Gas is a state of matter in which the molecules are bound by forces and are widely separated, meaning they are also invisible, shapeless and capable of spreading freely.
In industrial settings, many gases are used or produced and they often fall into categories such as reactive vs. non-reactive. A non-reactive gas does not readily react with other elements and highly reactive gases are engineered or generated for processes that depend on chemical reactivity.
Beyond that broad distinction, industrial gases are also categorized by elemental vs. compound, artificial vs. naturally occurring, and by hazard type (toxic, asphyxiant, flammable). Because gases are often invisible and without odor or color, the potential risk is that workers and facilities may be exposed without noticing.
For example, gases like nitrogen or argon can displace oxygen and become asphyxiants, while others like ammonia or carbon monoxide are chemically hazardous.
Key Industrial Gas Types & Their Applications
Here are some of the most frequently encountered industrial gases, their primary uses in the industry and the hazards associated with each.
Ammonia (NH3)
Ammonia is a colorless gas with a strong odor. It occurs naturally in the environment (soil, water, plants, animals) and is used widely in fertilizers, refrigeration, cleaning products, and industrial processes. Lower exposures may irritate the nose and throat, while higher exposures can cause corrosive burns to skin, eyes, throat and lungs because ammonia reacts with body water to form ammonium hydroxide.
- Applications: agriculture, livestock/farming ventilation, industrial refrigeration, manufacturing of chemicals.
- Hazards: Corrosivity, irritation, potentially severe respiratory damage; exposure limits apply (for example OSHA’s PEL is 50 ppm averaged over eight hours).
- Gas Detection Solutions: Use fixed ammonia or combustible detectors that provide visual and audible alarms when thresholds are exceeded.
Argon (AR)
Argon is an inert (non-reactive) noble gas, making up about 0.93% of the earth’s atmosphere and produced industrially by fractional distillation of liquid air. It is colorless, odorless, non-flammable and generally non-toxic but it is denser than air and can displace oxygen in enclosed spaces, creating a risk of asphyxiation.
- Applications: inert shielding gas in welding (e.g., MIG/TIG), food packaging (to preserve shelf life), as a carrier gas in chromatography, in graphite furnace processes.
- Hazards: Oxygen displacement in confined or poorly ventilated spaces; because argon is heavier than air, it can accumulate near floors or low-lying areas.
- Gas Detection Solutions: Oxygen depletion monitors are critical in argon-rich zones. Fixed monitors should be placed at appropriate heights and connected to alarms or ventilation systems.
Carbon Dioxide (CO2)
CO2 consists of one carbon atom and two oxygen atoms. It’s vital for life (plants use it in photosynthesis and it plays roles in both food/beverage and industrial processing). It is colorless, odorless and tasteless with a density roughly 53% higher than air. Natural sources include volcanoes, hot springs and carbonate rocks; industrially, CO2 is used for beverage carbonation, dry ice and more.
- Applications: beverage carbonation, indoor agriculture, modified atmosphere packaging and dry ice blasting.
- Hazards: At elevated concentrations, CO2 can cause headaches, dizziness, asphyxiation, elevated blood pressure, fatality. The typical ambient level is 400ppm outdoors and industrial exposure will rise higher in poorly ventilated areas.
- Gas Detection Solutions: Fixed CO2 detectors or multi-gas safety systems are essential where CO2 is stored, used or released. They trigger visual and audible alarms and can integrate with third party ventilation systems.
Carbon Monoxide (CO)
CO is a colorless, odorless, tasteless gas formed by incomplete combustion (from furnaces, stoves, engines, dryers). Because it binds to hemoglobin, CO prevents oxygen transport in the body and is extremely dangerous even at low concentrations.
- Applications: While not typically used as a purposeful industrial gas (except in some chemical processes), CO is a frequent by-product in automotive systems, boiler rooms, indoor appliance use, and other combustion environments.
- Hazards: CO is a poisoning risk, where occupants or workers may experience flu-like symptoms, confusion, loss of consciousness, or fatality. Because CO is invisible, detection is essential.
- Gas Detection Solutions: Fixed CO alarms or multi-gas safety systems should be used in indoor air quality monitoring, boiler rooms, automotive service areas, and other potential CO source zones.
Nitrogen (N2) and Oxygen (O2)
Nitrogen (N2) is an inert major component of air (78% by volume). It is used widely for blanketing, purging, packaging, in chemical and pharmaceutical applications, and more.
Though non-toxic, nitrogen can act as an asphyxiant by displacing oxygen. Between 1992-2008, 85 nitrogen asphyxiation incidents in workplace settings were documented by the US chemical safety board.
- Applications: Nitrogen is used by inerting tank atmospheres, purge gas, packaging of food/produce, medical‐pharma processes, cryogenics.
- Hazards: Oxygen displacement (asphyxiation) in confined spaces, liquid nitrogen hazards (rapid expansion, cold injuries).
- Gas Detection Safety Solutions: Oxygen depletion safety alarms must monitor areas where nitrogen is introduced. Fixed oxygen monitors, especially in labs, warehouses or storage rooms, help protect workers.
Oxygen (O2) itself is critical for life but high or enriched oxygen atmospheres can create extreme fire risk. Oxygen is colorless, odorless and tasteless, while not flammable, oxygen-rich environments lower the ignition energy of many materials.
- Applications: welding, metallurgy, cryogenics, medical/clinical uses, modified atmosphere packaging.
- Hazards: Oxygen enrichment causes materials to burn vigorously; oxygen depletion causes asphyxiation.
- Gas Detection Safety Solutions: Both oxygen enrichment and oxygen depletion monitors are necessary. Monitors should alarm when O2 falls below safe thresholds (below 19.5% by volume) or when O2 rises above safe enrichment levels.
Industrial Applications: Why Gas Monitoring Matters
Industrial gases are used across the industry and with each use comes a potential hazard if monitoring is neglected.
For example:
- Food & Beverage: CO2 in carbonation rooms, nitrogen/argon in packaging, O2 monitors in modified atmosphere systems.
- Agriculture / Indoor Cultivation: CO2 enrichment requires constant monitoring of oxygen and CO2 levels.
- Welding / Metal Fabrication: Argon, nitrogen, oxygen use demand inerting and enrichment detection.
- Chemical Manufacturing / Refrigeration: Ammonia leaks, nitrogen purge systems, CO2 refrigerant risk zones.
- Confined Spaces / Storage Tanks / Cryogenics: Nitrogen or argon fills may push out oxygen; liquid gases expand rapidly.
Fixed Multi-Gas Industrial Gas Safety Detector
According to industry sources, gas detection systems offer continuous monitoring of potentially dangerous gases, thus helping reduce risks of explosion, toxic exposure, asphyxiation and equipment damage. They also support regulatory compliance, improved worker confidence and production continuity.
Regulatory & Standards Considerations
Depending on your region and application, various codes and exposure limits apply. For instance we cover the most common below as it pertains to gas safety.
- In the U.S., exposure limits such as Time-Weighted Averages (TWA), Short-Term Exposure Limits (STEL) and Immediately Dangerous to Life or Health (IDLH) exist for gases like carbon dioxide.
- Fixed gas detection arrangements are incorporated in codes such as the National Fire Protection Association (NFPA), the International Code Council (ICC), International Fire Code (IFC) and the Occupational Safety and Health Administration (OSHA).
- In Europe, directives like the EH40 set workplace exposure limits for gases such as CO2 and oxygen.
- Australia’s AS5034 covers installation and use of inert gases (CO2, N2, AR) in beverage dispensing systems.
Because these requirements differ by jurisdiction and by gas type and because they evolve, it's essential you consult your compliance team and safety vendor.
Best Practices for Gas Safety and Code Compliance
- Conduct a gas-hazard assessment: Identify which gases are present, used, stored or generated, and what the associated hazards are (toxic, asphyxiant, flammable).
- Select the right gas detection safety solution: Choose fixed or portable systems; pick sensor technology suitable for the specific gas; ensure alarms, data logging and integration with safety systems.
- Deploy and maintain correctly: Place gas safety monitors in based on gas density and airflow; calibrate regularly; train personnel on standard operating procedures and alarm levels.
- Educate staff: Even the best gas detection safety system can't substitute for worker awareness - train staff on what to do in a leak, how to respond and overall evacuation plans.
References:
- Araos, J. (2012, March 20). U.S. Air Force Staff Sgt. Dustin Volpi, 354th Logistics Readiness Squadron fuels distribution supervisor, tests liquid oxygen for purity [Photograph]. Eielson Air Force Base, Fairbanks North Star.
- Argon. (2021, January 09). Retrieved from Wikipedia.
- Brasted, R. C. (2020, May 21). Oxygen. Retrieved from Encyclopedia Britannica.
- Chapter 354A. (2009). In Workplace Safety and Health Act: Chapter 354A. Singapore: Government Printer.
- CO and CO2 – What’s the difference? (2020, December 03). Retrieved from CO2Meter.com.
- Defining OSHA Confined Spaces, Meeting Requirements. (2020, December 3). Retrieved from CO2Meter.com.
