Boosting New Electrochemical Reactor Designs to Improve the Performance in H2O2 Production Using Gas Diffusion Electrodes

Abstract

This work presents a novel electrochemical cell design, developed using 3D printing technology, which enhances turbulence within the cell to promote increased hydrogen peroxide production. This new design is compared to a conventional flow cell that utilizes the same electrodes, membrane, and interelectrode distance, which has demonstrated strong performance in previous studies. Fluid dynamics and H₂O₂ production are analyzed in both reactors to assess their performance. Additionally, a scale factor of 12.5 is applied to the new concept to evaluate its effectiveness on a larger scale and increase the technology readiness level (TRL). The results demonstrate Faradaic efficiencies of 90% and energy consumption as low as 13 kW h kg^–1, placing them among the highest reported in the literature. The use of identical materials and operating conditions underscores the critical role of mechanical design in electrochemical cells, suggesting that future research in environmental electrochemical technology should prioritize cell designs tailored to specific target processes.