Modcon Systems Ltd, a United Kingdom-based engineering company, has been internationally recognised for its contribution to safer and more sustainable industrial monitoring. At the 35th International Research Awards on Sensing Technology, hosted by the Scifax Company Group and registered with the Ministry of Corporate Affairs, CEO Mr Gregory Shahnovsky was presented with the Best Industrial Sensing Technology Award for his leadership in the development of the MOD-1040 Optical Oxygen Analyzer.
This award highlights the role of thoughtful innovation in addressing complex global challenges—balancing technological progress with environmental stewardship and safety. For industries that power our homes, supply our fuel, and process our waste, the importance of safe and accurate oxygen measurement cannot be overstated. The MOD-1040 was designed specifically to meet this need.
The MOD-1040 represents a new class of optical oxygen analyzers that use quenched fluorescence—a light-based method that can detect even trace amounts of oxygen without physically interacting with the gas. Unlike older systems that require gas samples to be extracted and processed before analysis, the MOD-1040 conducts direct in-situ monitoring, eliminating the risk of contamination, delay, or data inaccuracy.
Technically, it is capable of operating under extreme pressures up to 100 bar, detecting oxygen at parts-per-million (ppm) levels, and delivering a response in under two seconds. It contains no consumable parts, is maintenance-free for long periods, and includes built-in diagnostic systems to detect anomalies or calibration drift. The device meets global safety standards including ATEX, IECEx and SIL-2 certification for explosion-proof environments, making it suitable for use in areas where flammable gases are present.
Its applications extend across a broad range of industries where safety, purity, and efficiency are essential:
- Green Hydrogen Production: As the world shifts to cleaner energy, hydrogen generated through electrolysis is becoming central. But this process involves splitting water into hydrogen and oxygen under high voltage, which creates potential for dangerous mixtures. The MOD-1040 is used at key points in this system—at the cathode, anode, and gas purification stages—to monitor oxygen levels in real time, preventing hazardous conditions and ensuring fuel-grade hydrogen purity.
- Natural Gas Processing and Storage: Even small amounts of oxygen in natural gas can lead to pipeline corrosion, safety risks, or decreased energy content. The analyzer monitors for oxygen ingress in compressors, storage tanks, and blending units without needing any sample extraction systems.
- Flare Stack and Combustion Systems: In oil refineries and chemical plants, excess gases are burned off through flares. Oxygen monitoring at the flare header is essential to ensure complete combustion, reduce toxic emissions, and comply with environmental regulations.
- Refineries and Petrochemical Facilities: In many processing units—such as hydrocrackers, catalytic reformers, and storage tanks—oxygen intrusion can trigger chemical instability, catalyst poisoning, or explosion. MOD-1040 supports proactive monitoring in these critical zones.
- Biogas and Waste-to-Energy Plants: Anaerobic digestion systems rely on oxygen-free conditions. Any leak of atmospheric air can destabilise the process or lead to system failure. The MOD-1040 allows early detection of such contamination, increasing methane yield and plant reliability.
- Chemical Manufacturing and Inert Gas Blanketing: Many processes require oxygen to be kept below critical thresholds to avoid fire, degradation, or unwanted reactions. The analyzer supports nitrogen inerting systems by accurately tracking residual oxygen in closed vessels.
- Semiconductor and Specialty Gas Industries: In the production of ultra-high-purity gases like nitrogen or argon, even a few ppm of oxygen can compromise quality. The MOD-1040’s high precision makes it well suited for monitoring gas lines in cleanroom environments.
What distinguishes this analyzer is not only its sensitivity or ruggedness, but also its ability to integrate into modern digital control systems. It supports Modbus RTU and analog protocols, making it easy to connect with industrial PLCs, SCADA systems, or remote dashboards. This opens the door for AI-based process optimization, predictive maintenance, and reduced operational downtime.
Mr Shahnovsky’s recognition is a reminder of how scientific and engineering talent, when guided by a sense of responsibility, can protect both people and the planet. In the context of our growing concern about environmental sustainability, Modcon’s work represents a meaningful contribution to making essential industries cleaner, safer, and more efficient.