Performance of five commercial bipolar membranes under forward and reverse bias conditions for acid-base flow battery applications

Using Layer-by-layer Assembled Clay Composite Junctions to Enhance the Water Dissociation in Bipolar Membranes

Bipolar membranes (BPMs) with a layer-by-layer (LbL) assembled montmorillonite (K30 MMT) clay-polyelectrolyte (PE) composite junction coated onto a sulfonated poly(ether ether ketone (SPEEK)) electrospun support are prepared, characterized and their water dissociation performance is analyzed. In particular, the focus is on the effect of the presence of the K30 MMT clay as a catalyst for water dissociation, the bilayer number (three, six, and nine), and the PE strength (poly(ethylenimine) (PEI) as a weak PE and poly(diallyl dimethylammonium chloride) (PDADMAC) as a strong PE) on the BPM performance. The BPMs are prepared by electrospinning and hot pressing SPEEK and the Fumion FAA-3 polymer. Adding the composite multilayers in the BPM junction decreases the membrane area resistance in reverse bias from 560 to 21 Ohms cm2 for the best-performing modified BPM. The bilayer number has limited influence on the overall membrane resistance, while the PDADMAC BPMs outperform the PEI BPMs due to the higher and more stable PE and clay adsorptions. Electrochemical impedance spectroscopy shows that the depletion layer thickness decreases exponentially with the number of bilayers as the water dissociation reaction becomes less dependent on the junction electric field. Furthermore, the higher Donnan exclusion at the modified junctions improves the BPM permselectivity 3-fold compared to the BPM containing no catalyst. Altogether, these improvements lead to 6.7 times less energy being used in BPM electrodialysis for the production of acid and base when a BPM with composite LBL junction is used compared to a BPM without catalyst. Thus, adding MMT clay composite LbL catalyst to BPM junctions is a promising method to improve the efficiency and reduce the energy consumption of electrochemical processes that rely on BPMs.

Gas-Induced Structural Damages in Forward-Bias Bipolar Membrane CO2 Electrolysis Studied by Fast X-ray Tomography

Forward-bias bipolar membrane (BPM) CO2 coelectrolysis (CO2ELY) aims at overcoming the issues of salt precipitation and CO2 crossover in anion exchange membrane CO2ELY. Increasing the stability of BPM-CO2ELY is crucial for widespread application of the technique. In this study, we employ time-resolved X-ray tomographic microscopy to elucidate the structural dynamics that occur within the electrochemical cell during operation under various conditions. Using advanced image processing methods, including custom 4D machine learning segmentation, we can visualize and quantify damages in the membrane and anode catalyst layer (CL). We compare our results to a CO2 transport model and hypothesize gaseous CO2 as the cause of the observed damages. At any operation condition, CO2 is formed at the junction in the center of the BPM by recombination of carbonate ions. CO2 migrates to the anode by diffusion and goes into the gas phase at the interface of the membrane and anode CL. After sufficient CO2 accumulation and pressure buildup after only tens of minutes, small irreversible holes break into the CL distributed over the entire active area. Additionally, at higher current densities, the CO2 accumulation leads to membrane delamination at the BPM junction. Despite the clear degradation processes, we do not observe an obvious direct effect on the electrochemical performance. The poor stability of BPM-CO2ELY remains an open question.

Combined Electrospinning-Electrospraying for High-Performance Bipolar Membranes with Incorporated MCM-41 as Water Dissociation Catalysts

Electrospinning has been demonstrated as a very promising method to create bipolar membranes (BPMs), especially as it allows three-dimensional (3D) junctions of entangled anion exchange and cation exchange nanofibers. These newly developed BPMs are relevant to demanding applications, including acid and base production, fuel cells, flow batteries, ammonia removal, concentration of carbon dioxide, and hydrogen generation. However, these applications require the introduction of catalysts into the BPM to allow accelerated water dissociation, and this remains a challenge. Here, we demonstrate a versatile strategy to produce very efficient BPMs through a combined electrospinning-electrospraying approach. Moreover, this work applies the newly investigated water dissociation catalyst of nanostructured silica MCM-41. Several BPMs were produced by electrospraying MCM-41 nanoparticles into the layers directly adjacent to the main BPM 3D junction. BPMs with various loadings of MCM-41 nanoparticles and BPMs with different catalyst positions relative to the junction were investigated. The membranes were carefully characterized for their structure and performance. Interestingly, the water dissociation performance of BPMs showed a clear optimal MCM-41 loading where the performance outpaced that of a commercial BPM, recording a transmembrane voltage of approximately 1.11 V at 1000 A/m2. Such an excellent performance is very relevant to fuel cell and flow battery applications, but our results also shed light on the exact function of the catalyst in this mode of operation. Overall, we demonstrate clearly that introducing a novel BPM architecture through a novel hybrid electrospinning-electrospraying method allows the uptake of promising new catalysts (i.e., MCM-41) and the production of very relevant BPMs.

Understanding the Impact of the Three-Dimensional Junction Thickness of Electrospun Bipolar Membranes on Electrochemical Performance

The use of electrospun bipolar membranes (BPMs) with an interfacial three-dimensional (3D) junction of entangled nano-/microfibers has been recently proposed as a promising fabrication strategy to develop high-performance BPMs. In these BPMs, the morphology and physical properties of the 3D junction are of utmost importance to maximize the membrane performance. However, a full understanding of the impact of the junction thickness on the membrane performance is still lacking. In this study, we have developed bipolar membranes with the same composition, only varying the 3D junction thicknesses, by regulating the electrospinning time used to deposit the nano-/microfibers at the junction. In total, four BPMs with 3D junction thicknesses of ∼4, 8, 17, and 35 μm were produced to examine the influence of the junction thickness on the membrane performance. Current-voltage curves for water dissociation of BPMs exhibited lower voltages for BPMs with thicker 3D junctions, as a result of a three-dimensional increase in the interfacial contact area between cation- and anion-exchange fibers and thus a larger water dissociation reaction area. Indeed, increasing the BPM thickness from 4 to 35 μm lowered the BPM water dissociation overpotential by 32%, with a current efficiency toward HCl/NaOH generation higher than 90%. Finally, comparing BPM performance during the water association operation revealed a substantial reduction in the voltage from levels of its supplied open circuit voltage (OCV), owing to excessive hydroxide ion (OH-) and proton (H+) leakage through the relevant layers. Overall, this work provides insights into the role of the junction thickness on electrospun BPM performance as a crucial step toward the development of membranes with optimal entangled junctions.

Electrodialysis with Bipolar Membranes for the Generation of NaOH and HCl Solutions from Brines: An Inter-Laboratory Evaluation of Thin and Ultrathin Non-Woven Cloth-Based Ion-Exchange Membranes

The SEArcularMINE project aims to recover critical raw materials (CRMs) from brines from saltworks, thus facing a CRM shortage within Europe. To promote a fully circular scheme, the project valorises concentrated brines using electrodialysis with bipolar membranes (EDBM) to generate the required amounts of reactants (i.e., acids and bases). Regarding the performances of new non-woven cloth ion-exchange membranes (Suez): (i) an ultra-thin non-woven polyester cloth and (ii) a thin polypropylene cloth acting as the support structures were assessed. Additionally, the anion layer includes a catalyst to promote the water dissociation reaction. The effect of current density (100, 200, and 300 A m^-2) on the performance of two combinations of membranes in an inter-laboratory exercise using 2 M NaCl was evaluated. According to statistical analysis ANOVA, there was an agreement on the results obtained in both laboratories. NaOH/HCl solutions up to 0.8 M were generated working at 300 A m^-2 using both combinations of membranes. Regarding the performance parameters, stack set-ups incorporating thin polypropylene membranes showed lower specific energy consumption (SEC) and higher specific productivity (SP) than ultra-thin polypropylene ones. Hence, for ultra-thin polypropylene membranes, SEC was reported to be between 2.18 and 1.69 kWh kg^-1_NaOH and SP between 974 and 314 kg m^-2 y^-1.

Technical and Environmental Feasibilities of the Commercial Production of NaOH from Brine by Means of an Integrated EDBM and Evaporation Process

Electrodialysis with bipolar membranes (EDBMs) is a technology that offers a great potential for the introduction of the principles of a circular economy in the desalination industry, by providing a strategy for the recovery of HCl and NaOH from brine via the process of seawater reverse osmosis (SWRO). Both chemicals are widely employed in desalination facilities, however NaOH presents a special interest due to its higher requirements and cost. Nevertheless, the standard commercial concentrations that are commonly employed in the facilities cannot be obtained using the state of the art EDBM technology itself. Therefore, the aim and main purpose of this work is to prove the technical and environmental feasibilities of a new approach to produce commercial NaOH (50%wt.) from SWRO brine by means of an integrated process of EDBMs followed by a triple effect evaporation. The global process has been technically evaluated in terms of the specific energy consumption (SEC) (kWh·kg^-1 NaOH) and the environmental sustainability performance has been analyzed by its carbon footprint (CF) (kg CO₂-eq.·kg^-1 NaOH). The influence of the current density, and the power source in the EDBM stage have been evaluated on a laboratory scale while the influence of the feed stream concentration in the evaporation stage has been obtained through simulations using Aspen Plus. The lowest SEC of the integrated process (SEC_OV), 31.1 kWh·kg^-1 NaOH, is obtained when an average current density of 500 A·m^-2, provided by a power supply (grid mix), is applied in the EDBM stage. The environmental burdens of the integrated process have been quantified by achieving reductions in the CF by up to 54.7% when solar photovoltaic energy is employed as the power source for EDBMs, with a value of 5.38 kg CO₂-eq.·kg^-1 NaOH. This study presents a great potential for the introduction of the principles of a circular economy in the water industry through the recovery of NaOH from the high salinity waste stream generated in SWRO facilities and opens the possibility of the reuse of NaOH by its self-supply in the desalination plant.