Chemical Engineering Journal Advances最新文献

{"title":"Experimental and numerical study of non-spherical particles in moving bed heat exchangers","authors":"Aidana Boribayeva ,&nbsp;Arsen Musahanov ,&nbsp;Assiya Baigarina ,&nbsp;Islam Lukmanov ,&nbsp;Sultan Sultaniyar ,&nbsp;Assanali Patkhollayev ,&nbsp;Nicolin Govender ,&nbsp;Boris Golman","doi":"10.1016/j.ceja.2025.100859","DOIUrl":"10.1016/j.ceja.2025.100859","url":null,"abstract":"<div><div>Moving Bed Heat Exchangers (MBHE) are vital for high-temperature thermal management in applications like concentrated solar power and waste heat recovery. Although spherical particles are often used in MBHE research, industrial granular materials typically have complex, non-spherical shapes that significantly influence flow, packing, and heat transfer. This study investigates the flow behavior and heat transfer of non-spherical particles in a staggered tube MBHE, comparing with spherical particles. The first objective involves experimentally characterizing the flow of non-spherical and spherical bauxite particles around a tube using a particle tracking technique and subsequently validating a Discrete Element Method model. The second objective utilizes the validated model to analyze flow, heat transfer, and packing structure under varying outlet velocities. Non-spherical particles form broader stagnation zones, asymmetric sidewall flow, and narrower void zones, enhancing tube contact. Spherical particles create narrower stagnation and wider void zones with less contact. Cylindrical particles heat the tube faster and stabilize temperature earlier due to larger contact areas, while spherical particles heat slower with smaller contact areas. Furthermore, the packing structure at the tube surface was thoroughly analyzed for cylindrical particles for contact types classification. Higher outlet velocities enhance cylindrical particle alignment, thereby increasing the number of thermally favorable contact types as face–plane with larger contact areas. In contrast, spherical particles maintain more uniform but significantly small contact areas. Nonspherical particles significantly improve MBHE performance by enhancing flow behavior, particle–tube contact, and heat transfer efficiency, enabling more effective thermal management solutions in industrial applications.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100859"},"PeriodicalIF":7.1,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096190","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel poly(ether-Sulfone) mixed matrix membranes infused with TiO2-BiFeO3 nanomaterials for the removal of toxic Congo red dye from textile wastewater","authors":"Hussain Ali Ibrahim ,&nbsp;Khalid T. Rashid ,&nbsp;Adnan A. AbdulRazak ,&nbsp;Mohammed Ahmed Shehab ,&nbsp;Mohammed A. Salih ,&nbsp;Munaf Al-lami ,&nbsp;Mohammed A.Taher Al-Mayyahi ,&nbsp;Sarah Z. Al-Ashoor ,&nbsp;Sahab K. Shakir ,&nbsp;Haidar Hasan Mohammed ,&nbsp;Alhafadhi Mahmood","doi":"10.1016/j.ceja.2025.100867","DOIUrl":"10.1016/j.ceja.2025.100867","url":null,"abstract":"<div><div>By modification of ultrafiltration (UF) membranes for increased water flow and enhanced antifouling qualities, this work fills a significant gap in membrane filtration. Nonsolvent-induced phase separation (NIPS) was used to create a self-cleaning polyethersulfone (PES) membrane functionalized with TiO₂-BiFeO₃ (TBF) nanoparticles. FTIR, contact angle, TEM, FESEM, and porosity studies were used to characterize the membrane. While retaining good dye rejection, adding 0–0.1 wt percent TBF increased pure water flow from 10 to 55 kg m^-2 h^-1 and enhanced wettability (25 %) and porosity (35 %). With decreased dye adsorption and pore obstruction, CR elimination rose from 80 % (pristine PES) to 94.84 %. TBF functioned as a photocatalyst in visible light, producing reactive oxygen species (ROS) that broke down contaminants and allowed for self-cleaning; after 10 h in the sun, the 0.05 wt percent TBF membrane recovered all of its flow. These findings show that PES/TBF membranes are a sustainable choice for improved membrane performance (permeability, selectivity, self-cleaning membrane characteristics include anti-fouling capabilities), effective dye treatment, and photocatalytic degradation, all of which help to safeguard the environment and provide cleaner water.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100867"},"PeriodicalIF":7.1,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096147","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Comparing electrocatalytic oxygen evolution using laser-fabricated NiO and CuO – A look at the influence of fabrication, kinetics and the inevitable phase transitions","authors":"Sandra Susan Koshy ,&nbsp;Jyotisman Rath ,&nbsp;Amirkianoosh Kiani","doi":"10.1016/j.ceja.2025.100870","DOIUrl":"10.1016/j.ceja.2025.100870","url":null,"abstract":"<div><div>The oxygen evolution reaction (OER) is the principal energy barrier in water electrolysis, often demanding overpotentials exceeding 400 mV on state-of-the-art catalysts and thus limiting sustainable hydrogen production. Here, we compare nanoporous NiO and CuO electrodes fabricated via ultrashort-pulse laser irradiation (ULPING) directly onto metal foils. By tuning pulse duration (∼150 ps), repetition rate (1.2 MHz), power (10 W) and scan speed (50 mm/s), we produced extensive hierarchical pore networks without binders or post-treatment. SEM and EDX mapping confirm distinct morphologies—elongated, fibrous ridges in CuO vs. globular, cauliflower-like clusters in NiO—and near-stoichiometric metal-to-oxygen ratios, with subsurface non-stoichiometries revealed by XPS (mixed Cu¹⁺/Cu²⁺ and Ni²⁺/Ni³⁺ species, abundant surface hydroxyls). In 1 M KOH, iR-corrected LSVs show NiO achieves 10 mA·cm⁻² at 430 mV and sustains 200 mA·cm⁻² at &lt;800 mV, outperforming CuO (η₁₀ ≈ 511 mV). Tafel slopes of 127 mV/dec (NiO) vs. 168 mV/dec (CuO) reflect faster charge-transfer kinetics, corroborated by exchange current densities (j₀ ≈ 4.1 × 10⁻³ vs. 9.2 × 10⁻³ mA cm⁻²). EIS fits reveal lower R_ct and diffusion impedance for NiO, while representative free-energy diagrams illustrate how transition-state positioning governs kinetic asymmetry. Theory-guide information, such as phase-diagram modeling (Ni–O–H, Cu–O–H at 300 K) predicts stable NiOOH formation under OER conditions, contrasting with metastable Cu(OH)₂ that rapidly reverts to CuO/Cu₂O. Furthermore, this work highlights that transition metal oxides inevitably undergo oxidation-state transitions under applied potential, with the +3 states of Ni and Cu emerging as the most active for OER but prone to over-oxidation and instability at higher potentials. It emphasizes the importance of experimentally and theoretically tracking these dynamic oxidation-state transformations to distinguish between catalytic activity and degradation mechanisms. Future work will focus on operando XRD/XAS to track these dynamic phase changes and DFT-guided defect engineering to further optimize earth-abundant OER catalysts for large-scale green hydrogen.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100870"},"PeriodicalIF":7.1,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096152","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"UV-driven trace Cu(II)/peroxymonosulfate for efficient degradation of phosphonate: Mechanism and broad pH adaptability","authors":"Tianhong Wang ,&nbsp;Jiahui Xu ,&nbsp;Anhong Cai ,&nbsp;Jibo Xiao ,&nbsp;Peng Wang ,&nbsp;Min Zhao ,&nbsp;Xianfeng Huang","doi":"10.1016/j.ceja.2025.100866","DOIUrl":"10.1016/j.ceja.2025.100866","url":null,"abstract":"<div><div>Organic phosphonates detected frequently in water bodies pose severely environmental risks, and the cleavage of their C-P bonds to converse orthophosphate (PO₄^3-) serves as a prerequisite step for achieving deep phosphorus elimination. Although the in situ generation of Cu(III) via Cu(II)/oxidant system for selective phosphonates degradation has been studied, the oxidation efficiency is constrained by sluggish Cu(II)/Cu(I) reduction, especially under acidic conditions. In this study, the introduction of UV irradiation accelerated the Cu(I)/Cu(II)/Cu(III) cycle in Cu(II)/peroxymonosulfate (PMS) process, enabling efficient and selective oxidation of 1,1-diphosphonic acid (HEDP, a typical phosphonate) into PO₄^3- across a wide pH range. UV-driven trace Cu(II)/PMS system can convert 90 % of HEDP into PO₄^3- within 10 min at the pH range of 4–10, which was significantly higher than the conversion efficiency of HEDP by UV/PMS, Cu(II)/PMS and UV/Cu(II)/H₂O₂ processes. The decomposition of HEDP was enhanced with increasing Cu(II) and PMS concentrations. Notably, mechanistic investigation revealed that Cu(III)-induced intramolecular electron transfer was the key contributor during the UV/Cu(II)/PMS-driven decomposition of HEDP into PO₄^3-. The experimental results of competitive ligands clearly suggested that the high selectivity of HEDP oxidation by UV/Cu(II)/PMS was closely related to the complexation of Cu(II) with HEDP. Additionally, although natural organic matter and inorganic anions to some extent affected HEDP degradation, UV-driven trace Cu(II)/PMS system still exhibited satisfactory results in treating HEDP in actual wastewater. This study proposes a strategy for efficient phosphonate removal under varying pH conditions, which provides new insights for practical wastewater treatment applications.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100866"},"PeriodicalIF":7.1,"publicationDate":"2025-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096188","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Green frothers and modern characterization tools: Toward sustainable flotation performance","authors":"Arefeh Zahab Nazoori,&nbsp;Bahram Rezai,&nbsp;Aliakbar Abdolahzadeh,&nbsp;Ebrahim Allahkarami","doi":"10.1016/j.ceja.2025.100860","DOIUrl":"10.1016/j.ceja.2025.100860","url":null,"abstract":"<div><div>Flotation remains the most widely used method for recovering valuable minerals, particularly sulfide ores and certain non-sulfide ores such as oxides and phosphates. However, its environmental impact driven by high energy consumption, substantial water usage, and dependence on petrochemical-based reagents presents increasing sustainability challenges. In recent years, green frothers produced from renewable resources or industrial waste, including rhamnolipids, sophorolipids, plant-derived glycosides, polymer–surfactant blends, and esters, have emerged as sustainable alternatives. These frothers exhibit improved foamability, froth stability, controlled bubble size distribution, and enhanced flotation selectivity compared to conventional reagents. Advanced characterization indices, such as critical micelle concentration (CMC), froth stability index, Sauter mean bubble diameter (SMD), gas holdup, and water recovery index, are highlighted to quantify frother behavior and flotation efficiency. Computational approaches, including molecular dynamics simulations and density functional theory (DFT), provide predictive insights for rational design and performance optimization of next-generation frothers. Furthermore, challenges such as variability in water quality, cost, and industrial scalability are considered, and future research directions are proposed to accelerate the transition toward environmentally sustainable and efficient flotation practices. By integrating experimental, computational, and environmental assessment methods, this manuscript aims to provide a comprehensive framework for the development and application of green frothers in mineral processing. The novelty of this article lies in its holistic framework that connects green frother chemistry, advanced characterization metrics (e.g., CMC, SMD, water recovery index), and computational tools, thereby bridging the gap between environmental sustainability and flotation performance.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100860"},"PeriodicalIF":7.1,"publicationDate":"2025-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096151","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Direct oxidation of organic micropollutants by persulfate and hydrogen peroxide: A potentially misleading contribution in advanced oxidation processes","authors":"Ehsan Ranjbar ,&nbsp;Sunil Paul M. Menacherry ,&nbsp;Junchao Pang ,&nbsp;Aki Sebastian Ruhl","doi":"10.1016/j.ceja.2025.100862","DOIUrl":"10.1016/j.ceja.2025.100862","url":null,"abstract":"<div><div>Advanced oxidation processes (AOPs) are becoming increasingly attractive for the removal of organic micropollutants (OMPs) from water. However, various aspects of AOPs need to be carefully evaluated. Most AOPs involve the introduction of oxidants such as hydrogen peroxide and persulfate, which are subsequently activated by UV irradiation, ozone, dissolved transition metals, solid catalysts, or other techniques. However, the direct reactions between OMPs and hydrogen peroxide/persulfate are rarely discussed. In this study, direct reactions between eight OMPs including acesulfame, atenolol, carbamazepine, diclofenac, metoprolol, primidone, saccharin, and valsartan acid and hydrogen peroxide/persulfate were investigated without any activation and under dark conditions. To evaluate the impact of the water matrices, removals of OMPs were compared in deionized water, tap water and wastewater effluent. The results demonstrated the influence of direct reactions on the oxidation of most OMPs to varying extents. Notably, diclofenac, a widely studied indicator contaminant, could be completely removed through direct reactions with both hydrogen peroxide and persulfate under the highest oxidant dose (2 mM) and contact time (240 min). Carbamazepine, another well-studied indicator contaminant, showed removals of approximately 30% and 55% with hydrogen peroxide and persulfate, respectively. Atenolol and metoprolol also exhibited high oxidation, particularly with persulfate, achieving removals exceeding 70%. Furthermore, the formation of selected transformation products was also studied to gain deeper insights into the reaction mechanisms.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100862"},"PeriodicalIF":7.1,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145216839","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Boron separation and concentration from pre-treated seawater reverse osmosis brines by selective ion-exchange resins and electrodialysis","authors":"M. Figueira,&nbsp;M. Fernández de Labastida,&nbsp;C. Valderrama,&nbsp;M. Reig","doi":"10.1016/j.ceja.2025.100863","DOIUrl":"10.1016/j.ceja.2025.100863","url":null,"abstract":"<div><div>Seawater reverse osmosis (SWRO) desalination brines contain a wide range of elements, at concentrations higher than those in seawater. Typically, these brines are discharged into the ocean after the reverse osmosis process for drinking water production, resulting in a loss of their potential value. Thus, recent research has focused on recovering valuable elements, including boron, from SWRO brines. This study investigates the use of selective ion-exchange (IX) resins and electrodialysis (ED) at a lab-scale for the separation and concentration of boron from SWRO brines. Dynamic experiments were conducted to test selective IX resins for boron separation. Batch tests were conducted to determine the minimum eluent concentration required to recover boron from the IX resins. Results indicated that it was possible to separate boron from almost all other elements in the brine. However, after the elution step, the major element in the solution was the anion used in the elution acid (Cl from HCl), with a concentration higher than that of boron (5 g Cl/L vs 1 g B/L). Thus, ED at an acidic pH was used for the separation of boron from the elution anion. Results showed that this process was suitable for this separation, obtaining two main streams: Cl-rich and B-rich. The latter was a solution, mainly containing boron, and without decreasing the initial boron concentration (around 1 g/L). Subsequently, ED at a basic pH was employed to concentrate boron at different stages. In this case, the use of two stages was the optimum for concentrating boron up to 2.5 g/L.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100863"},"PeriodicalIF":7.1,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096150","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Gas-phase flow-through photocatalysis using wirelessly anodized WO3 nanoporous layers on Tungsten 3D meshes produced by extrusion-based additive manufacturing","authors":"Marcela Sepúlveda ,&nbsp;Michal Baudys ,&nbsp;Carolina Oliver-Urrutia ,&nbsp;Veronika Cicmancova ,&nbsp;Jhonatan Rodriguez-Pereira ,&nbsp;Ludek Hromadko ,&nbsp;Hanna Sopha ,&nbsp;Edgar B. Montufar ,&nbsp;Ladislav Celko ,&nbsp;Josef Krysa ,&nbsp;Jan M. Macak","doi":"10.1016/j.ceja.2025.100861","DOIUrl":"10.1016/j.ceja.2025.100861","url":null,"abstract":"<div><div>Herein, hierarchically porous 3D W meshes were fabricated via extrusion-based additive manufacturing, using commercially pure W powder as feedstock. These mechanically robust structures exhibit high porosity and an effective surface area of approximately 60 cm², making them highly promising for gas-phase photocatalysis. Wireless anodization via bipolar electrochemistry was successfully applied to form nanoporous WO₃ layers on the 3D meshes, for the first time. These meshes were then employed for photocatalytic acetaldehyde degradation in a flow-through reactor designed according to ISO standards. Compared with thermally grown WO₃ layers on identical 3D W meshes, the nanoporous WO₃ layers showed superior performance due to their larger surface area, achieving ∼7% acetaldehyde conversion and a mineralization rate of ∼93%, indicating that nearly all removed acetaldehyde was fully mineralized. These findings highlight the potential of anodized 3D W meshes for innovative applications in flow-through photocatalytic reactors.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100861"},"PeriodicalIF":7.1,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145045950","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Selective dysprosium/terbium recovery from mine waste using ion-specific alkali/urea chitosan hydrogels","authors":"John Earwood ,&nbsp;Luke Henke ,&nbsp;Baolin Deng","doi":"10.1016/j.ceja.2025.100864","DOIUrl":"10.1016/j.ceja.2025.100864","url":null,"abstract":"<div><div>Heavy rare earth elements (HREEs), particularly dysprosium (Dy) and terbium (Tb), are essential for high-performance magnets yet challenging to separate due to similar electronic structures. This study demonstrates <u>A</u>lkali/<u>U</u>rea dissolved <u>C</u>hitosan <u>H</u>ydrogels (AUCH) for selective HREE extraction from mine waste. Two crosslinking strategies created pH-optimized materials: AUCH-D (1,2,7,8-diepoxyoctane) for acidic conditions and AUCH-G (glutaraldehyde) for alkaline environments. AUCH materials achieved exceptional sorption capacities of 162.53 mg/g for Tb (III) and 132.05 mg/g for Dy (III), following pseudo-second-order kinetics and Langmuir isotherms. Thermodynamic analysis revealed endothermic processes with activation energies of 32.22-68.28 kJ/mol, indicating inner-sphere complexation mechanisms. AUCH-D showed distinct binding energetics: ΔH = 17.88 kJ/mol for Dy (III) vs 76.13 kJ/mol for Tb (III), providing new insights for selective separation design. Field validation using Pea Ridge mine samples achieved 95.77% Tb (III) removal from acidic drainage and 78.06% Dy (III) removal from alkaline tailings while maintaining selectivity against competing lanthanides. Materials retained &gt;70% capacity after five regeneration cycles, demonstrating sustainable HREE recovery from secondary sources.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100864"},"PeriodicalIF":7.1,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096187","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Bipolar membrane 3D microlattice electrode assembly design for zero-gap bicarbonate (CO2) electrolysis","authors":"Ramato Ashu Tufa ,&nbsp;Babak Rezaei ,&nbsp;Wenjian Hu ,&nbsp;Debabrata Chanda ,&nbsp;Ben Jacobs ,&nbsp;Sergio Santoro ,&nbsp;Efrem Curcio ,&nbsp;Deepak Pant ,&nbsp;Stephan Sylvest Keller","doi":"10.1016/j.ceja.2025.100865","DOIUrl":"10.1016/j.ceja.2025.100865","url":null,"abstract":"<div><div>The electrochemical reduction of CO₂ (eCO₂R) from carbon capture solutions, such as (bi)carbonate, offers a promising pathway for energy-efficient carbon recycling compared to traditional gas-phase approaches. However, the development of optimized membrane-electrode designs remains a critical challenge for advancing this technology toward commercial viability. In this study, we present a novel integration of 3D-printed microlattice carbon electrodes with bipolar membranes (BPMs) for bicarbonate electrolysis. We used projection micro-stereolithography (PμSL) to fabricate unique free-standing carbon electrodes with nature-inspired honeycomb architectures. Silver nanoparticles were deposited onto the electrodes via chronoamperometry under varying conditions of deposition potential (-0.1, -0.2, and -0.5 V vs Ag/AgCl), deposition time (0 to 1200 s), and catalyst loading (0 to 0.7 mg/cm²). The optimal BPM-3D electrode assembly significantly enhanced CO production efficiency, achieving a Faradaic efficiency for CO (FE_CO) of 38 % - a 22 times increase over uncoated electrodes (1.7 %) - at a current density of 12.5 mA/cm². This configuration, prepared at -0.2 V for 900 s with an Ag loading of 0.5 mg/cm², exhibited improved catalytic activity because of the formation of highly active Ag nanostructures. The electrode demonstrated an Integrated Catalytic Performance Index (ICPI) of approximately 150 mA/Vmg at 50 mA/cm². Stability tests revealed minimal degradation over 14 h of operation, affirming the durability of the Ag-coated 3D electrodes. A preliminary techno-economic analysis projects that CO production costs could be reduced by optimizing Faradaic efficiency (FE) and catalyst loading under scaled conditions. This work lays the foundation for integrating 3D printing and BPM technology for sustainable eCO₂R. However, achieving high selectivity and stability at &gt;100 mA/cm² remains challenging, requiring optimized electrode design and interface engineering for commercial viability.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"24 ","pages":"Article 100865"},"PeriodicalIF":7.1,"publicationDate":"2025-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145096146","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}