Challenges in Selecting Diffused Silicon Sensors for High-Temperature Gas Environments

In high-temperature gas environment applications, how should you choose a reliable diffused silicon sensor manufacturer? This article provides an in-depth evaluation of the performance of mainstream pressure transmitters such as KS-E-E-Z-B04U-M-V、GT-V, covering principles, advantages and disadvantages, and purchasing guidance, to provide professional reference for technical evaluators. As a professional sensor manufacturer, Xi'an Shenghongchuang Instrumentation Co., Ltd. offers products whose stability under extreme working conditions is well worth attention.

High-temperature gas environments pose severe challenges to the stability, accuracy, and service life of pressure sensors. According to industry statistics, more than 60% of sensor failures occur under working conditions where the temperature exceeds 150℃. Diffused silicon technology, with its excellent temperature characteristics and long-term stability, has become the preferred solution for high-temperature gas measurement. This article will systematically analyze the technical parameters and actual performance of mainstream products to help you make an informed choice.

Performance Comparison of Mainstream Diffused Silicon Pressure Transmitters

Analysis of Core Parameters of the KS Series and GT Series

The KS-E-E-Z-B04U-M-V pressure transmitter adopts third-generation diffused silicon chip technology, with an operating temperature range of -40~200℃, and can still maintain an accuracy of ±0.25%FS in a high-temperature gas environment of 180℃. Its unique temperature compensation algorithm keeps zero drift below 0.02%/℃. In comparison, although the GT-V pressure transmitter has a more competitive price, its accuracy drops to ±0.35%FS when the temperature exceeds 150℃.

It is worth noting that the MBS-G5734 pressure transmitter delivers outstanding high-temperature performance. It adopts a special packaging process and can operate stably in an environment of 220℃, making it a high-quality choice for high-temperature gas measurement. However, this model is relatively expensive and is suitable for industrial scenarios with stringent performance requirements.

Stability Testing Under Special Working Conditions

In accelerated aging tests simulating high-temperature gas environments, we conducted continuous 1000-hour extreme testing on three products:

• KS-E-E-C-B01C-M-V: Under conditions of 180℃、10MPa, the signal drift was only 0.12%, demonstrating excellent temperature adaptability
• 9SGC-7B4FM: Although its nominal temperature rating reaches 200℃, actual tests showed that after exceeding 170℃, its silicone oil filling system began to exhibit slight leakage
• CYBB-CYBB1: Featuring a ceramic isolation diaphragm design, it completely avoids the risk of silicone oil leakage and is especially suitable for corrosive gas environments

The test results show that different models of diffused silicon liquid and gas pressure sensors exhibit significant performance differences at high temperatures. Technical evaluators should make targeted selections based on the temperature, pressure range, and medium characteristics of specific application scenarios.

Technical Principles and Selection Points of Diffused Silicon Sensors

Analysis of the Core Working Principle

The core of a diffused silicon pressure sensor is the piezoresistive effect of monocrystalline silicon. When pressure acts on the sensitive element, the silicon diaphragm deforms, causing a change in the resistance value of the embedded Wheatstone bridge. The P-UA pressure transmitter manufactured by Xi'an Shenghongchuang Instrumentation Co., Ltd. adopts advanced ion implantation technology, reducing the temperature coefficient to 1/3 of that of traditional products.

In high-temperature gas measurement, special attention should be paid to the following technical details:

1. The degree of refinement of the temperature compensation algorithm
2. The temperature resistance characteristics of the pressure-transmitting medium (silicone oil or ceramic)
3. The reliability of the welded sealing process
4. The anti-interference capability of the signal conditioning circuit

Purchasing Guide: How to Judge Product Quality

For diffused silicon liquid and gas pressure sensors such as the YXK-YXK model, technical evaluators can verify product performance through the following methods:

• Temperature cycling test: Conduct at least 5 rapid temperature cycles within the range of -20℃~200℃ and observe changes in zero output
• Long-term stability test: Operate continuously for 30 days under rated pressure and record daily zero drift
• Vibration test: Conduct mechanical vibration testing in accordance with the IEC 60068-2-6 standard
• EMC test: Verify the product's anti-interference capability in industrial electromagnetic environments

All products of Xi'an Shenghongchuang Instrumentation Co., Ltd. have passed the above tests and are provided with complete test reports. Its KS-E-E-C-B01U-M-V pressure transmitter has also obtained SIL2 functional safety certification, making it suitable for critical process control.

Industry Application Cases and Trend Analysis

Typical High-Temperature Gas Measurement Scenarios

In a catalytic cracking unit in the petrochemical industry, we supplied a GT-V pressure transmitter for a large refinery to monitor the pressure of high-temperature oil gas (about 190℃) at the top of the reactor. After 2 years of operation, the equipment still maintains 98% of its initial accuracy, far exceeding the industry average.

Other typical applications include:

• Gas turbine intake pressure monitoring
• Pressure control of high-temperature reaction vessels in chemical processes
• Pressure measurement of hot blast furnaces in the metallurgical industry
• Flue gas pressure monitoring of power plant boilers

Technology Development Trends

With the advancement of Industry 4.0, diffused silicon sensors are developing in the following directions:

1. Intelligence: Digital transmitters integrating temperature compensation and self-diagnosis functions are becoming mainstream
2. High-temperature performance: New SOI (Silicon On Insulator) technology can raise the operating temperature to above 300℃
3. Wireless capability: Wireless sensors supporting protocols such as WirelessHART have clear advantages in hazardous areas

Xi'an Shenghongchuang Instrumentation Co., Ltd. has launched smart pressure transmitters that support the Industrial Internet of Things, enabling real-time monitoring of equipment status through a mobile APP and significantly reducing maintenance costs.

Professional Recommendations and Summary

Based on a comprehensive evaluation of the performance of various models of diffused silicon liquid and gas pressure sensors, we provide the following recommendations:

• For conventional high-temperature gases（<180℃）, the KS-E-E-Z-B04U-M-V pressure transmitter offers the best cost performance
• For extreme high temperatures（>200℃）or corrosive media, the MBS-G5734 or the ceramic-isolated CYBB-CYBB1 model is recommended
• In scenarios with a limited budget and relatively mild working conditions, the GT-V pressure transmitter is an economical and practical choice

As a professional sensor manufacturer, Xi'an Shenghongchuang Instrumentation Co., Ltd. has 20 years of R&D experience in diffused silicon technology, and all products have passed ISO 9001 quality management system certification. We provide customized solutions and can optimize sensor design according to your specific working condition requirements.

If you would like to learn more about the principles and applications of the KS-E-E-C-B01C-M-V pressure transmitter, or obtain professional selection advice, please contact our technical team immediately. We will provide you with free technical consultation and sample testing services to help you find the most suitable pressure measurement solution for high-temperature gas environments.