Flexible Materials Gas Detection Solutions: Nexisense Ensures Safety in Graphene and Film Production

Flexible materials, especially graphene-based flexible electronics, conductive films, wearable device substrates, and flexible battery separators, are becoming essential in next-generation electronics, energy, and biomedical applications. Their production involves chemical vapor deposition (CVD), reduction methods, liquid-phase exfoliation, coating, and curing processes. Raw materials and intermediates often release hazardous gases such as carbon monoxide (CO), methane (CH4), hydrogen sulfide (H2S), ammonia (NH3), TVOC (total volatile organic compounds), benzene compounds (benzene, toluene, etc.), and formic acid. These gases are flammable, explosive, or toxic, and even minor leaks can cause poisoning, fire, explosion, or long-term health hazards.

The Graphene Industry Safety Guidelines (group standard) and GB 5044 “Occupational Exposure Toxicity Classification” require high-risk process areas to deploy fixed gas detection systems, enabling continuous online monitoring, early warning, and emergency linkage. Nexisense provides high-precision, stable online detection solutions for flexible material production, helping companies establish multi-layer protection at CVD furnace zones, reduction reactors, coating workshops, and exhaust treatment areas to ensure personnel safety, equipment stability, and product quality.

Gas Risks and Monitoring Necessity in Flexible Material Production

• CVD Graphene Growth: CH4/H2 mixture; high-temperature decomposition produces CO and unreacted hydrocarbons, forming explosive-limit mixtures.

• Chemical Reduction: Hydrazine or amino reductants release NH3/H2S; acidic environments may emit formic acid/benzene compounds.

• Coating and Curing: Organic solvent evaporation generates TVOC/benzene compounds; excessive concentrations may cause dizziness or skin irritation.

• Exhaust Emission: Residual CO, CH4, H2S require real-time monitoring to prevent exceeding thresholds.

These gases are often invisible at early leak stages, with minimal odor, making sensory detection difficult. Effective monitoring triggers alarms when concentrations approach 10-20% of LEL or occupational exposure limits, activating ventilation, gas shutdown, or neutralization, significantly reducing accidents and environmental risks.

How to Choose Gas Detection Equipment for Flexible Materials

• Target Gases and Range: CO/CH4: 0–1000 ppm or 0–100% LEL; H2S/NH3/TVOC: 0–10/50/100 ppm micro-range.

• Sampling Method: Diffusion for workshop air; pump sampling for pipelines/reactors; duct sampling for direct exhaust integration.

• Performance: Accuracy ±2% FS, response<30 s, full-range temperature/humidity compensation; explosion-proof Ex d IIC T6 Gb, IP65+ protection.

• Output Compatibility: 4-20 mA / RS485 Modbus RTU / WiFi, supports PLC/DCS integration and environmental platforms.

• Reliability: Imported sensors with patented algorithms, CPA certification, explosion-proof certificate, third-party calibration.

  
  

Core Products of Nexisense

SGA-500 Series Online Fixed Gas Detector
24V powered, plug-and-play, LCD displays real-time concentrations, automatic audible/visual alarm and relay output. Supports diffusion, pump, and duct sampling, covering CO, CH4, H2S, NH3, TVOC, and benzene compounds.

• CPA certification, national explosion-proof certificate, third-party calibration, high accuracy, low error.

• Multiple outputs: RS485, 4-20 mA, 0-5 V, WiFi; suitable for long-distance and wireless integration.

• Compatible with over 90% of PLC/DCS/DDC systems.

Alarm Controllers and System Integration

SGA-800 controller supports multi-channel power supply, centralized display of concentrations, and historical storage. Built-in relays (220V/5A) link fans, valves, explosion-proof alarms, and sprinklers. Automatic graded response upon threshold exceedance ensures closed-loop control.

Extensions include SGA-600 portable inspection device, SGA-500 ambient air monitor, SGA-100X air monitoring module, and SGA-900 pollution source online monitoring system.

Installation and Standard Guidelines

• Heavy gases (CO, H2S, benzene, TVOC): 30-60 cm below leak source.

• Light gases (NH3, CH4, H2): upper area or 30-60 cm below highest point.

• Horizontal spacing: Toxic gases ≤1 m; flammable gases ≤7.5 m.

• Oxygen: upper and lower; recommended 30-60 cm.

• Cabling: 3/4-core shielded; connect to S+/V+/V- or S-/GND; avoid dust/solvent splashes.

• Controller: select channels per points; flexible wiring.

Typical Applications

• Graphene CVD zone: CH4/CO/H2 monitoring with ventilation and gas shutoff linkage.

• Chemical reduction workshop: NH3/H2S real-time alerts for personnel protection.

• Coating and curing area: TVOC/benzene multi-gas detection prevents solvent poisoning.

• Exhaust treatment: Multi-parameter online system ensures emission compliance.

  
  

FAQ

1. Which gases does SGA-500 monitor in flexible materials production and recommended ranges? CO 0-1000 ppm, CH4 0-100% LEL, H2S 0-10/50 ppm, NH3 0-50/100 ppm, TVOC 0-100/500 ppm, benzene compounds 0-50/100 ppm, formic acid 0-100 ppm. CVD: high range for CH4/CO; Coating: micro-range for TVOC/benzene; Multi-gas: combined configuration.

2. Explosion-proof certification and applicable hazardous zones? CPA, national Ex certificate (Ex d IIC T6 Gb), third-party calibration, patented enclosure. Suitable for Zone 1/2 explosive atmospheres, corrosion-resistant aluminum alloy shell.

3. How to choose sampling per process stage? Diffusion for open workshop (TVOC), pump for reactors/pipes (NH3/H2S), duct for direct exhaust (M45×1.5). Pump includes vacuum pump and filter for fresh sample.

4. Sensor accuracy, lifespan, and calibration? ±2% FS, response<30 s. Electrochemical 2-3 years, catalytic/IR 3-5 years. Full-range T/H compensation, self-diagnosis, check every 6 months, calibrate annually. Pre-filters reduce poisoning in high-volatility environments.

5. Installation location and wiring for graphene workshop? Heavy gases 30-60 cm below, light gases 30-60 cm from top; horizontal ≤1 m (toxic) / 7.5 m (flammable). Shielded cable, avoid solvent/dust, controller channels per points.

6. How is multi-level alarm and linkage achieved? Three-stage thresholds: stage 1 ventilation, stage 2 gas shutoff, stage 3 sprinklers/evacuation. Controller relays customizable; RS485/4-20 mA to PLC/DCS for trend analysis and remote monitoring.

7. Exhaust or ambient air extension monitoring? SGA-900 online monitors multiple parameters; SGA-500/SGA-100X modules for ambient TVOC/benzene; SGA-600 portable for inspection; wireless HJ212 connection for environmental platforms.

8. How to obtain customized solutions, manuals, cases, and quote response? Submit process, target gases, layout, and points; team responds in 24h with solution and selection table. Provides manuals, certificates, installation drawings, cases, 3D models. Standard product: 1-3 days, custom system: 5-10 days.

Conclusion: Nexisense Safeguards Safety in Flexible Material Production

The rapid development of flexible materials, especially graphene and films, requires reliable gas safety. Nexisense offers high-precision sensors, multi-sampling, and flexible integration, providing end-to-end monitoring for CVD, reduction, and coating processes. Helps companies control CO, CH4, H2S, NH3, TVOC risks, ensuring safe production and green manufacturing. Contact Nexisense for tailored solutions, on-site survey, and technical support. Innovative production starts with safety monitoring.