Intelligent Sensor Solutions for Industrial Gas Generators

Manometer with reducer in a hospital

How smart sensors ensure safety, quality and energy efficiency

High-purity oxygen, nitrogen and hydrogen gases are crucial in industrial processes – for food, electronics and pharmaceutical production – and in the healthcare and scientific sectors. Demand for these gases, especially hydrogen, is rising fast – nitrogen and oxygen demand is growing at over 6 % annually; hydrogen demand is forecast to grow at a rate of almost 10 % per year to 2030. In turn, this is driving the development and manufacture of new gas generation systems capable of offering ever higher levels of efficiency, reliability and, most importantly, safety. 

Although specialized gas generation systems have been commercially available for some time, it is only in recent years that the use of stand-alone on-site generators has become widespread. Nitrogen, for example, was traditionally supplied either as bottled gas or drawn from bulk storage tanks. This established market was difficult for the early manufacturers of gas generation systems to penetrate; the situation began to change when discussion turned to the rising financial and environmental costs of transporting gas by road, and health and safety concerns over handling of heavy cylinders and storage of gas at high pressures. 

Today, the advantages of on-site, on-demand gas generation are widely recognized. By comparison with traditional methods of supply, gas generators are more cost-effective, sustainable, safer and provide far greater flexibility to meet the changing needs of production operations. As a result, although on-demand systems currently account for a small percentage of the market, their use is growing steadily; the demand for stand-alone nitrogen generators, for example, is growing annually at around 6 % (MarketsandMarkets). 

Safety built in 

As the market has grown, so too has the number of companies manufacturing and selling gas generation systems. For example, a growing number of OEMs involved in compressed air treatment are now offering their own self-contained units or providing specialized sub-assemblies to major system integrators. 

There is considerable knowledge and experience available, but as the market expands – especially in hydrogen generation – the skills-base among manufacturers and end users will inevitably become increasingly diluted.  

This is where intelligent or smart sensor technologies, with embedded knowledge, have a key role to play. Devices such as oxygen and dew-point sensors, combined with advanced analysis instruments, can provide vital system monitoring and measurement capabilities to ensure safe and efficient operation. They can, for example, detect changes in operating conditions and automatically initiate adjustments, either to return system operation to safe levels or to shut it down in a controlled and secure manner. 

Evidently, system safety has to be the first and most important criterion for all manufacturers of gas generators. It therefore makes sense for OEMs to choose smart sensors from suppliers that have in-depth knowledge of all aspects of instrument safety – especially SIL (Safety Integrity Levels) – as well as operation with pressure containment systems and in hazardous areas. This essentially provides the best combination of technology with embedded knowledge. 

Moisture monitoring specialists

At Process Sensing Technologies, we have many years of experience working with manufacturers and end users of gas generation and compressed air treatment systems. In particular, we specialize in the measurement of dew point and oxygen in nitrogen, hydrogen and oxygen generators. See our Senz-Tx Oxygen Transmitter. We have developed a range of intelligent sensors, which meet the functional requirements of a SIL environment (for more on SIL, see the ‘Did you know?’ section); we also have a range of advanced analyzers, with all our products being backed by specialized knowledge and technical support. 

This unique combination of smart products and process knowledge enables us to work closely with OEMs, to help them develop systems that provide the highest standards of safety, while also being reliable, energy efficient and competitively priced. For example, our dew-point sensors and dew-point meters are widely used in gas drying systems, providing high-value solutions that minimize energy consumption, extend the intervals between desiccant regeneration, and reduce maintenance costs. 

We are the world’s leading experts in sensors used in compressed gas treatment, covering dew point, oxygen, hydrogen and nitrogen. We have a range of technologies, backed by unrivalled technical and customer support. To learn more, talk to one of our application specialists today.

SIL stands for Safety Integrity Level. In simple terms, it is an integral part of Functional Safety – the degree of safety that control systems provide to a process or plant. Functional Safety describes a safety system that is dependent on the correct function of the control, sensing and associated systems required to meet a specified risk reduction level. SIL is a means of defining the performance of a safety system in terms of probability of failure on demand: i.e., the probability that a safety system will not function when it is required. There are four SIL categories (one to four): the higher the number, the lower the probability of failure on demand. 

Sources

Nitrogen market

Oxygen market

Hydrogen market

Nitrogen generators

Related Blogs

The Importance of Measuring Dew Point in Class 1 & Class 2 Compressed Air Dryers

How to Optimize the Operation of Compressed Air Dryers with Dew-Point Sensors

How to Achieve the Best Results from Specialist Industrial Gases




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Related Products

Dew-Point Transmitter - Michell Easidew EA2
Compact Oxygen Transmitter - SenzTx
Dew-Point Transmitter for Industrial Dryers - SF52


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