Design, Fabrication and Validation of Chemical Sensors for Detecting Hydrocarbons to Facilitate Oil Spillage Remediation

To address the environmental hazards posed by oil spills and the limitations of conventional hydrocarbon monitoring techniques, a cost-effective and user-friendly gas sensor system was developed for the real-time detection and quantification of hydrocarbon contaminants in soil. This system utilizes carbon black (CB)-filled poly(methyl methacrylate) (PMMA) and poly(vinyl chloride) (PVC) nanocomposites to create chemoresistive sensors. The CB-PMMA and CB-PVC composites were synthesized and deposited as thin films onto interdigitated electrodes, with their morphologies characterized using scanning electron microscopy. The composites, optimized at a composition of 10% w/w CB and 90% w/w polymer, exhibited a sensitive response to hydrocarbon vapors across a tested range from C20 (99 ppmV) to C8 (8750 ppmV). The sensor’s response mechanism is primarily attributed to the swelling-induced resistance change of the amorphous polymer matrix in hydrocarbon vapors. These findings demonstrate the potential use of CB–polymer composites as field-deployable gas sensors, providing a rapid and efficient alternative to traditional gas chromatography methods for monitoring soil remediation efforts and mitigating the environmental impact of oil contamination.