Engineered Porosity ZnO Sensor Enriched with Oxygen Vacancies Enabled Extraordinary Sub-ppm Sensing of Hydrogen Sulfide and Nitrogen Dioxide Air Pollution Gases at Low Temperature in Air

We report the results of a zinc oxide (ZnO) low-power microsensor for sub-ppm detection of NO2 and H2S in air at 200 °C. NO2 emission is predominantly produced by the combustion processes of fossil fuels, while coal-fired power plants are the main emitter of H2S. Fossil fuels (oil, natural gas, and coal) combined contained 74% of USA energy production in 2023. It is foreseeable that the energy industry will utilize fossil-based fuels more in the ensuing decades despite the severe climate crises. Precise NO2 and H2S sensors will contribute to reducing the detrimental effect of the hazardous emission gases, in addition to the optimization of the combustion processes for higher output. The fossil fuel industry and solid-oxide fuel cells (SOFCs) are exceptional examples of energy conversion–production technologies that will profit from advances in H2S and NO2 sensors. Porosity and surface activity of metal oxide semiconductor (MOS)-based sensors are both vital for sensing at low temperatures. Oxygen vacancies ((Formula presented.)) act as surface active sites for target gases, while porosity enables target gases to come in contact with a larger MOS area for sensing. We were able to create an open porosity network throughout the ZnO microstructure and simultaneously achieve an abundance of oxygen vacancies by using a heat treatment procedure. Surface chemistry and oxygen vacancy content in ZnO were examined using XPS and AES. SEM was used to understand the morphology of the unique characteristics of distinctive grain growth during heat treatment. Electrical resistivity measurements were completed. The valance band was examined by UPS. The Engineered Porosity approach allowed the entire ZnO to act as an open surface together with the creation of abundant oxygen vacancies ((Formula presented.)). NO2 detection is challenging since both oxygen (O2) and NO2 are oxidizing gases, and they coexist in combustion environments. Engineered porosity ZnO microsensor detected sub-ppm NO2 under O2 interference, which affects mimicking realistic sensor operation conditions. Engineered porosity ZnO performed better than the previous literature findings for H2S and NO2 detection. The exceptionally high sensor response is attributed to the high number of oxygen vacancies ((Formula presented.)) and porosity extending through the thickness of the ZnO with a high degree of tortuosity. These features enhance gas adsorption and diffusion via porosity, leading to high sensor response.