Performance of a semi-pilot tubular microbial electrolysis cell (MEC) under several hydraulic retention times and applied voltages

Scale-up and techno-economic analysis of microbial electrolysis cells for hydrogen production from wastewater

Microbial electrolysis cells (MECs) have demonstrated high-rate H₂ production while concurrently treating wastewater, but the transition in scale from laboratory research to systems that can be practically applied has encountered challenges. It has been more than a decade since the first pilot-scale MEC was reported, and in recent years, many attempts have been made to overcome the barriers and move the technology to the market. This study provided a detailed analysis of MEC scale-up efforts and summarized the key factors that should be considered to further develop the technology. We compared the major scale-up configurations and systematically evaluated their performance from both technical and economic perspectives. We characterized how system scale-up impacts the key performance metrics such as volumetric current density and H₂ production rate, and we proposed methods to evaluate and optimize system design and fabrication. In addition, preliminary techno-economic analysis indicates that MECs can be profitable in many different market scenarios with or without subsidies. We also provide perspectives on future development needed to transition MEC technology to the marketplace.

Membrane-based technologies for biohydrogen production: A review

Overcoming the existing environmental issues and the gradual depletion of energy sources is a priority at global level, biohydrogen can provide a sustainable and reliable energy reserve. However, the process instability and low biohydrogen yields are still hindering the adoption of biohydrogen production plants at industrial scale. In this context, membrane-based biohydrogen production technologies, and in particular fermentative membrane bioreactors (MBRs) and microbial electrolysis cells (MECs), as well as downstream membrane-based technologies such as electrodialysis (ED), are suitable options to achieve high-rate biohydrogen production. We have shed the light on the research efforts towards the development of membrane-based technologies for biohydrogen production from organic waste, with special emphasis to the reactor design and materials. Besides, techno-economic analyses have been traced to ensure the suitability of such technologies in bio-H₂ production. Operation parameters such as pH, temperature and organic loading rate affect the performance of MBRs. MEC and ED technologies also are highly affected by the chemistry of the membrane used and anode material as well as the operation parameters. The limitations and future directions for application of membrane-based biohydrogen production technologies have been individuated. At the end, this review helps in the critical understanding of deploying membrane-based technologies for biohydrogen production, thereby encouraging future outcomes for a sustainable biohydrogen economy.

A scalable model of fluid flow, substrate removal and current production in microbial fuel cells

Mathematical modelling can reduce the cost and time required to design complex systems, and is being increasingly used in microbial electrochemical technologies (METs). To be of value such models must be complex enough to reproduce important behaviour of MET, yet simple enough to provide insight into underlying causes of this behaviour. Ideally, models must also be scalable to future industrial applications, rather than limited to describing existing laboratory experiments. We present a scalable model for simulating both fluid flow and bioelectrochemical processes in microbial fuel cells (MFCs), benchmarking against an experimental pilot-scale bioreactor. The model describes substrate transport through a two-dimensional fluid domain, and biofilm growth on anode surfaces. Electron transfer is achieved by an intracellular redox mediator. We find significant spatial variations in both substrate concentration and current density. Simple changes to the reactor layout can greatly improve the overall efficiency, measured in terms of substrate removal and total current generated.

Green approach and strategies for wastewater treatment using bioelectrochemical systems: A critical review of fundamental concepts, applications, mechanism, and future trends

Millions of litters of multifarious wastewater are directly disposed into the environment annually to reduce the processing costs leading to eutrophication and destroying the clean water sources. The bioelectrochemical systems (BESs) have recently received significant attention from researchers due to their ability to convert waste into energy and their high efficiency of wastewater treatment. However, most of the performed researches of the BESs have focused on energy generation, which created a literature gap on the utilization of BESs for wastewater treatment. The review highlights this gap from various aspects, including the BESs trends, fundamentals, applications, and mechanisms. A different review approach has followed in the present work using a bibliometric review (BR) which defined the literature gap of BESs publications in the degradation process section and linked the systematic review (SR) with it to prove and review the finding systematically. The degradation mechanisms of the BESs have been illustrated comprehensively in the current work, and various suggestions have been provided for supporting future studies and cooperation.

Scaling-up up-flow microbial electrolysis cells with a compact electrode configuration for continuous hydrogen production

Maintaining high current densities is a key challenge in scaling-up microbial electrolysis cell (MEC) reactors. In this study, a novel 10 L MEC reactor with a total electrode surface area greater than 1 m² was designed and evaluated to maximize the current density and H₂ recovery. Performances of the reactor suggest that the longitudinal structure with parallel vertical orientation of the electrodes encouraged high fluid mixing and the sheet metal electrode frames provided distributed electrical connection. Results also demonstrated that the electrode pairs located next to reactor walls decreased current density, as did separating the electrodes with separators. High volumetric H₂ production rate of 5.9 L/L/d was achieved at a volumetric current density of 970 A/m³ (34 A/m²). Moreover, the observed current densities of the large reactor were accurately predicted based on the internal resistance analysis of small scale MECs (0.15 L), demonstrating the scalability of the single chamber MEC design.

The war using microbes: A sustainable approach for wastewater management

Anthropogenic activities and population growth have resulted in a reduced availability of drinking water. To ensure consistency in the existence of drinking water, it is inevitable to establish wastewater treatment plants (WWTPs). 70% of India's rural population was found to be without WWTP, waste disposal, and good sanitation. Wastewater has emerged from kitchens, washrooms, etc., with industry activities. This scenario caused severe damage to water resources, leading to degradation of water quality and pathogenic insects. Thus, it is a need of an hour to prompt for better WWTPs for both rural and urban areas. Many parts of the world have started to face severe water shortages in recent years, and wastewater reuse methods need to be updated. Clean water supply is not enough to satisfy the needs of the planet as a whole, and the majority of freshwater in the polar regions takes the form of ice and snow. The increasing population requires clean water for drinks, hygiene, irrigation, and various other applications. Lack of water and contamination of water result from human activities. 90% of wastewater is released to water systems without treatment in developing countries. Studies show that about 730 megatons of waste are annually discharged into water from sewages and other effluents. The sustenance of water resources, applying wastewater treatment technologies, and calling down the percentage of potable water has to be strictly guided by mankind. This review compares the treatment of domestic sewage to its working conditions, energy efficiency, etc. In this review, several treatment methods with different mechanisms involved in waste treatment, industrial effluents, recovery/recycling were discussed. The feasibility of bioaugmentation should eventually be tested through data from field implementation as an important technological challenge, and this analysis identifies many promising areas to be explored in the future.

Industrially scalable surface treatments to enhance the current density output from graphite bioanodes fueled by real domestic wastewater

Acid and electrochemical surface treatments of graphite electrode, used individually or in combination, significantly improved the microbial anode current production, by +17% to +56%, in well-regulated and duplicated electroanalytical experimental systems. Of all the consequences induced by surface treatments, the modifications of the surface nano-topography preferentially justify an improvement in the fixation of bacteria, and an increase of the specific surface area and the electrochemically accessible surface of graphite electrodes, which are at the origin of the higher performances of the bioanodes supplied with domestic wastewater. The evolution of the chemical composition and the appearance of C-O, C=O, and O=C-O groups on the graphite surface created by combining acid and electrochemical treatments was prejudicial to the formation of efficient domestic-wastewater-oxidizing bioanodes. The comparative discussion, focused on the positioning of the performances, shows the industrial interest of applying the surface treatment method to the world of bioelectrochemical systems.

Bio-Hydrogen Production from Wastewater: A Comparative Study of Low Energy Intensive Production Processes

Billions of litres of wastewater are produced daily from domestic and industrial areas, and whilst wastewater is often perceived as a problem, it has the potential to be viewed as a rich source for resources and energy. Wastewater contains between four and five times more energy than is required to treat it, and is a potential source of bio-hydrogen—a clean energy vector, a feedstock chemical and a fuel, widely recognised to have a role in the decarbonisation of the future energy system. This paper investigates sustainable, low-energy intensive routes for hydrogen production from wastewater, critically analysing five technologies, namely photo-fermentation, dark fermentation, photocatalysis, microbial photo electrochemical processes and microbial electrolysis cells (MECs). The paper compares key parameters influencing H2 production yield, such as pH, temperature and reactor design, summarises the state of the art in each area, and highlights the scale-up technical challenges. In addition to H2 production, these processes can be used for partial wastewater remediation, providing at least 45% reduction in chemical oxygen demand (COD), and are suitable for integration into existing wastewater treatment plants. Key advancements in lab-based research are included, highlighting the potential for each technology to contribute to the development of clean energy. Whilst there have been efforts to scale dark fermentation, electro and photo chemical technologies are still at the early stages of development (Technology Readiness Levels below 4); therefore, pilot plants and demonstrators sited at wastewater treatment facilities are needed to assess commercial viability. As such, a multidisciplinary approach is needed to overcome the current barriers to implementation, integrating expertise in engineering, chemistry and microbiology with the commercial experience of both water and energy sectors. The review concludes by highlighting MECs as a promising technology, due to excellent system modularity, good hydrogen yield (3.6–7.9 L/L/d from synthetic wastewater) and the potential to remove up to 80% COD from influent streams.

Hydrogen production from lignocellulosic hydrolysate in an up-scaled microbial electrolysis cell with stacked bio-electrodes

Hydrogen production from renewable resources via microbial electrolysis cells (MECs) is a promising approach for sustainable energy production. Yet high hydrogen yield from real feedstocks has not been demonstrated in up-scaled MECs. In this study, a 10-L single chamber MEC with a high electrode surface area to volume ratio (66 m²/m³) was constructed and electroactive cathodic biofilms were enriched for hydrogen evolution reaction. A high hydrogen yield of 91% was achieved using lignocellulosic hydrolysate with a hydrogen production rate of 0.71 L/L/D at an organic loading rate of 0.4 g/D. The anodic and cathodic microbial communities, with Enterococcus spp. as the known electroactive bacteria, were capable of achieving current densities of 13.7 A/m² and 16.5 A/m², respectively. A machine learning algorithm was used to investigate the correlation between community data and electrochemical performance, and the critical genera on determining current density were identified.

A Comprehensive Understanding of Electro-Fermentation

Electro-fermentation (EF) is an upcoming technology that can control the metabolism of exoelectrogenic bacteria (i.e., bacteria that transfer electrons using an extracellular mechanism). The fermenter consists of electrodes that act as sink and source for the production and movement of electrons and protons, thus generating electricity and producing valuable products. The conventional process of fermentation has several drawbacks that restrict their application and economic viability. Additionally, metabolic reactions taking place in traditional fermenters are often redox imbalanced. Almost all metabolic pathways and microbial strains have been studied, and EF can electrochemically control this. The process of EF can be used to optimize metabolic processes taking place in the fermenter by controlling the redox and pH imbalances and by stimulating carbon chain elongation or breakdown to improve the overall biomass yield and support the production of a specific product. This review briefly discusses microbe-electrode interactions, electro-fermenter designs, mixed-culture EF, and pure culture EF in industrial applications, electro methanogenesis, and the various products that could be hence generated using this process.

Optimising the Hydraulic Retention Time in a Pilot-Scale Microbial Electrolysis Cell to Achieve High Volumetric Treatment Rates Using Concentrated Domestic Wastewater

Bioelectrochemical systems (BES) have the potential to deliver energy-neutral wastewater treatment. Pilot-scale tests have proven that they can operate at low temperatures with real wastewaters. However, volumetric treatment rates (VTRs) have been low, reducing the ability for this technology to compete with activated sludge (AS). This paper describes a pilot-scale microbial electrolysis cell (MEC) operated in continuous flow for 6 months. The reactor was fed return sludge liquor, the concentrated filtrate of anaerobic digestion sludge that has a high chemical oxygen demand (COD). The use of a wastewater with increased soluble organics, along with optimisation of the hydraulic retention time (HRT), resulted in the highest VTR achieved by a pilot-scale MEC treating real wastewater. Peak HRT was 0.5-days, resulting in an average VTR of 3.82 kgCOD/m³∙day and a 55% COD removal efficiency. Finally, using the data obtained, a direct analysis of the potential savings from the reduced loading on AS was then made. Theoretical calculation of the required tank size, with the estimated costs and savings, indicates that the use of an MEC as a return sludge liquor pre-treatment technique could result in an industrially viable system.

Mutual benefits of acetate and mixed tungsten and molybdenum for their efficient removal in 40 L microbial electrolysis cells

Practical application of metallurgical microbial electrolysis cells (MECs) requires efficient removal of metals and organics in larger reactors. A 40 L cylindrical single-chamber MEC fed acetate was used to achieve high removals of W(VI) and Mo(VI). In the presence of both metals, there were nearly complete removals of W (97 ‒ 98%), Mo (98 ‒ 99%), and acetate (95 ‒ 96%), along with a low level of hydrogen production (0.0037-0.0039 L/L/d) at a hydraulic residence time (HRT) of 2 d (influent ratios of W:Mo:acetate of 0.5:1.0:24 mM). The final concentrations of these conditions were sufficient to meet national wastewater discharge standards. In the controls with individual metals or acetate, lower contaminant removals were obtained (W, 2 ‒ 4%; Mo, 3 ‒ 5%, acetate, 36 ‒ 39%). Metals removal in all cases was primarily due to the biocathodes rather than the bioanodes. The presence of metals decreased microbial diversity on the anodes and increased diversity on the cathodes, based on analysis at the phylum, class and genus levels, as a function of HRT and influent concentration. This study demonstrated the feasibility of larger-scale single-chamber MECs for efficient treatment of W and Mo, moving metallurgical MECs closer to commercialization for wastewater treatment of these two metals.

Improving Anaerobic Digestion of Sewage Sludge by Hydrogen Addition: Analysis of Microbial Populations and Process Performance

The effect of hydrogen pulse addition on digestion performance of sewage sludge was evaluated as a means for studying the increase in efficiency of methane production. Microbial communities were also evaluated to get an insight of the changes caused by the operational modifications of the digester. An energy evaluation of this alternative was performed considering the theoretical process of coupling bioelectrochemical systems (BES) for the treatment of wastewater along with hydrogen production and the subsequent anaerobic digestion. The addition of hydrogen to sewage sludge digestion resulted in an increase of 12% in biogas production over the control (1353 mL CH4 d−1 at an injection flow rate of 1938 mL H2 d−1). The liquid phase of the sludge reactor and the H2 supplemented one did not show significant differences, thus indicating that the application of hydrogen as the co-substrate was not detrimental. High-throughput sequencing analysis showed slight changes in archaeal relative abundance after hydrogen addition, whereas eubacterial community structure and composition revealed noteworthy shifts. The mass and energy balance indicated that the amount of hydrogen obtained from a hypothetical BES can be assimilated in the sludge digester, improving biogas production, but this configuration was not capable of covering all energy needs under the proposed scenario.

Understanding nitrogen recovery from wastewater with a high nitrogen concentration using microbial electrolysis cells

This study was aimed at understanding the effect of applied voltage, catholyte and reactor scale on nitrogen recovery from two different organic wastes (digestate and pig slurry) by means of microbial electrolysis cell (MEC) technology. For this purpose, MEC sizes of 100, 500 and 1000 mL were tested at applied voltages of 0.6, 1 and 1.4 V using either a phosphate-buffered solution or NaCl solution as the catholyte. By increasing the reactor size from 500 to 1000 mL, a decrease in the ammonia recovery efficiency from 47 to 42% was observed. The results also showed that the phosphate-buffered solution is preferable as the catholyte and that the voltage applied does not have a noticeable effect on current production and ammonia recovery. Low biodegradability of the wastes was identified as the main bottleneck.

Evaluation of Inlet Design and Flow Rate Effect on Current Density Distribution in a Microbial Electrolysis Cell Using Computational Simulation Techniques, Coupling Hydrodynamics and Bioanode Kinetics

A theoretical model that describe the effect of design and operational conditions on current density distribution in a bioelectrochemical reactor used as microbial electrolysis cell (MEC) is described in this study. This model is proposed considering an approach where a direct electron transfer mechanism from the biofilm to the electrode surface takes place (mechanism present in most of microbial systems) and is governed by a dual donor-acceptor Nernst-Monod bioelectrochemical kinetic expression. The bioelectrochemical reactor is modelled considering two flow electrochemical reactor designs (a reactor design based in literature reports and a modified system proposed by the authors) operating at different flow inlet velocities and electrical overpotentials.

Results obtained from the numerical solution shows that flow distribution is an essential aspect that impact the reactor performance, since concentration profiles and electrical potential-current distributions are strongly dependent on flow regime. Modified inlet configuration displays a more homogeneous fluid distribution and this behavior directly affects the mass transport and current density performance, as a result higher current density values are obtained for such configuration. Finally, it is expected that the information obtained from the analysis carried out in this report will provide us with a theoretical basis to realize the construction of a bioelectrochemical reactor prototype to develop the MEC concept.

Hydrogen peroxide production in a pilot-scale microbial electrolysis cell

A pilot-scale dual-chamber microbial electrolysis cell (MEC) equipped with a carbon gas-diffusion cathode was evaluated for H2O2 production using acetate medium as the electron donor. To assess the effect of cathodic pH on H2O2 yield, the MEC was tested with an anion exchange membrane (AEM) and a cation exchange membrane (CEM), respectively. The maximum current density reached 0.94-0.96 A/m2 in the MEC at applied voltage of 0.35-1.9 V, regardless of membranes. The highest H2O2 conversion efficiency was only 7.2 ± 0.09% for the CEM-MEC. This low conversion would be due to further H2O2 reduction to H2O on the cathode or H2O2 decomposition in bulk liquid. This low H2O2 conversion indicates that large-scale MECs are not ideal for production of concentrated H2O2 but could be useful for a sustainable in-situ oxidation process in wastewater treatment.

Unravelling biocomplexity of electroactive biofilms for producing hydrogen from biomass

Leveraging nature's biocomplexity for solving human problems requires better understanding of the syntrophic relationships in engineered microbiomes developed in bioreactor systems. Understanding the interactions between microbial players within the community will be key to enhancing conversion and production rates from biomass streams. Here we investigate a bioelectrochemical system employing an enriched microbial consortium for conversion of a switchgrass-derived bio-oil aqueous phase (BOAP) into hydrogen via microbial electrolysis (MEC). MECs offer the potential to produce hydrogen in an integrated fashion in biorefinery platforms and as a means of energy storage through decentralized production to supply hydrogen to fuelling stations, as the world strives to move towards cleaner fuels and electricity-mediated transportation. A unique approach combining differential substrate and redox conditions revealed efficient but rate-limiting fermentation of the compounds within BOAP by the anode microbial community through a division of labour strategy combined with multiple levels of syntrophy. Despite the fermentation limitation, the adapted abilities of the microbial community resulted in a high hydrogen productivity of 9.35 L per L-day. Using pure acetic acid as the substrate instead of the biomass-derived stream resulted in a three-fold improvement in productivity. This high rate of exoelectrogenesis signifies the potential commercial feasibility of MEC technology for integration in biorefineries.

On the Edge of Research and Technological Application: A Critical Review of Electromethanogenesis

The conversion of electrical current into methane (electromethanogenesis) by microbes represents one of the most promising applications of bioelectrochemical systems (BES). Electromethanogenesis provides a novel approach to waste treatment, carbon dioxide fixation and renewable energy storage into a chemically stable compound, such as methane. This has become an important area of research since it was first described, attracting different research groups worldwide. Basics of the process such as microorganisms involved and main reactions are now much better understood, and recent advances in BES configuration and electrode materials in lab-scale enhance the interest in this technology. However, there are still some gaps that need to be filled to move towards its application. Side reactions or scaling-up issues are clearly among the main challenges that need to be overcome to its further development. This review summarizes the recent advances made in the field of electromethanogenesis to address the main future challenges and opportunities of this novel process. In addition, the present fundamental knowledge is critically reviewed and some insights are provided to identify potential niche applications and help researchers to overcome current technological boundaries.

Influence of applied voltage on the performance of bioelectrochemical anaerobic digestion of sewage sludge and planktonic microbial communities at ambient temperature

The influence of applied voltage on the bioelectrochemical anaerobic digestion of sewage sludge was studied at ambient temperature (25±2°C). The stability of the bioelectrochemical anaerobic digestion was considerably good in terms of pH, alkalinity and VFAs at 0.3V and 0.5V, but VFA accumulation occurred at 0.7V. The specific methane production rate (370mLCH4/L.d) was the highest at 0.3V, but the methane content (80.6%) in biogas and the methane yield (350mLCH4/gCODr) were higher at 0.5V, significantly better than those of 0.7V. The VS removal efficiency was 64-66% at 0.3V and 0.5V, but only 31% at 0.7V. The dominant species of planktonic microbial communities was Cloacamonas at 0.3V and 0.5V, but the percentage of hydrolytic bacteria species such as Saprospiraceae, Fimbriimonas, and Ottowia pentelensis was much higher at 0.7V. The optimal applied voltage for bioelectrochemical anaerobic digestion was 0.3-0.5V according to digestion performance and planktonic microbial communities.

Long-term continuous production of H2 in a microbial electrolysis cell (MEC) treating saline wastewater

A biofilm-based 4 L two chamber microbial electrolysis cell (MEC) was continuously fed with acetate under saline conditions (35 g/L NaCl) for more than 100 days. The MEC produced a biogas highly enriched in H2 (≥90%). Both current (10.6 ± 0.2 A/m(2)Anode or 199.1 ± 4.0 A/m(3)MEC) and H2 production (201.1 ± 7.5 LH2/m(2)Cathode·d or 0.9 ± 0.0 m(3)H2/m(3)MEC·d) rates were highly significant when considering the saline operating conditions. A microbial analysis revealed an important enrichment in the anodic biofilm with five main bacterial groups: 44% Proteobacteria, 32% Bacteroidetes, 18% Firmicutes and 5% Spirochaetes and 1% Actinobacteria. Of special interest is the emergence within the Proteobacteria phylum of the recently described halophilic anode-respiring bacteria Geoalkalibacter (unk. species), with a relative abundance up to 14%. These results provide for the first time a noteworthy alternative for the treatment of saline effluents and continuous production of H2.

Scaling-up of membraneless microbial electrolysis cells (MECs) for domestic wastewater treatment: Bottlenecks and limitations

Microbial electrolysis cells (MECs) have the potential to become a sustainable domestic wastewater (dWW) treatment system. However, new scale-up experiences are required to gain knowledge of critical issues in MEC designs. In this study we assess the ability of two twin membraneless MEC units (that are part of a modular pilot-scale MEC) to treat dWW. Batch tests yielded COD removal efficiencies as high as 92%, with most of the hydrogen (>80% of the total production) being produced during the first 48h. During the continuous tests, MECs performance deteriorated significantly (energy consumption was relatively high and COD removal efficiencies fell below 10% in many cases), which was attributed to an inadequate configuration of the anodic chamber, insufficient mixing inside this chamber, inefficient hydrogen management on the cathode side and finally to dWW in itself. Some alternatives to the current design are suggested.