ATEX-Certified, FPGA-Based Three-Channel Quantum Cascade Laser Sensor for Sulfur Species Detection in Petrochemical Process Streams

Abstract

In this work, a highly sensitive, selective, and industrially compatible gas sensor prototype is presented. The sensor utilizes three distributed-feedback quantum cascade lasers (DFB-QCLs), employing wavelength modulation spectroscopy (WMS) for the detection of hydrogen sulfide (H₂S), methane (CH₄), methyl mercaptan (CH₃SH), and carbonyl sulfide (COS) in the spectral regions of 8.0 µm, 7.5 µm, and 4.9 µm, respectively. In addition, field-programmable gate array (FPGA) hardware is used for real-time signal generation, laser driving, signal processing, and handling industrial communication protocols. To comply with on-site safety standards, the QCL sensor prototype is housed in an industrial-grade enclosure and equipped with the necessary safety features to ensure certified operation under ATEX/IECEx regulations for hazardous and explosive environments. The system integrates an automated gas sampling and conditioning module, alongside a purge and pressurization system, with intrinsic safety electronic components, thereby enabling reliable explosion prevention and malfunction protection. Detection limits of approximately 0.3 ppmv for H₂S, 60 ppbv for CH₃SH, and 5 ppbv for COS are demonstrated. Noise-equivalent absorption sensitivity (NEAS) levels for H₂S, CH₃SH, and COS were determined to be 5.93 × 10⁻⁹, 4.65 × 10⁻⁹, and 5.24 × 10⁻¹⁰ cm⁻¹ Hz⁻¹/². The suitability of the sensor prototype for simultaneous sulfur species monitoring is demonstrated in process streams of a hydrodesulphurization (HDS) and fluid catalytic cracking (FCC) unit at the project's industrial partner, OMV AG.