Scale-up of the perforated bipole trickle-bed electrochemical reactor for the generation of alkaline peroxide

This paper reports work on the scale-up of a perforated bipole trickle-bed electrochemical reactor for the electro-synthesis of alkaline peroxide. The reactor uses a relatively simple cell configuration in which a single electrolyte flows with oxygen gas in a flow-by graphite felt cathode, sandwiched between a microporous polyolefin diaphragm and a nickel mesh/perforated Grafoil anode/bipole. Both one and two-cell reactors are scaled-up from cathode dimensions 120 mm high by 25 mm wide and 3.2 mm thick (reactor-A) to 630 mm high by 40 mm wide and 3.2 mm thick (reactor-B). The scale-up is achieved by the use of constrictions that prevent segregation of the 2-phase flow in the larger cell, combined with switching from a polypropylene to a polyethylene diaphragm with improved transport properties and raising the electrolyte feed concentration from 1 to 2 M NaOH.For the one-cell reactor-B with a polypropylene diaphragm, operating on a feed of 1 M NaOH and oxygen at 900 kPa(abs)/20 °C, the peroxide current efficiency at a superficial current density of 5 kA m⁻² increases from 27% (un-constricted cathode) to 57% with a constricted cathode. The corresponding current efficiencies at 3–5 kAm⁻² for reactor-A and the constricted reactor-B are respectively 69–64% and 66–57%. Under similar conditions at 3–5 kA m⁻² the one-cell constricted reactor-B with a polyethylene diaphragm gives current efficiencies of 88–64%, and changing to an electrolyte of 2 M NaOH raises this range to 90–80%. At 3–5 kA m⁻² the equivalent two-cell (bipolar) constricted reactor-B shows current efficiencies of 82–74% and at 5 kA m⁻² obtains 0.6 M peroxide in 2 M NaOH with specific energy 6.5 kWh per kg H₂O₂.     

Electrocatalytic hydrogenation of soybean oil in a radial flow-through Raney nickel powder reactor

Soybean oil has been hydrogenated electrocatalytically on Raney nickel powder catalyst at atmospheric pressure and moderate temperatures in a novel undivided packed bed radial flow-through reactor. The reactor consisted of a single anode/cathode tubular element, where Raney nickel catalyst powder was contained in the annular space between two concentric porous ceramic tubes and the flow of the reaction medium (a dispersion of oil in a water/t-butanol/tetraethylammonium p-toluenesulfonate electrolyte) was either in the inward or outward radial direction. The innovative design of this reactor allows for a thin nickel bed and a high anode/cathode interfacial area without the normal problems associated with electrolyte flow distribution. The total size of the reactor can be increased without changing the relative anode/cathode position and the electrolyte flow pattern by simply increasing the length and/or number of anode/cathode elements in a single common shell (similar to a shell-and-tube heat exchanger). For the brush hydrogenation of soybean oil, current efficiencies of 90–100% were achieved with a single element reactor when the electrolyte oil content was 10 or 25 wt/vol %, the apparent current density was 10 or 15 mA cm^–2, the temperature was 75 °C, and the electrolyte flowed in the inward radial direction. The electrohydrogenated oil product was characterized by a high stearic acid content and low concentrations of linolenic acid and trans fatty acid isomers, as compared to the traditional high temperature chemical catalytic oil hydrogenation route with hydrogen gas.     

Characterisation of a laboratory electrochemical ozonation system and its application in advanced oxidation processes

An electrochemical reactor for oxygen/ozone production was developed using perforated planar electrodes. An electroformed -PbO₂ coating, deposited on a platinised titanium substrate, was employed as anode while the cathode was a platinised titanium substrate. The electrodes were pressed against a solid polymer electrolyte to minimise ohmic drop and avoid mixing of the gaseous products (H₂ and O₂/O₃). Electrochemical ozone production (EOP) was investigated as function of current density, temperature and electrolyte composition. Electrochemical characterisation demonstrated ozone current efficiency, Φ_EOP, ozone production rate (g h⁻¹), , and grams of O₃ per total energy demand (g h⁻¹ W⁻¹), increase on decreasing electrolyte temperature and increasing current density. The best reactor performance for EOP was obtained with the base electrolyte (H₂SO₄ 3.0 mol dm⁻³) containing 0.03 mol dm⁻³ KPF₆. Degradation of reactive dyes used in the textile industry (Reactive Yellow 143 and Reactive Blue 264) with electrochemically-generated ozone was investigated in alkaline medium as function of ozone load (mg h⁻¹) and ozonation time. This investigation revealed ozonation presents very good efficiency for both solution decolouration and total organic carbon (TOC) removal.     

Mathematical model for a direct propane phosphoric acid fuel cell

A mathematical model was developed and used to predict the performance of direct propane phosphoric acid (PPAFC) fuel cells, utilizing both Pt/C state-of the-art electrodes and older Pt black electrodes. It was found that the overpotential caused by surface processes on the platinum catalyst in the anode is much greater than the potential losses caused by either ohmic resistance or propane diffusion in gas-filled and liquid-filled pores. In one comparison, the anode overpotential (0.5 V) was larger than the cathode overpotential (0.3 V) at a current density of 0.4 A cm⁻² for Pt loadings 4 mg Pt cm⁻². The need for sufficient water concentration at the anode, where water is a reactant, was indicated by the large effect of H₃PO₄ concentration. In another comparison, the model predicted that at 0.2 A cm⁻², modern carbon supported Pt catalysts would produce 0.35 V compared to 0.1 V for unsupported Pt black catalysts that were used several decades ago, when the majority of the research on direct hydrocarbon fuel cells was performed. The propane anode and oxygen cathode catalyst layers were modeled as agglomerates of spherical catalyst particles having their interior spaces filled with liquid electrolyte and being surrounded by gas-filled pores. The Tafel equation was used to describe the electrochemical reactions. The model incorporated gas and liquid-phase diffusion equations for the reactants in the anode and cathode and ionic transport in the electrolyte. Experimental data were used for propane and oxygen diffusivities, and for their solubilities in the electrolyte. The accuracy of the predicted electrical potentials and polarization curves were normally within ±0.02 V of values reported in experimental investigations of temperature and electrolyte concentration. Polarization curves were predicted as a function of temperature, pressure, electrolyte concentration, and Pt loading. A performance of 0.45 V at 0.5 A cm⁻² was predicted at some conditions.     

Fabrication and performance of PEN SOFCs with proton-conducting electrolyte

A positive-electrolyte-negative (PEN) assembly solid oxide fuel cell (SOFC) with a thin electrolyte film for intermediate temperature operation was fabricated. Instead of the traditional screen-printing method, both anode and cathode catalysts were pressed simultaneously and formed with the fabrication of nano-composite electrolyte by press method. This design offered some advantageous configurations that diminished ohmic resistance between electrolyte and electrodes. It also increased the proton-conducting rate and improved the performance of SOFCs due to the reduction of membrane thickness and good contact between electrolyte and electrodes. The fabricated PEN cell generated electricity between 600°C and 680°C using H₂S as fuel feed and air as oxidant. Maximum power densities 40 mW·cm⁻² and 130 mW·cm⁻² for the PEN configuration with a Mo-Ni-S-based composite anode, nano-composite electrolyte (Li₂SO₄+Al₂O₃) film and a NiO-based composite cathode were achieved at 600°C and 680°C, respectively.     

Characterizations of composite cathodes with La0.6Sr0.4Co0.2Fe0.8O3?δ and Ce0.9Gd0.1O1.95 for solid oxide fuel cells

Composite cathodes with La_0.6Sr_0.4Co_0.2Fe_0.8O_3−δ (LSCF) and Ce_0.9Gd_0.1O_1.95 (GDC) are investigated to assess for solid oxide fuel cell (SOFC) applications at relatively low operating temperatures (650–800 °C). LSCF with a high surface area of 55 m²g⁻¹ is synthesized via a complex method involving inorganic nano-dispersants. The fuel cell performances of anode-supported SOFCs are characterized as a function of compositions of GDC with a surface area of 5 m²g⁻¹. The SOFCs consist of the following: LSCF-GDC composites as a cathode, GDC as an interlayer, yttrium stabilized zirconia (YSZ) as an electrolyte, Ni-YSZ (50: 50 wt%) as an anode functional layer, and Ni-YSZ (50: 50 wt%) for support. The cathodes are prepared for 6LSCF-4GDC (60: 40 wt%), 5LSCF-5GDC (50: 50 wt%), and 4LSCF-6GDC (40: 60 wt%). The 5LSCF-5GDC cathode shows 1.29 Wcm⁻², 0.97 Wcm⁻², and 0.47 Wcm⁻² at 780 °C, 730 °C, and 680 °C, respectively. The 6LSCF-4GDC shows 0.92 Wcm⁻², 0.71 Wcm⁻², and 0.54 Wcm⁻² at 780 °C, 730 °C, and 680 °C, respectively. At 780 °C, the highest fuel cell performance is achieved by the 5LSCF-5GDC, while at 680 °C the 6LSCF-4GDC shows the highest performance. The best composition of the porous composite cathodes with LSCF (55 m²g⁻¹) and GDC (5 m²g⁻¹) needs to be considered with a function of temperature.     

Optimization of the process parameters for an electrochemical preparation of strontium perchlorate

The electrochemical preparation of strontium perchlorate, Sr(ClO₄)₂, from strontium chlorate employing platinum anode and a rotating stainless steel cathode is described. The effect of electrolyte concentration, current density, pH and temperature of the electrolyte and cathode rotation on current efficiency for the preparation of strontium perchlorate was studied. A maximum current efficiency of 42% was achieved corresponding to an energy consumption of 6.1 kWh. kg⁻¹.     

Effects of lanthanum strontium cobalt ferrite (LSCF) cathode properties on hollow fibre micro-tubular SOFC performances

Single layer La_0.6Sr_0.4Co_0.2Fe_0.8O₃ hollow fibre (HF) precursors (<1 mm ID) produced by phase inversion (PI) were sintered at 1,200, 1,350 and 1,400 °C. The increase in sintering temperature resulted in microstructural changes in the LSCF fibres, reflected in their electrical conductivities. LSCF-based cathodes with different designs were brushed onto co-extruded nickel–gadolinium-doped ceria (CGO) anode/CGO electrolyte dual-layer HFs (<1 mm ID) fabricated by PI. The effect of cathode layers on the overall performance of the fuel cells (FCs) was assessed using nearly identical anode and electrolyte compositions, thicknesses, and microstructures. Cathode microstructure design caused cells to perform differently producing peak power densities of 0.35–0.7 W cm⁻² at 600 °C. Impedance spectroscopy analysis at 600 °C on the FCs produced 0.12–0.24 Ω cm² confirming the cathode’s structural effect on the overall area-specific resistance of the FCs. The best performing FC with a brush-deposited cathode was compared to a similar FC where cathode was deposited by dip coating; at 600 °C the first produced 0.6 W cm⁻² while the second cell 0.7 W cm⁻². Co-extruding anodes and electrolytes by using PI and combining dip coating for cathode deposition could lead to the fabrication of FCs with enhanced microstructures and improved performances.     

Electrochemical reforming of CH4−CO2 mixed gas using porous Gd-doped ceria electrolyte with Cu electrode

This paper reports on the composition and flow rate of outlet gas and current density during the reforming of CH₄ with CO₂ using three different electrochemical cells: cell A, with Ni−GDC (Gd-doped ceria: Ce_0.8Gd_0.2O_1.9) cathode/porous GDC electrolyte/Cu−GDC anode, cell B, with Cu−GDC cathode/ porous GDC electrolyte/Cu−GDC anode and cell C, with Ru−GDC cathode/ porous GDC electrolyte/ Cu−GDC anode. In the cathode, CO₂ reacts with supplied electrons to form CO fuel and O²⁻ ions (CO₂+2e⁻→CO+O²⁻). Too low affinity of Cu cathode to CO₂ in cell B reduced the reactivity of the CO₂ with electrons. The CO fuel, O²⁻ ions and CH₄ gas were transported to the anode through the porous GDC mixed conductor of O²⁻ ions and electrons. In the anode, CH₄ reacts with O²⁻ ions to produce CO and H₂ fuels (CH₄+O²⁻→2 H₂+CO+2e⁻). The reforming efficiency at 700−800 °C was lowest in cell B and highest in cell A. The Cu anode in cells A and C worked well to oxidize CH₄ with O²⁻ ions (2Cu+O²⁻→Cu₂O+2e⁻, Cu₂O+CH₄→2Cu+CO+2H₂). However, a blockage of the outlet gas occurred in all the cells at 700−800 °C. The gas flow is inhibited due to a reduction in pore size in the cermet cathode, as well as sintering and grain growth of Cu metal in the anode during the reforming.     

Alkaline peroxide generation using a novel perforated bipole trickle-bed electrochemical reactor

A novel perforated bipole trickle-bed electrochemical reactor is investigated for the electro-synthesis of alkaline peroxide. The process uses a relatively simple cell configuration in which a single electrolyte flows with oxygen gas in a flow-by graphite felt cathode, sandwiched between a micro-porous diaphragm and a perforated bipolar electrode plate. The graphite felt cathodes are 120 mm high by 25 mm wide and have a thickness of 3.2 mm. The reactor is operated at current densities in the range 1–5 kA m⁻², ca. 800 kPa (abs) pressure and temperature (In/Out) 20–45 °C with one and two-cells. The reactor shows good performance (current efficiency ∼78% at 2 kA m⁻² and a specific energy of 5 kWh per kg of peroxide generated) with peroxide concentrations from 0.02 to 0.15 M in 1 M NaOH.     

A parametric study of a platinum ruthenium anode in a direct borohydride fuel cell

Data on the performance of a direct borohydride fuel cell (DBFC) equipped with an anion exchange membrane, a Pt–Ru/C anode and a Pt/C cathode are reported. The effect of oxidant (air or oxygen), borohydride and electrolyte concentrations, temperature and anode solution flow rate is described. The DBFC gives power densities of 200 and 145 mW cm⁻² using ambient oxygen and air cathodes respectively at medium temperatures (60 °C). The performance of the DBFC is very good at low temperatures (ca. 30 °C) using modest catalyst loadings of 1 mg cm⁻² for anode and cathode. Preliminary data indicate that the cell will be stable over significant operating times.     

Ameliorating effect of silica addition in the anode-catalyst layer of the membrane electrode assemblies for polymer electrolyte fuel cells

Incorporation of silica particles through a sol-gel process into the anode-catalyst layer with a sol-gel modified Nafion-silica composite membrane renders easy retention of back-diffused water from the cathode to anode through the composite membrane electrolyte, increases the catalyst-layer wettability and improves the performance of the Polymer Electrolyte Fuel Cell (PEFC) while operating under relative humidity (RH) values ranging between 18% and 100% with gaseous hydrogen and oxygen reactants at atmospheric pressure. A peak power density of 300 mW cm⁻² is achieved at a load current-density value of 1200 mA cm⁻² for the PEFC employing a sol-gel modified Nafion-silica composite membrane and operating at 18% RH. Under similar operating conditions, the PEFC with a Membrane Electrode Assembly (MEA) comprising Nafion-silica composite membrane with silica in the anode-catalyst layer delivers a peak power density of 375 mW cm⁻². By comparison, the PEFC employing commercial Nafion membrane fails to deliver satisfactory performance at 18% RH due to the limited availability of water at its anode, acerbated electro-osmotic drag of water from anode to cathode and insufficient water back diffusion from cathode to anode causing the MEA to dehydrate.     

The electrochemical hydrogenation of edible oils in a solid polymer electrolyte reactor. I. Reactor design and operation

A new electrochemical method has been devised and tested for the moderate temperature/atmospheric pressure hydrogenation of edible oils, fatty acids, and fatty acid methyl esters. The method employed a solid polymer electrolyte (SPE) reactor, similar to that used in H₂/O₂ fuel cells, with water as the source of hydrogen. The key component of the reactor was a membrane-electrode-assembly, composed of a RuO₂ powder anode and either a Pt-black or Pd-black powder cathode that were hot-pressed as thin films onto the opposing surfaces of a Nafion cation-exchange membrane. During reactor operation at a constant applied current, water was back-fed to the RuO₂ anode, where it was oxidized electrochemically to O₂ and H⁺. Protons migrated through the Nafion membrane under the influence of the applied electric field and contacted the Pt or Pd cathode, where they were reduced to atomic and molecular hydrogen. Oil was circulated past the back side of the cathode and unsaturated triglycerides reacted with the electrogenerated hydrogen species. The SPE reactor was operated successfully at a constant applied current density of 0.10 A/cm² and a temperature between 50 and 80°C with soybean, canola, and cottonseed oils and with mixtures of fatty acids and fatty acid methyl esters. Reaction products with iodine values in the range of 60–105 were characterized by a higher stearic acid content and a lower percentage of trans isomers than those produced in a traditional hydrogenation process.     

Fabrication of YSZ electrolyte for intermediate temperature solid oxide fuel cell using electrostatic spray deposition: II – Cell performance

Electrostatic spray deposition (ESD) was applied to fabricate a thin-layer of yttria-stabilized zirconia (YSZ) electrolyte on a solid oxide fuel cell (SOFC) anode substrate consisting of nickel-YSZ cermet. A colloidal solution of 8 mol% YSZ in ethanol was sprayed onto the substrate anode surface at 250–300 °C by ESD. After sintering the deposited layer at 1250–1400 °C for 1–2 h depending on temperature, the cathode layer, consisting of lanthanum strontium manganate (LSM), was sprayed or brush coated onto the electrolyte layer. Performance tests and AC impedance measurements of the complete cell were carried out at 800 °C to evaluate the density and conductance of the electrolyte layer formed by ESD. With a 97% H₂/3% H₂O mixture and air as fuel and oxidant gas, respectively, the open-circuit voltage (OCV) was close to theoretical and electrolyte impedance was about 0.23Ω cm². A power density of 0.45 W cm⁻² at 0.62 V was obtained. No abnormal degradation was observed after 170 h operation. The electrolyte sintering temperature and time did not significantly affect the electrolyte impedance. on leave from     

Chemical Bulk Diffusion Coefficient of a La0.5Sr0.5CoO3−δ Cathode for Intermediate‐Temperature Solid Oxide Fuel Cells

In the first part of this study, the characteristics of a La_0.5Sr_0.5CoO_3?δ cathode are described, including its chemical bulk diffusion coefficient (D_chem), and electrical conductivity relaxation experiments are performed to obtain experimental D_chem measurements of this cathode. The second part of this study describes two methods to improve the single‐cell performance of solid oxide fuel cells. One method uses a composite cathode, i.e., a mix of 30 wt% electrolyte and 70 wt% cathode; the other method uses an electrolyte‐infiltrated cathode, i.e., an active ionic‐conductive electrolyte with nano‐sized particles is deposited onto a porous cathode surface using the infiltration method. In this work, 0.2M Ce_0.8Sm_0.2O_1.9 (SDC)‐infiltrated La_0.5Sr_0.5CoO_3?δ exhibits a maximum peak power density of 1221 mW/cm² at an operating temperature of 700°C with a thick‐film SDC electrolyte (30 μm), a NiO + SDC anode (1 mm) and a La_0.5Sr_0.5CoO_3?δ cathode (10 μm). The enhancement in electrochemical performances using the electrolyte‐infiltrated cathode is attributed to the creation of electrolyte/cathode phase boundaries, which considerably increases the number of electrochemical sites available for the oxygen reduction reaction.     

Underscale corrosion behavior of carbon steel in a NaCl solution using a new occluded cavity cell for simulation

A new occluded corrosion cavity (OCC) simulation cell was designed to study the underscale corrosion behavior of carbon steel (N80) in 0.2 mol L⁻¹ NaCl solution. The chemical components of the solution in the OCC were measured and the electrochemical behavior of the occluded anode and the bulk cathode were studied by electrochemical impedance spectroscopy (EIS). The newly designed OCC cell can easily simulate the auto-catalyzing acidification process and may be used to study the mechanism of underscale corrosion. The corrosion scale exacerbates the underscale corrosion and the area ratio of the bulk cathode to the occluded anode (R = S_c/S_a) determines the development of simulated localized corrosion in the OCC cell. When R was within a certain range, the corrosion rate in the OCC could be kept at a persistently high level. The pH of the solution in the OCC decreased and the chloride ions (Cl⁻) concentrated as the local corrosion developed. The anodic process on the occluded anode was controlled by irreversible charge transfer and the cathodic process on the bulk cathode was controlled mainly by oxygen diffusion.     

Evaluation of porous cathodes for the electrochemical reduction of nitrates and nitrites in alkaline waste streams

This paper describes the mathematical modelling and experimental work performed to evaluate porous cathodes for the electrochemical reduction of nitrates and nitrites in alkaline waste streams. A dynamic model of a batch process was developed that included a divided cell with a porous cathode, a cation-selective separator, a planar anode, and reservoirs for electrolyte recirculation and gas–liquid separation. Constant current experiments were done using a divided cell with nickel foam as the porous cathode. The experiments were performed with a catholyte feed of either 0.6 M NaNO₂ or 1.95 M NaNO₃, both supported by a 1.33 M NaOH solution, a current density of 0.25 A cm^–2 and a solution temperature of 32 C. The experimental results showed that the ammonia production reaction is the dominant cathodic reaction (80% of the current). Estimates of the kinetic parameters were obtained using the experimental data and the model. The model was then used to simulate and study the performance of the porous electrode compared to the planar electrode for a range of operating currents. The results showed that at the optimum current density for a planar electrode of 0.25 A cm^–2, use of a porous cathode results in one-third the energy costs and time required to achieve 95% destruction of nitrate and nitrite compared to a planar cathode. At 0.40 A cm^–2, the energy and time required to achieve 95% destruction was an order-of-magnitude less for the porous electrode.     

An experimental study of aluminium electrowinning using a nickel-based hydrogen diffusion anode

Laboratory scale electrolysis experiments were conducted to investigate the electrowinning of aluminium using hydrogen diffusion anodes. A potassium-based electrolyte (KF–AlF₃–Al₂O₃), porous nickel alloy anode and molybdenum disk cathode were used in experiments at 750 °C. Hydrogen gas was supplied to the anode/electrolyte interface through the porous anode. Experiments were conducted in potentiostatic, galvanostatic and galvanodynamic modes. There was a measurable depolarisation of the anode potential and also anode reaction of hydrogen and oxygen ions in the bath to form water vapour was confirmed by the water vapour condensate found at the electrolysis exit gas pipe. Metallic aluminium was found on the spent cathode. The experiments conducted in the galvanodynamic mode suggested that the rate limiter for hydrogen oxidation was the availability of surface hydrogen at the anode/electrolyte interface. The anode surface corroded during electrolysis and impurities were found both in the molten bath and on the cathode.     

Role of Mo<Superscript>6+</Superscript> during nickel electrodeposition from sulfate solutions

The effect of Mo⁶⁺ on the current efficiency, deposit quality, surface morphology, crystallographic orientations and polarisation behaviour of the cathode during electrodeposition of nickel from sulfate solutions was investigated. Mo⁶⁺ did not have a significant effect on current efficiency over the concentration range 2–100 mg dm⁻³. However; a decrease in current efficiency by a magnitude of more than 20% was seen at 500 mg dm⁻³. The quality of the nickel deposit with reference to the visual appearance and contamination level varied with varying concentration of Mo⁶⁺; this was also reflected in the morphology and crystallographic orientations of the deposits. Addition of Mo⁶⁺ to the electrolyte introduced two new crystal planes i.e., (220) and (311). Depolarisation of the cathode was noted at lower concentrations of Mo⁶⁺ (2–40 mg dm⁻³) whereas polarisation of the cathode was observed at Mo⁶⁺ concentration >40 mg dm⁻³ .The effect of Mo⁶⁺ on parameters such as Tafel slope (b), transfer coefficient (α) and exchange current density (i ₀) were also determined.     

Electronic Switch in the Carbon-Centered [Re12CS17(CN)6] n− Nanocluster

An abrupt change in internuclear Re–Re distances between {Re₆} subunits in the carbon-centered [Re₁₂μ₆-CS₁₇(CN)₆] ⁿ⁻ complexes caused by the change of the oxidation state (n = 6, 8) is first theoretically shown to be possibly controlled by an external electric field. ¹³C NMR signal is shown to change over ~400 ppm (~37G) for μ₆-C atom together with n. Thereby, the metal cluster [Re₁₂μ₆-CS₁₇(CN)₆] ⁿ⁻ can be considered as a perspective model of a molecular switch.