Gas Concentration Sensors for Chemical Manufacturing

Q: What gases can these sensors measure?

These sensors can measure specific gases such as CO, CO₂, NOx, SOx, O₂, or hydrocarbons, depending on the sensor element and configuration. The exact gas and range must be confirmed with the manufacturer for the specific model.

Q: What is the typical measurement range?

The typical measurement range is 0–1000 ppm, but this can vary based on the target gas and sensor type. Always verify the range for your specific application with the supplier.

Q: What output signals are available?

The standard output is a 4–20 mA analog signal. Options such as HART or Modbus may be available, but these must be confirmed with the manufacturer.

Q: What is the operating temperature range?

The typical operating temperature range is -20 to 60 °C. Operating outside this range may affect sensor performance, so verify the limits for your environment.

Product Specifications

Technical details and manufacturing context for Gas Concentration Sensors

Definition

Gas concentration sensors are critical components within exhaust gas management systems that detect and quantify the levels of specific gases (such as CO, CO₂, NOx, SOx, O₂, or hydrocarbons) present in industrial exhaust streams. They provide real-time data essential for process optimization, regulatory compliance, emission control, and safety monitoring. These sensors are designed for integration into chemical manufacturing processes where accurate gas measurement is required. The sensors operate on various principles depending on the target gas, including electrochemical cells, infrared absorption, catalytic bead, and semiconductor technologies. They generate an electrical signal proportional to the gas concentration, which is then processed and transmitted to control systems. Key parameters include measurement range (0–1000 ppm), accuracy (±2% FS), response time (<30 s), operating temperature (-20–60 °C), operating humidity (0–95% RH non-condensing), supply voltage (24 V DC ±10%), output signal (4–20 mA), ingress protection (IP65–IP67 per IEC 60529), sensor element (electrochemical), process connection (G1/2 per ISO 228-1), weight (0.5–1.5 kg), and power consumption (<2 W). These values are typical reference ranges and must be verified for the specific model and application. The sensors are available with various housing materials and options, which affect weight and suitability for different environments. For outdoor or washdown environments, higher ingress protection ratings are recommended. The sensors are not certified for any specific standard unless explicitly stated by the manufacturer. Always confirm model-specific specifications and compliance with the legal manufacturer or supplier before procurement.

Working Principle

Gas concentration sensors operate based on various principles depending on the target gas. Common technologies include electrochemical cells (measuring current generated by gas reactions), infrared absorption (detecting gas-specific IR light absorption), catalytic bead sensors (measuring heat from catalytic combustion), and semiconductor sensors (detecting changes in electrical conductivity upon gas exposure). The sensor generates an electrical signal proportional to the gas concentration, which is then processed and transmitted to control systems.

Common Materials

Catalytic bead (platinum wire/alumina bead), Electrochemical cell (electrodes/electrolyte), Infrared source/detector (IR LED/photodetector), Semiconductor substrate (metal oxide)

Technical Parameters

Parameter	Typical range	Notes & selection driver
Measurement Range	0–1000 ppm	Select range based on target gas concentration.
Accuracy	±2% FS	Full scale accuracy; better than ±5% for most applications.
Response Time	<30 s	Time to reach 90% of final value.
Operating Temperature	-20–60 °C	Outside range may affect sensor performance.
Operating Humidity	0–95 %RH	Non-condensing; condensation may damage sensor.
Supply Voltage	24 ±10% V DC	Typical industrial supply; other voltages available.
Output Signal	4–20 mA	Analog output; HART or Modbus options.
Ingress Protection	IP65–IP67	For outdoor or washdown environments.IEC 60529
Sensor Element	Electrochemical	Other types: infrared, catalytic, PID.
Process Connection	G1/2	Other threads available on request.ISO 228-1
Weight	0.5–1.5 kg	Depends on housing material and options.
Power Consumption	<2 W	At 24 V DC supply.

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM

Sensing Element Part
Detects and responds to target gas molecules through chemical, electrical, or optical changes

Material: Varies by technology (e.g., catalytic bead, electrochemical cell, IR filter)
Signal Processor
Converts raw sensor signal into standardized output (e.g., 4-20mA, 0-10V, digital protocol)

Material: Electronic components (PCB, ICs)
Protective Housing Part
Provides mechanical protection, environmental sealing, and mounting interface for the sensor

Material: Stainless steel or corrosion-resistant polymer

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Exhaust Gas Management

View system integration details

Manufacturers of Gas Concentration Sensors

Manufacturer profiles associated with Gas Concentration Sensors.

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Frequently Asked Questions

What gases can these sensors measure?

These sensors can measure specific gases such as CO, CO₂, NOx, SOx, O₂, or hydrocarbons, depending on the sensor element and configuration. The exact gas and range must be confirmed with the manufacturer for the specific model.

What is the typical measurement range?

The typical measurement range is 0–1000 ppm, but this can vary based on the target gas and sensor type. Always verify the range for your specific application with the supplier.

What output signals are available?

The standard output is a 4–20 mA analog signal. Options such as HART or Modbus may be available, but these must be confirmed with the manufacturer.

What is the operating temperature range?

The typical operating temperature range is -20 to 60 °C. Operating outside this range may affect sensor performance, so verify the limits for your environment.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

Preliminary Technical Classification

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pressure:	0.5 to 2 bar (standard), up to 10 bar with pressure-rated housings
flow rate:	0.1 to 5 m/s (optimal), up to 20 m/s with flow conditioning
temperature:	-20°C to 80°C (typical), up to 200°C with special configurations
slurry concentration:	Not applicable for optical sensors; limited to <5% solids for catalytic/electrochemical types

Gas Concentration Sensors

Product Specifications

Applied To / Applications

Industrial Ecosystem & Supply Chain Structure

Application Fit & Sizing Matrix

Reliability & Engineering Risk Analysis

Compliance & Manufacturing Standards