A review of chromium(VI) use in chlorate electrolysis: Functions, challenges and suggested alternatives

Comparative Study of Different Polymeric Binders in Electrochemical CO Reduction

Electrochemical reduction of carbon monoxide offers a possible route to produce valuable chemicals (such as acetate, ethanol or ethylene) from CO2 in two consecutive electrochemical reactions. Such deeply reduced products are formed via the transfer of 4-6 electrons per CO molecule. Assuming similar-sized CO2 and CO electrolyzers, 2-3-times larger current densities are required in the latter case to match the molar fluxes. Such high reaction rates can be ensured by tailoring the structure of the gas diffusion electrodes. Here, the structure of the cathode catalyst layer was systematically varied using different polymeric binders to achieve high reaction rates. Simple linear polymers, bearing the same backbone but different functional groups were compared to highlight the role of different structural motifs. The comparison was also extended to simple linear, partially fluorinated polymers. Interestingly, in some cases similar results were obtained as with the current state-of-the-art binders. Using different surface-wetting characterization techniques, we show that the hydrophobicity of the catalyst layer-provided by the binder- is a prerequisite for high-rate CO electrolysis. The validity of this notion was demonstrated by performing CO electrolysis experiments at high current density (1 A cm-2) for several hours using PVDF as the catalyst binder.

Electrochemical and chemical cycle for high-efficiency decoupled water splitting in a near-neutral electrolyte

Green hydrogen produced by water splitting using renewable electricity is essential to achieve net-zero carbon emissions. Present water electrolysis technologies are uncompetitive with low-cost grey hydrogen produced from fossil fuels, limiting their scale-up potential. Disruptive processes that decouple the hydrogen and oxygen evolution reactions and produce them in separate cells or different stages emerge as a prospective route to reduce system cost by enabling operation without expensive membranes and sealing components. Some of these processes divide the hydrogen or oxygen evolution reactions into electrochemical and chemical sub-reactions, enabling them to achieve high efficiency. However, high efficiency has been demonstrated only in a batch process with thermal swings that present operational challenges. This work introduces a breakthrough process that produces hydrogen and oxygen in separate cells and supports continuous operation in a membraneless system. We demonstrate high faradaic and electrolytic efficiency and high rate operation in a near-neutral electrolyte of NaBr in water, whereby bromide is electro-oxidized to bromate concurrent with hydrogen evolution in one cell, and bromate is chemically reduced to bromide in a catalytic reaction that evolves oxygen in another cell. This process may lead the way to high-efficiency membraneless water electrolysis that overcomes the limitations of century-old membrane electrolysis.

Cerium Oxide on a Fluorinated Carbon-Based Electrode as a Promising Catalyst for Hypochlorite Production

Sodium hypochlorite (NaOCl) is widely used as a disinfectant agent for water treatment and surface cleaning. A straightforward way to produce NaOCl is by the electrolysis of an aqueous sodium chloride (NaCl) solution. This process presents several side reactions decreasing its efficiency with hypochlorite reduction on the cathode surface being one of the main detrimental reactions. In this work, we have studied carbon-based electrodes modified with cerium oxide (CeO₂), fluorine, and platinum nanoparticles as cathodes for hypochlorite production. Fluorination was carried out electrochemically; the polyol method was used to synthesize platinum nanoparticles; and the hydrothermal process was applied to form a CeO₂ layer. Scanning electron microscopy, FTIR, and inductively coupled plasma (ICP) indicated the presence of cerium oxide as a film, fluorine groups on the substrate, and a load of 3.2 mg/cm² of platinum nanoparticles and 2.7 mg/cm² of CeO₂. From electrochemical impedance spectroscopy, it was possible to demonstrate that incorporating platinum and fluorine decreases the charge transfer resistance by 16% and 28%, respectively. Linear sweep voltammetry showed a significant decrease in hypochlorite reduction when the substrate was doped with fluorine from -16.6 mA/cm² at -0.6 V to -9.64 mA/cm² that further reduced to -8.78 mA/cm² with cerium oxide covered fluorinated electrodes. The performance of the cathode materials during hypochlorite production improved by 80% compared with pristine activated carbon cloth (ACC) electrodes. The improvement toward hindering NaOCl reduction is probably caused by the incorporation of a partial negative charge upon doping with fluorine.

Controlled Synthesis of Chromium-Oxide-Based Protective Layers on Pt: Influence of Layer Thickness on Selectivity

Chromium-oxyhydroxide (CrxOyHz)-based thin films have previously been shown in photocatalysis and industrial chlorate production to prevent unwanted reduction reactions to occur, thereby enhancing the selectivity for hydrogen evolution and thus the overall process efficiency. Here, a highly reproducible synthesis protocol was developed to allow for the electrodeposition of CrxOyHz-based thin films with controlled thickness in the range of the sub-monolayer up to (>4) multilayer coverage. Electrodeposited CrxOyHz coatings were electrochemically characterized using voltammetry and stripping experiments, allowing thickness-dependent film selectivity to be deduced in detail. The results are discussed in terms of mass transport properties and structure of the electrodeposited chromium oxyhydroxide films. It is shown that the permeation of diatomic probe molecules, such as O2 and CO, was significantly reduced by films as thin as four monolayers. Importantly, it is shown that the prepared thin film coatings enabled prolonged hydrogen oxidation in the presence of CO (up to 5 vol.%), demonstrating the benefits of thin-film-protected electrocatalysts. In general, this study provides insight into the synthesis and use of thin-film-protected electrodes leading to improvements in (electro)catalyst selectivity and durability.

Factors Affecting the Detection of Hexavalent Chromium in Cr-Contaminated Soil

The alkali digestion pretreatment method in the United States Environmental Protection Agency (USEPA) Method 3060A could underestimate the content of Cr(VI) in Cr-contaminated soils, especially for soils mixed with chromite ore processing residue (COPR), which leads to a misjudgment of the Cr(VI) level in soils after remediation, causing secondary pollution to the environment. In this study, a new pretreatment method to analyze Cr(VI) concentration in contaminated soils was established. The impacts of soil quality, particle size, alkali digestion time and the rounds of alkali digestion on Cr(VI) detection in contaminated soils was explored and the alkali digestion method was optimized. Compared with USEPA Method 3060A, the alkaline digestion time was prolonged to 6 h and multiple alkali digestion was employed until the amount of Cr(VI) in the last extraction was less than 10% of the total amount of Cr(VI). Because Cr(VI) in COPR is usually embedded in the mineral phase structure, the hydration products were dissolved and Cr(VI) was released gradually during the alkaline digestion process. The amount of Cr(VI) detected showed high correlation coefficients with the percentage of F1 (mild acid-soluble fraction), F2 (reducible fraction) and F4 (residual fraction). The Cr(VI) contents detected by the new alkaline digestion method and USEPA Method 3060A showed significant differences for soil samples mixed with COPR due to their high percentage of residual fraction. This new pretreatment method could quantify more than 90% of Cr(VI) in Cr-contaminated soils, especially those mixed with COPR, which proved to be a promising method for Cr(VI) analysis in soils, before and after remediation.

Full and Sustainable Electrochemical Production of Chlorine Dioxide

With the final purpose of manufacturing electrochemically-based devices that produce chloride dioxide efficiently, this paper focuses on the production of chlorates and hydrogen peroxide in two different electrochemical cells, in which operation conditions are selected to obtain high efficiencies, and in the subsequent combination of both electrochemically manufactured solutions to produce chlorine dioxide. Results demonstrate that suitable reagents can be produced by electrolyzing 20 g L−1 sodium chloride solutions at 50 mA cm−2 and 50 °C, and 3000 mg L−1 NaClO4 solutions at 5.0 mA cm−2 and 15 °C with current efficiencies of 30.9% and 48.0%, respectively. Different tests performed with these electrolyzed solutions, and also with commercial hydrogen peroxide and chlorate solutions, demonstrate that the ratio between both reagents plays a very important role in the efficiency in the production of chlorine dioxide. Results clearly showed that, surplus chlorate should be contained in the reagent media to prevent further reduction of chlorine dioxide by hydrogen peroxide and consequently, loses of efficiency in the process. During the reaction, a gas with a high oxidation capacity and consisting mainly in chloride dioxide is produced. The results contributed to the maximum conversion reached being 89.65% using electrolyzed solutions as precursors of ClO2, confirming that this technology can be promising to manufacture portable ClO2 devices.

Mixed Chromate and Molybdate Additives for Cathodic Enhancement in the Chlorate Process

The economic viability of the electrochemical chlorate process depends on toxic chromate to induce cathodic selectivity to hydrogen and mitigate reduction of hypochlorite or chlorate. In this study, it is shown that performance of a pilot plant for chlorate production can be sustained when a 1000-fold reduction in chromate concentration is compensated by addition of molybdate. Laboratory measurements employing a Quartz Crystal Microbalance suggest growth of a nanometre-thick hybrid Mo–Cr-oxide film to induce cathodic selectivity. An optimized energy efficiency for pilot plant operation was obtained using 0.8 mM molybdate and 27 μM chromate, balancing formation of an effective oxide layer and undesired Mo-induced decomposition of hypochlorite to oxygen in solution. Refinement at the pilot scale level is expected to further optimize the energy consumption, thereby increasing safety aspects and the economic viability of chlorate production.

Graphical Abstract

Stand-Alone Microgrid with 100% Renewable Energy: A Case Study with Hybrid Solar PV-Battery-Hydrogen

A 100% renewable energy-based stand-alone microgrid system can be developed by robust energy storage systems to stabilize the variable and intermittent renewable energy resources. Hydrogen as an energy carrier and energy storage medium has gained enormous interest globally in recent years. Its use in stand-alone or off-grid microgrids for both the urban and rural communities has commenced recently in some locations. Therefore, this research evaluates the techno-economic feasibility of renewable energy-based systems using hydrogen as energy storage for a stand-alone/off-grid microgrid. Three case scenarios in a microgrid environment were identified and investigated in order to select an optimum solution for a remote community by considering the energy balance and techno-economic optimization. The “HOMER Pro” energy modelling and simulating software was used to compare the energy balance, economics and environmental impact amongst the proposed scenarios. The simulation results showed that the hydrogen-battery hybrid energy storage system is the most cost-effective scenario, though all developed scenarios are technically possible and economically comparable in the long run, while each has different merits and challenges. It has been shown that the proposed hybrid energy systems have significant potentialities in electrifying remote communities with low energy generation costs, as well as a contribution to the reduction of their carbon footprint and to ameliorating the energy crisis to achieve a sustainable future.

Exploring the mechanism of hypochlorous acid decomposition in aqueous solutions

Hypochlorous acid is an intermediate in important industrial processes such as the production of chlorate but is also used for water treatment and disinfection. In aqueous solutions hypochlorous acid may decompose into oxygen or chlorate. Using density functional theory (DFT) modelling we have for the first time established detailed mechanisms for the respective decomposition pathways. Our calculations indicate, that both oxygen and chlorate formation proceed through an identical set of intermediates. At neutral pH the reaction is initiated by a fast equilibrium between HOCl, OCl^-, Cl₂O and Cl₃O₂^-. The subsequent abstraction of Cl^- to form Cl₂O₂ is rate determining for chlorate formation while it is the decomposition of Cl₂O₂ in the case of oxygen formation. Under alkaline conditions, OCl^- decomposition to chlorate proceeds through chlorite. This reaction path is significantly less active. The highest rate for chlorate or oxygen formation is found at pH 7.1. These results highlight the need to consider a complex mixture of different Cl species when addressing the chemistry of hypochlorous acid containing solutions.

A comparative performance analysis of stand-alone, off-grid solar-powered sodium hypochlorite generators

Sodium hypochlorite (NaClO) is a chemical commodity widely employed as a disinfection agent in water treatment applications. Its production commonly follows electrochemical routes in an undivided reactor. Powering the process with photovoltaic (PV) electricity holds the potential to install stand-alone, independent generators and reduce the NaClO production cost. This study reports the comparative assessment of autonomous, solar-powered sodium hypochlorite generators employing different photovoltaic (PV) technologies: silicon hetero-junction (SHJ) and multi-junction (MJ) solar cells. For Si hetero-junctions, the series connection of either four or five SHJ (4SHJ and 5SHJ, respectively) cells was implemented to obtain the reaction potential required. MJ cells were illuminated by a novel planar solar concentrator that guarantees solar tracking with minimal linear displacements. The three solar-hypochlorite generators were tested under real atmospheric conditions, demonstrating solar-to-chemical conversion efficiencies (SCE) of 9.8% for 4SHJ, 14.2% for 5SHJ and 25.1% for MJ solar cells, respectively. Simulations based on weather databases allowed us to assess efficiencies throughout the entire model year and resulted in specific sodium hypochlorite yearly production rates between 7.2-28 gNaClO cm-2 (referred to the PV surface), depending on the considered PV technology, location, and deployment of electronics converters. The economic viability and competitiveness of solar hypochlorite generators have been investigated and compared with an analog disinfection system deploying ultraviolet lamps. Our study demonstrates the feasibility of off-grid, solar-hypochlorite generators, and points towards the implementation of SHJ solar cells as a reliable technology for stand-alone solar-chemical devices.

Driving Surface Redox Reactions in Heterogeneous Photocatalysis: The Active State of Illuminated Semiconductor-Supported Nanoparticles during Overall Water-Splitting

Materials used for photocatalytic overall water splitting (POWS) are typically composed of light-absorbing semiconductor crystals, functionalized with so-called cocatalytic nanoparticles to improve the kinetics of the hydrogen and/or oxygen evolution reactions. While function, quantity, and protection of such metal(oxide) nanoparticles have been addressed in the literature of photocatalysis, the stability and transients in the active oxidation-state upon illumination have received relatively little attention. In this Perspective, the latest insights in the active state of frequently applied cocatalysts systems, including Pt, Rh/Cr₂O₃, or Ni/NiO_x, will be presented. While the initial morphology and oxidation state of such nanoparticles is a strong function of the applied preparation procedure, significant changes in these properties can occur during water splitting. We discuss these changes in relation to the nature of the cocatalyst/semiconductor interface. We also show how know-how of other disciplines such as heterogeneous catalysis or electro-catalysis and recent advances in analytical methodology can help to determine the active state of cocatalytic nanoparticles in photocatalytic applications.

MnOx/IrOx as Selective Oxygen Evolution Electrocatalyst in Acidic Chloride Solution

The oxygen evolution reaction (OER) and chlorine evolution reaction (CER) are electrochemical processes with high relevance to water splitting for (solar) energy conversion and industrial production of commodity chemicals, respectively. Carrying out the two reactions separately is challenging, since the catalytic intermediates are linked by scaling relations. Optimizing the efficiency of OER over CER in acidic media has proven especially difficult. In this regard, we have investigated the OER versus CER selectivity of manganese oxide (MnO_x), a known OER catalyst. Thin films (∼5–20 nm) of MnO_x were electrodeposited on glassy carbon-supported hydrous iridium oxide (IrO_x/GC) in aqueous chloride solutions of pH ∼0.9. Using rotating ring–disk electrode voltammetry and online electrochemical mass spectrometry, it was found that deposition of MnO_x onto IrO_x decreases the CER selectivity of the system in the presence of 30 mM Cl^– from 86% to less than 7%, making it a highly OER-selective catalyst. Detailed studies of the CER mechanism and ex-situ structure studies using SEM, TEM, and XPS suggest that the MnO_x film is in fact not a catalytically active phase, but functions as a permeable overlayer that disfavors the transport of chloride ions.

Kinetics and mechanism of the chromium(vi) catalyzed decomposition of hypochlorous acid at elevated temperature and high ionic strength

The decomposition of hypochlorous acid was studied under industrially relevant conditions (6.0 M NaClO₃, 80 °C). Chromium(vi) catalyzes the decomposition and the catalytically active form is CrO₄²⁻. A detailed kinetic model is proposed for the process.