the respiration of the animals and by the digestion of the food. Humidity increases due to the high population and because the waste remains in place for a while. Many methane gases are produced during digestion of green fodder. NH3 and H2S are toxic gases and harm animals in higher concentrations.

To optimize cultivation and make the shelf life of our future food acceptable, the following air quality basics should be observed:
1. Temperature and Humidity: Humidities above 70% r.H. and temperatures below 10°C or above 30°C stress our future food.
2. Odors generated by the waste of the animals: Same as us humans, animals produce CO2. However, the animal waste falls to the ground and produces CO2 in the air. Due to a high animal density, the concentration inside a barn is higher than outside. High CO2 levels make the animals tired and weak, sometimes even aggressive. Farmers have to add drugs to the diet to control the situation.
Good air quality would reduce these problems to a minimum.

Pig Farms

Typically, the concentration in a piggery should be below 10ppm. At this level, the pigs remain healthy.
At concentrations above 20ppm NH3, the pigs’ health becomes unstable. The following health risks may occur:
a. Lung infection
b. Heart and cardiac system problems
c. Aggressive behavior, tails and ears are bitten off.
The animals’ health degrades faster, infecting others and not growing as quickly and successfully.
To counteract these problems, the following activities have to happen:
a. Animal wastes are mainly NH3 ammonia, sulfide, amines. Keep this level at least below 15ppm.
b. Measure the NH3 concentration with the ECtox, the only long-life Gas Sensor available at the moment.
c. In case the values are too high air exchange is required.
High NH3 concentrations leaving the piggery will also enter the neighborhood. The gas should be cleaned up before it leaves the stall area. Ozone would be a good cleaning agent for this application.

Chickens, Ducks and Cows

However, the concentration level which affects the animals is in different ranges. As chickens are smaller, they are also affected by smaller ammonia concentrations. The controlled level should be around 5ppm. Only at this level the growth runs at full speed and less medicine is needed to stabilize the animals’ health.

ECtox - Long Life NH3 Sensor Device

Our NH3 Gas Sensor, like any other Gas Sensor on the market, also has problems with continuous background concentrations, whose lifetime quickly deteriorates due to the continuously high ammonia concentrations in the environment. The reason for this is a drift of the zero line over time.
Therefore, EC Sense created an instrument to counteract this common problem in animal husbandry gas sensing.
The ECtox has a free zero line. The technology to detect NH3 is called coulometry. This type of detection does not require calibration because the NH3 is analysed each time it is detected.

Advantages of the ECtox:

  • Long Lifetime
  • Humidity Resistance
  • Anti-Interference
  • Poison Resistance
  • Detects Single Gas + Temp. + Humidity
  • Water and Dust Proof
  • Automatic Scaling from 1 to 500ppm NH3
  • Fully Compensated Digital Output
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