As this type of application of sensors in the device for landfills is novel, first of all, the principle and design of the prototype is provided. Then, a section on device calibration follows, and lastly, a section on measurement processes in the area of interest.
2.2.1. Concept and System Design
A new specialised sensor array was designed to measure the average concentration values of flammable gases (specific goal—CH
4) from the components mounted on the board—semiconductor sensors. Semiconductor sensors respond to the ratio of the gas mixture to oxygen (O
2). Electronic humidity and vapour sensors, which measure the concentration of a liquid while it is in a gas phase, also work on this principle. The selected components used in household and industrial equipment (heating, ventilation, air conditioning, medical, meteorological equipment, warehousing, archive maintenance processes) are of high quality and have been improved according to user feedback because of a high demand lasting a couple of decades (
Figure 1).
The main components of new sensor system are illustrated in
Figure 2. The system consists of three modules: (1) gas sensors array (MQ2, MQ4, MQ135, DHT22); (2) system controller; and (3) measurement—data capture.
The main sensor system module component MQ4 sensor is specialised in capturing flammable gases in the environment and has an increased sensitivity to CH4 gas (compared to other explosive gases). An additional component integrated to the module is the MQ2 explosive gas sensor, which is a semiconductor sensor optimised for a faster response and sensitivity to lower gas concentrations. The MQ135 sensor is sensitive to various air pollutants and changes in the ratio of carbon dioxide (CO2) with other gases in the air. DHT22 registers current temperature and relative humidity.
The sensor system is controlled by an Arduino microcontroller, a two-line liquid crystal display (LCD) connected to its data output, an integrated module with a real-time clock (RTC) chip, and a secure digital (SD) card reader for date and time stamps recording (
Figure 3).
The data flow is transmitted in real time through the integrated BlueToothTM module HC-06 to any device capable of receiving within a radius of 10 m or more (the exact maximum distance was not tested, as it varies due to environmental conditions). An algorithm in Arduino programming language (C/C ++ based) was developed and implemented for the sensor control.
Multiple sensors in the sensor system allow the results between sensors to be checked in real time and reject incorrect readings or estimate the mean values between several sensors and apply sensor fusion and machine learning algorithms, thus avoiding incorrect measurements with cost-effective electronic components. One data line consists of the read resistances (analogue signal) from the MQ2, MQ4, and MQ135 sensors, and the relative humidity and the temperature (digital signal) from the DHT22 sensor with a time stamp calculated by the RTC module. The data string is saved to the SD card (4 Gb, speed class 10 used) using the RTC module in CSV format by creating a new file after starting the device or adding a new line at the end of the opened digital file. The HC-06 module pairs with the desired Android device and receives a data packet when streaming at a speed of 115,200 kbps to a mobile device (a Samsung S6 Edge + was used) running the Android operating system via a Bluetooth scanning application (the free application ArduTooth was used). During the experimental studies, the data were also transferred to the controller Spectra Precision MobileMapper 50 of the Spectra Precision geodetic GPNS receiver SP60 (
Figure 4).
Global geographic coordinates recorded by a professional geodetic (leisure equipment or consumer grade if necessary) GNSS device moving at the landfill site, in characteristic places or at a given interval (time or distance) are recalculated in the state coordinate system and the height of each point. The sensor measures, records, and transmits readings continuously at a frequency of 1 Hz. The GPNS receiver operates in RTK mode, is configured to, and receives corrections via GSM connection from the network of permanent continuous stations of the control (LitPOS) information system, thus obtaining an average error of no more than 2 cm for the horizontal position. Pre-processing is not required after measurements with the device are made in the area, but in the event of technical obstacles, some data rows may be damaged or recorded incompletely. Such rows need to be taken care of by deleting or manually filling in most common or average values to incomplete rows by using programming tools or Microsoft Excel.
The device was calibrated before using in field measurements.
2.2.2. Device Calibration
The calibration of the gas sensor prototype was performed in the environmental laboratory of Luleå University of Technology in Sweden. A sealed diffusion-proof gas collection bag was used for the tests. Air was removed from the bag before the test by an air compressor. After the electronic components had warmed up (stable readings had been reached), a known amount of gas was injected into the bag through a valve system with a glass syringe (
Figure 5). A high purity gas for laboratory instrument calibration from AGA Gas AB was used for the sensor calibration.
After extracting the gas with an air compressor, known amounts of known gases (CH4, CO2) were injected using a glass syringe. Resistance values measured with the electronic sensor were converted into the gas concentration expressed in ppm. After the first attempt at calibrating the sensors, the device was improved by redesigning the connections, separating the sensor block, and repeating the measurements. The obtained data were used to generate a calibration curve. Additionally, several tests were performed to determine the sensitivity of the sensors and to define the measurement limits and conditions.
Twelve-point tables with increasing known CH4 concentrations and other gases were compiled for each sensor. The values were in a range of 100k ppm up to 500k ppm. Each gas concentration was compared to the decimal analogue value obtained over an average of several 300 s readings. Three test sessions were performed at different concentrations of CH4 and He as the background gas.
The values of each sensor were compared with the precisely known amount of gas through the linear regression equation for the calibration of each sensor. To derive the equation, a linear correlation between the parameters was calculated. The straight-line approximation of the true relationship was made. An important objective of regression analysis is to estimate the unknown parameters in the regression model; this process is also called fitting the model to the data [
18,
19]
The purpose of OLS is to determine estimates of regression parameters that minimise the sum of the squares of the values of the variable dependent on the actual (
) and calculated (
) dependences of the selected regression equation. The method of ordinary least squares mathematically is written as follows:
where
is the actual value,
is the calculated value and
ei is residual of each data point.
Using the statistics theory [
18,
19], the correlation coefficients and the coefficient of determination were calculated, and the analogue values of the decimal system of the sensors and the known concentrations were related.
During testing, calibration, and experiments, the sensor readings and transmissions of the measurement data occurred once a second. After device calibration, an equation for each sensor was obtained; the variance of sample values was calculated, and goodness of fit was expressed by the coefficient of determination.
Using a factory datasheet, another slope was made from the table of points represented in a figure with logarithmic base. The ordinate was the resistance ratio of the sensor (
Rs/Ro), and the abscissa was the concentration of gases.
Rs represented the resistance in a target gas with different concentrations,
Ro indicated the resistance of the sensor in clean air [
20]. Eighteen data points were extracted using the graphing software called “GetData Graph Digitizer”, by extracting values from the intersections of sloped typical sensitivity curve lines and minor axis [
21]. Then, the equation used for the calibration of concentrations from 200 ppm to 5000 ppm was derived. To obtain the
Rs/Ro ratio, an equation was used to convert analogue values to digital ones of the microcontroller to
Ro in clean air, and later, analogue to digital values were recalculated again for each second of measurements in field and divided by
Ro to obtain
Rs/Ro ratio of the landfill site measurements. Then, inverses of laboratory and factory calibration equations were used again. Using the equations, the values measured at the landfill site were transformed into amounts of methane at a certain location and time.
2.2.3. Measurement Processes in the Area of Interest
The main module of the sensor system consisted of an analogue of the open platform microcontroller Arduino Uno with a package of six AA batteries and a compatible cable connector attached to a metal plate using a holder for the GNSS receiver rod, which was fixed 20 cm above the ground (
Figure 6).
Measurements were started by initialising each sensor. The gas sensors started immediately (<1 s), but it took time before the readings stabilised. The time duration depended on how frequently the device was used and on the temperature of each gas sensor. If the device had been switched on during the last couple of hours, it only took around 30 s for the readings to become stable. Otherwise, if the device was kept in warm, it would take some minutes, if used within a month. The device was restarted when stable readings were achieved.
Firstly, Ro values were derived from at least a 30 s average of readings in clean air (clear of gases to be detected). Then, the readings were recalculated based on the calibration equation and Ro for particular air conditions (temperature, humidity, pressure) and voltages, which depended on the sum of all hardware components (inner resistance) and battery charge level. Then, the real-time resistances were recalculated to quantities of the amount of CH4 gas in ppm.
For sensor measurements to be more accurate, the temperature should be close to that previously recommended during the calibration and in the factory specification (approximately 22 °C); the wind should not be strong or there should be a constant internal flow. A strong change in humidity should be avoided if the change is not compensated by a real-time algorithm. The sensors can be upgraded to newer ones or be constructed with better characteristics, in most cases with little or no change to the algorithm code and circuit, and some sensors can be sold pre-calibrated at the factory.