Zinc oxide-based sensor prepared by modified sol–gel route for detection of low concentrations of ethanol, methanol, acetone, and formaldehyde

Abstract We successfully synthesized zinc oxide (ZnO) nanoparticles using the sol–gel method, followed by their application onto alumina substrates for sensor testing. Comprehensive characterization of the nanomaterials was carried out utilizing XRD, SEM, TEM, UV–VIS-IR, and Photoluminescence (PL) techniques. The nanoparticles displayed a hexagonal wurtzite crystal structure, typical of ZnO. UV–Vis-IR spectroscopy revealed significant absorption in the UV region, with the band gap energy calculated to be 3.22 eV. PL spectra indicated the presence of various defects, such as oxygen vacancies and zinc interstitials, within the ZnO structure. SEM analysis of the deposited film surface showed spherical agglomerates, confirming the nanoscale dimensions, while energy-dispersive x-ray spectroscopy spectra affirmed the high purity of the ZnO films, rich in Zn and O elements. Sensor tests demonstrated the ZnO sensor’s high sensitivity to low concentrations of volatile organic compounds such as ethanol, formaldehyde, methanol, and acetone. Notably, at an operational temperature of 300 °C, the sensor exhibited a remarkable response to 5 ppm of each gas, with the following response and response/recovery times: for methanol, 11.47 and 36 s/57 s; for acetone, 11.54 and 25 s/52 s; for formaldehyde, 0.79 and 53 s/58 s; and for ethanol, 3.88 and 9 s/59 s.