(Invited) Past, Present and Future for Electrochemical Gas Sensors in Energy Applications
Authors: Stetter Joseph R. , Russ Tamara 
Published: August 2024

The markets for modern low-cost electrochemical gas sensors have been growing for longer than sensors have been around. Energy markets for gas sensors include the oil, gas and electricity industries as well as the new developing and fast growing green energy sectors. The primary gases to detect include combustible hydrocarbons, oxygen, and toxic gases. Specifically, we are interested in methane (blue and green), ammonia, and H2 for the renewable energy sectors but include hydrocarbon fuels and CO2 as a greenhouse gas emission. The reasons for monitoring crosscut all areas of the energy business and include applications in production, transport, storage and use. Primary sensor uses include: 1) health and safety (people and assets), 2) leak detection and isolation to help mitigate product losses, 3) monitoring to protect the environment and 4) measurements for process control and efficacy. Each of these areas of sensing have special requirements and demand cost-effective and time efficient sensor performance in many and varied real world scenarios.

Electrochemical gas sensors have a long and rich history starting with the commercialization of the first practical potentiometric CO2 gas sensor by Severinghaus in 1954 and the O2 amperometric sensor by Clark in 1956 that launched the modern blood gas analysis industry. Additional milestones include the introduction of the “diffusion electrode” in 1968 creating the modern amperometric sensor which has produced a large array of sensors for toxic and hazardous gases including H2, ammonia, and other energy gases. Progress has been made in the field of electrochemical gas sensors, not only in improving performance, sensitivity, selectivity, response time, and stability, but also in logistical properties including miniaturization, lower power consumption, low cost as well as communication and computation to make automated-operational systems. New high-volume production has contributed to lower costs commensurate with a chip-based sensor mentality. The evolution of one of the gas sensor technologies is given below (the room temperature AGS or amperometric gas sensor) and similar progress has been seen in mixed potential and solid state gas sensors.

The growing understanding of the sensor’s fundamental electrocatalytic reactions has led to tailored designs of electrode-electrolyte combinations and packages for the various applications. Often ignored in sensor publications of performance, the fundamental electrocatalytic studies are poised to make significant advances in energy gas sensor selectivity and sensitivity. The additional implementation of intelligent algorithms (AI/ML) to make “smart” sensors and sensor arrays complements advanced nano-materials and designs for improving sensor performance. One major improvement is our understanding of the sensor response mechanisms at the electrocatalytic level. This new research will enable new electrochemical sensor advances that are poised to impact the health and wellbeing of both people and the planet. Ideas and concepts that significantly contribute to the safe and efficient rollout of the newest green energy platforms are presented.

Figure 1