Electrochemical Wastewater Refining: A Vision for Circular Chemical Manufacturing

Reverse-engineered Electro-Fenton for the selective synthesis of oxalic or oxamic acid through the degradation of acetaminophen: A novel green electrocatalytic refinery approach

The Electro-Fenton process (EF) has been conventionally applied to efficiently degrade refractory and/or toxic pollutants. However, in this work, EF was used as a reverse engineering tool to selectively synthesize highly value-added products (oxalic or oxamic acid) through the degradation of the model pollutant acetaminophen, a widely used analgesic and antipyretic drug. It was found that the production of either oxalic or oxamic acid is dictated by the applied current density. Hence, oxalic acid is favored at low current densities trough a mechanism dominated by homogeneous •OH radical oxidation, while oxamic acid is the majoritarian product at high current densities where electron transfer at the anode surface becomes an important mechanism in combination with •OH oxidation. Under optimal reaction conditions (0.71 mA cm-2 and 100 mg l-1 of initial total organic carbon (TOC) concentration), up to 227.1 ± 26.3 mg l-1 of oxalic acid were produced, with high yield and selectivity of 54.9 ± 5.1 % and 94.7 ± 9.9 %, respectively (the TOC removal was 42.0 ± 2.4 %). In the case of oxamic acid, the highest concentration of 33.8 ± 2.1 mg l-1 was produced at 2.13 mA cm-2 and an initial TOC concentration of 50 mg l-1, which represented a yield of 18.7 ± 0.3 % and 60.9 ± 9.3 % selectivity (71.1 ± 4.4 % of TOC removal). It is worth noting that at low current density when oxalic acid is favored, the selectivity for both products was 100 %, meaning that those were the only products remaining in the solution, with oxalic acid as the major product (94.7 ± 9.9 % with initial TOC of 100 mg l-1, and 98.7 ± 0.9 % with initial TOC of 50 mg l-1). This is a pioneer work on EF applications to the field of wastewater valorization/refining through the recovery of value-added products within a circular economy.

Chemical upcycling of Ni from electroplating wastewater into a well-defined catalyst for electrooxidation of glycerol to formate

Highly effective and efficient remediation of hazardous Ni waste from electroless electroplating wastewater remains a significant challenge. However, rather than regarding it as hazardous waste, Ni-electroplating wastewater can instead be considered a huge resource of Ni. Herein, we report a convenient hydrothermal strategy for upcycling Ni from nickel-electroplating wastewater into a carbon-doped Ni-P alloy (denoted as C/Ni-Px) electrocatalyst for the oxidation of glycerol to formate. This strategy can reduce the total Ni2+ concentration from thousands of milligrams per liter to lower than the advisory level of discharge standards for electroplating effluent in China (≤0.5 mg L-1), demonstrating an excellent nickel uptake capacity and potential for practical application in both simulated and actual Ni-electroplating wastewater. Furthermore, the resultant C/Ni-Px exhibited good electrooxidation of glycerol to formate with a selectivity of 96.4%, surpassing a vast majority of previously reported electrocatalysts. Therefore, our findings not only provide an efficient strategy for removing Ni from electroless electroplating wastewater but also advance the upcycling of Ni waste into a functional material for the electrocatalytic synthesis of value-added products.

Toward a circular nitrogen bioeconomy: integrating nitrogen bioconcentration, separations, and high-value products for nitrogen recovery

Recovering nitrogen (N) from wastewater is a potential avenue to reduce reliance on energy-intensive synthetic nitrogen fixation via Haber-Bosch and subsequent treatment of N-laden wastewaters through nitrification-denitrification. However, many technical and economic factors hinder widespread application of N recovery, particularly low N concentrations in municipal wastewater, paucity of high-efficiency separations technologies compatible with biological treatment, and suitable products and markets for recovered N. In this perspective, we contextualize the challenges of N recovery today, propose integrated biological and physicochemical technologies to improve selective and tunable N recovery, and propose an expanded product portfolio for recovered N products beyond fertilizers. We highlight cyanophycin, an N-rich biopolymer produced by a diverse range of bacteria, as a potential target for N bioconcentration and downstream recovery from municipal wastewater. This perspective emphasizes the equal importance of integrated biological systems, physicochemical separations, and market assessment in advancing nitrogen recovery from wastewater.

Regulating the Electrochemical Nitrate Reduction Performance with Controllable Distribution of Unconventional Phase Copper on Alloy Nanostructures

Electrochemical nitrate reduction reaction (NO3RR) is emerging as a promising strategy for nitrate removal and ammonia (NH3) production using renewable electricity. Although great progresses have been achieved, the crystal phase effect of electrocatalysts on NO3RR remains rarely explored. Here, the epitaxial growth of unconventional 2H Cu on hexagonal close-packed (hcp) IrNi template, resulting in the formation of three IrNiCu@Cu nanostructures, is reported. IrNiCu@Cu-20 shows superior catalytic performance, with NH3 Faradaic efficiency (FE) of 86% at -0.1 (vs reversible hydrogen electrode [RHE]) and NH3 yield rate of 687.3 mmol gCu -1 h-1, far better than common face-centered cubic Cu. In sharp contrast, IrNiCu@Cu-30 and IrNiCu@Cu-50 covered by hcp Cu shell display high selectivity toward nitrite (NO2 -), with NO2 - FE above 60% at 0.1 (vs RHE). Theoretical calculations have demonstrated that the IrNiCu@Cu-20 has the optimal electronic structures for NO3RR due to the highest d-band center and strongest reaction trend with the lowest energy barriers. The high electroactivity of IrNiCu@Cu-20 originates from the abundant low coordination of Cu sites on the surface, which guarantees the fast electron transfer to accelerate the intermediate conversions. This work provides a feasible tactic to regulate the product distribution of NO3RR by crystal phase engineering of electrocatalysts.

Direct electrosynthesis and separation of ammonia and chlorine from waste streams via a stacked membrane-free electrolyzer

Electrosynthesis, a viable path to decarbonize the chemical industry, has been harnessed to generate valuable chemicals under ambient conditions. Here, we present a membrane-free flow electrolyzer for paired electrocatalytic upcycling of nitrate (NO3-) and chloride (Cl-) to ammonia (NH3) and chlorine (Cl2) gases by utilizing waste streams as substitutes for traditional electrolytes. The electrolyzer concurrently couples electrosynthesis and gaseous-product separation, which minimizes the undesired redox reaction between NH3 and Cl2 and thus prevents products loss. Using a three-stacked-modules electrolyzer system, we efficiently processed a reverse osmosis retentate waste stream. This yielded high concentrations of (NH4)2SO4 (83.8 mM) and NaClO (243.4 mM) at an electrical cost of 7.1 kWh per kilogram of solid products, while residual NH3/NH4+ (0.3 mM), NO2- (0.2 mM), and Cl2/HClO/ClO- (0.1 mM) pollutants in the waste stream could meet the wastewater discharge regulations for nitrogen- and chlorine-species. This study underscores the value of pairing appropriate half-reactions, utilizing waste streams to replace traditional electrolytes, and merging product synthesis with separation to refine electrosynthesis platforms.

Effects of Ionic Interferents on Electrocatalytic Nitrate Reduction: Mechanistic Insight

Nitrate, a prevalent water pollutant, poses substantial public health concerns and environmental risks. Electrochemical reduction of nitrate (eNO3RR) has emerged as an effective alternative to conventional biological treatments. While extensive lab work has focused on designing efficient electrocatalysts, implementation of eNO3RR in practical wastewater settings requires careful consideration of the effects of various constituents in real wastewater. In this critical review, we examine the interference of ionic species commonly encountered in electrocatalytic systems and universally present in wastewater, such as halogen ions, alkali metal cations, and other divalent/trivalent ions (Ca2+, Mg2+, HCO3-/CO32-, SO42-, and PO43-). Notably, we categorize and discuss the interfering mechanisms into four groups: (1) loss of active catalytic sites caused by competitive adsorption and precipitation, (2) electrostatic interactions in the electric double layer (EDL), including ion pairs and the shielding effect, (3) effects on the selectivity of N intermediates and final products (N2 or NH3), and (4) complications by the hydrogen evolution reaction (HER) and localized pH on the cathode surface. Finally, we summarize the competition among different mechanisms and propose future directions for a deeper mechanistic understanding of ionic impacts on eNO3RR.

Long-Term Robustness and Failure Mechanisms of Electrochemical Stripping for Wastewater Ammonia Recovery

Nitrogen in wastewater has negative environmental, human health, and economic impacts but can be recovered to reduce the costs and environmental impacts of wastewater treatment and chemical production. To recover ammonia/ammonium (total ammonia nitrogen, TAN) from urine, we operated electrochemical stripping (ECS) for over a month, achieving 83.4 ± 1.5% TAN removal and 73.0 ± 2.9% TAN recovery. With two reactors, we recovered sixteen 500-mL batches (8 L total) of ammonium sulfate (20.9 g/L TAN) approaching commercial fertilizer concentrations (28.4 g/L TAN) and often having >95% purity. While evaluating the operation and maintenance needs, we identified pH, full-cell voltage, product volume, and water flux into the product as informative process monitoring parameters that can be inexpensively and rapidly measured. Characterization of fouled cation exchange and omniphobic membranes informs cleaning and reactor modifications to reduce fouling with organics and calcium/magnesium salts. To evaluate the impact of urine collection and storage on ECS, we conducted experiments with urine at different levels of dilution with flush water, extents of divalent cation precipitation, and degrees of hydrolysis. ECS effectively treated urine under all conditions, but minimizing flush water and ensuring storage until complete hydrolysis would enable energy-efficient TAN recovery. Our experimental results and cost analysis motivate a multifaceted approach to improving ECS's technical and economic viability by extending component lifetimes, decreasing component costs, and reducing energy consumption through material, reactor, and process engineering. In summary, we demonstrated urine treatment as a foothold for electrochemical nutrient recovery from wastewater while supporting the applicability of ECS to seven other wastewaters with widely varying characteristics. Our findings will facilitate the scale-up and deployment of electrochemical nutrient recovery technologies, enabling a circular nitrogen economy that fosters sanitation provision, efficient chemical production, and water resource protection.

Electrochemical sulfate production from sulfide-containing wastewaters and integration with electrochemical nitrogen recovery

Electrochemical methods can help manage sulfide in wastewater, which poses environmental and health concerns due to its toxicity, malodor, and corrosiveness. In addition, sulfur could be recovered as fertilizer and commodity chemicals from sulfide-containing wastewaters. Wastewater characteristics vary widely among wastewaters; however, it remains unclear how these characteristics affect electrochemical sulfate production. In this study, we evaluated how four characteristics of influent wastewaters (electrolyte pH, composition, sulfide concentration, and buffer strength) affect sulfide removal (sulfide removal rate, sulfide removal efficiency) and sulfate production metrics (sulfate production rate, sulfate production selectivity). We identified that electrolyte pH (3 × difference, i.e., 25.1 to 84.9 μM h-1 in average removal rate within the studied pH range) and sulfide concentration (16 × difference, i.e., 82.1 to 1347.2 μM h-1 in average removal rate) were the most influential factors for electrochemical sulfide removal. Sulfate production was most sensitive to buffer strength (6 × difference, i.e., 4.4 to 27.4 μM h-1 in average production rate) and insensitive to electrolyte composition. Together, these results provide recommendations for the design of wastewater treatment trains and the feasibility of applying electrochemical methods to varying sulfide-containing wastewaters. In addition, we investigated a simultaneous multi-nutrient (sulfur and nitrogen) process that leverages electrochemical stripping to further enhance the versatility and compatibility of electrochemical nutrient recovery.