New insights on efficient electrochemical production of hydrogen peroxide

Hydrogen peroxide production was investigated using a highly efficient 3D-printed electrochemical reactor (4 cm in height and width) equipped with a gas diffusion electrode. The system was evaluated across a broad range of current densities, approaching those required for industrial-scale production. Remarkably high efficiencies were achieved, which were found to be strongly influenced by the electrolyte composition but largely independent of current density. A maximum efficiency of 100 % was observed when sodium sulfate was used as the supporting electrolyte. Contrary to expectations, the use of perchlorate and nitrate instead of sulfate led to a significant decrease in efficiency, suggesting the presence of catalytic effects linked to mediated oxidation mechanisms. These findings highlight the critical role of the anodic process in the cathodic generation of hydrogen peroxide. Based on this evidence, a simple phenomenological model was developed to elucidate the primary mechanisms governing efficient hydrogen peroxide production. The model also provides practical recommendations for enhancing process efficiency, positioning this compact technology as a promising alternative to conventional electrochemical systems and a viable competitor to the industrial anthraquinone process.