Effect of Mesh Electrode Porosity on the Performance of Fuel-Cell-Based Electrochemical Sensors for Detecting Volatile Alcohols

Author

• Christopher Carrillo, The University of Texas Rio Grande Valley

Date of Award

5-1-2026

Document Type

Thesis

Degree Name

Master of Science in Engineering (MSE)

Department

Electrical Engineering

First Advisor

Ahmed Jalal

Second Advisor

Hasina Huq

Third Advisor

Fahmida Alam

Abstract

Alcohol vapors are frequently encountered in industrial processes, chemical manufacturing, and laboratory environments, where their reliable detection is essential for safety and control. Due to their volatility and potential health risks, accurate detection at low and moderate concentrations is critical. Fuel cell-based electrochemical sensors have become established as effective platforms for alcohol detection thanks to their ability to convert electrochemical reactions into measurable electrical signals with high sensitivity and rapid response. However, sensor performance is strongly influenced by the electrode structure, particularly by mesh porosity and the electrochemically active surface area, factors that govern vapor diffusion, reaction kinetics, and charge transfer processes.

In this study, the impact of mesh electrode porosity on sensor performance was investigated using woven Monel mesh electrodes with different mesh sizes (50, 100, and 200). The mesh structure determines the pore size, thread density, and available surface area, directly affecting electrochemical activity. Lower mesh densities provide larger pores that facilitate vapor diffusion, while higher mesh densities increase the number of active sites available for electrochemical reactions. Therefore, it was hypothesized that a higher mesh density would improve the sensor's sensitivity and stability due to greater surface interaction.

An electrochemical fuel cell-based sensor was developed using a phosphotungstic acid-doped SPEEK membrane combined with Monel mesh electrodes. The sensor was characterized by open-circuit potential (OCP), cyclic voltammetry (CV), and amperometric current-time (i-t) measurements under controlled vapor exposure conditions. Methanol and isopropanol (IPA) were evaluated in a concentration range of 1 to 500 ppm to determine the sensor's performance.

Experimental results demonstrated that the 200-mesh electrode provided the strongest electrochemical response, exhibiting a clearly concentration-dependent behavior and a high correlation (R² ≈ 0.978), indicating reliable detection capabilities. The improved performance is attributed to the larger electrochemically active surface area, which enhances alcohol oxidation and signal generation. Repeatability and reproducibility tests confirmed the sensor's stable operation.

The results demonstrate that mesh electrode porosity plays a critical role in the performance of fuel cell-based electrochemical sensors for alcohol vapor detection. These findings highlight the importance of electrode structural design for optimizing sensitivity and stability in practical detection applications.

Comments

Copyright 2026 Christopher Carrillo. All Rights Reserved. https://proquest.com/docview/3371180794

Recommended Citation

Carrillo, C. (2026). Effect of Mesh Electrode Porosity on the Performance of Fuel-Cell-Based Electrochemical Sensors for Detecting Volatile Alcohols [Master's thesis, The University of Texas Rio Grande Valley]. ScholarWorks @ UTRGV. https://scholarworks.utrgv.edu/etd/1945