Additive Manufacturing of a Microbial Fuel Cell--A detailed study

A comprehensive review of microbial fuel cells considering materials, methods, structures, and microorganisms

Microbial fuel cells (MFCs) are promising for generating renewable energy from organic matter and efficient wastewater treatment. Ensuring their practical viability requires meticulous optimization and precise design. Among the critical components of MFCs, the membrane separator plays a pivotal role in segregating the anode and cathode chambers. Recent investigations have shed light on the potential benefits of membrane-less MFCs in enhancing power generation. However, it is crucial to recognize that such configurations can adversely impact the electrocatalytic activity of anode microorganisms due to increased substrate and oxygen penetration, leading to decreased coulombic efficiency. Therefore, when selecting a membrane for MFCs, it is essential to consider key factors such as internal resistance, substrate loss, biofouling, and oxygen diffusion. Addressing these considerations carefully allows researchers to advance the performance and efficiency of MFCs, facilitating their practical application in sustainable energy production and wastewater treatment. Accelerated substrate penetration could also lead to cathode clogging and bacterial inactivation, reducing the MFC's efficiency. Overall, the design and optimization of MFCs, including the selection and use of membranes, are vital for their practical application in renewable energy generation and wastewater treatment. Further research is necessary to overcome the challenges of MFCs without a membrane and to develop improved membrane materials for MFCs. This review article aims to compile comprehensive information about all constituents of the microbial fuel cell, providing practical insights for researchers examining various variables in microbial fuel cell research.

3D Printed lattice-structured metal electrodes for enhanced current production in bioelectrochemical systems

Bioelectrochemical systems (BESs) are emerging techniques that use biological production of current for versatile activities, including energy recovery and bioremediation. The development of high-performance three-dimensional (3D) electrodes has attracted attention for facilitating current production in BESs. Carbon-based electrodes have been commonly used in BESs, but metal electrodes are not generally employed because of their low biocompatibility with microbes. In this study, 3D stainless-steel electrodes, composed of octahedral lattice, were fabricated using the 3D printing technique. Heat treatment was conducted to form an iron-oxide layer on the electrode surface for increasing biocompatibility. Another crucial parameter that determines current production is the pitch length of a lattice electrode as it affects the surface area and substrate diffusion. The pitch length was optimized by testing the lattice electrodes with pitches ranging from 1.5 mm to 6.0 mm. The highest current, obtained with the 3.0 mm-pitch electrode, was 50% higher than that obtained with common 3D carbon-felt electrodes. These results demonstrate the usefulness of 3D lattice-structured metal electrodes in BESs.

Structure evolution of air cathodes and their application in electrochemical sensor development and wastewater treatment

Cathode structure and material are the most important factors to determine the performance and cost of single chamber air-cathode microbial fuel cell (MFC), which is the most promising type of MFC technology. Since the first air cathode was invented in 2004, five major structures (1-layer, 2-layer, 3-layer, 4-layer and separator-support) have been invented and modified to fit new material, improve power performance and lower MFC cost. This paper reviewed the structure evolution of air cathodes in past 18 years. The benefits and drawbacks of these structures, in terms of power generation, material cost, fabrication procedure and modification process are analyzed. The practical application cases (e.g., sensor development and wastewater treatment) employed with different cathode structures were also summarized and analyzed. Based on practical performance and long-term cost analysis, the 2-layer cathode demonstrated much greater potential over other structures. Compared with traditional activated-sludge technology, the cost of an MFC-based system is becoming competitive when employing with 2-layer structure. This review not only provides a detailed development history of air cathode but also reveals the advantages/disadvantages of air cathode with different structures, which will promote the research and application of air-cathode MFC technology.

Hydrogen at symmetric tilt grain boundaries in aluminum: segregation energies and structural features

Aluminum is envisioned to be an important material in future hydrogen-based energy systems. Here we report an ab initio investigation on the interactions between H-atoms and common grain boundaries (GBs) of fcc Al: Σ9, Σ5, Σ11 and Σ3. We found that upon segregation to the GBs, single H-atoms can cause displacement of Al-atoms. Increasing their concentration revealed large cooperative effects between H-atoms that favor the segregation when other H-atoms are bound at neighboring sites. This makes these GBs able to accommodate high concentrations of H-atoms with considerable segregation energies per atom. Structural analyses derived from Laguerre–Voronoi tessellations show that these GBs have many interstitial sites with higher symmetry than the bulk tetrahedral interstitial site. Many of those sites have also large volumes and higher coordination numbers than the bulk sites. These factors are the increased driving force for H-atom segregation at the studied GBs in Al when compared to other metals. These GBs can accommodate a higher concentration of H-atoms which indicates a likely uniform distribution of H-atoms at GBs in the real material. This suggests that attempting to mitigate hydrogen uptake solely by controlling the occurrence of certain GBs may not be the most efficient strategy for Al.

Integration of various technology-based approaches for enhancing the performance of microbial fuel cell technology: A review

The conflict between climate change and growing global energy demand is an immense sustainability challenge that requires noteworthy scientific and technological developments. Recently the importance of microbial fuel cell (MFC) on this issue has seen profound investigation due to its inherent ability of simultaneous wastewater treatment, and power production. However, the challenges of economy-related manufacturing and operation costs should be lowered to achieve positive field-scale demonstration. Also, a variety of different field deployments will lead to improvisation. Hence, this review article discusses the possibility of integration of MFC technology with various technologies of recent times leading to advanced sustainable MFC technology. Technological innovation in the field of nanotechnology, genetic engineering, additive manufacturing, artificial intelligence, adaptive control, and few other hybrid systems integrated with MFCs is discussed. This comprehensive and state-of-the-art study elaborates hybrid MFCs integrated with various technology and its working principles, modified electrode material, complex and easy to manufacture reactor designs, and the effects of various operating parameters on system performances. Although integrated systems are promising, much future research work is needed to overcome the challenges and commercialize hybrid MFC technology.

Efficient Hydrogen Delivery for Microbial Electrosynthesis via 3D-Printed Cathodes

The efficient delivery of electrochemically in situ produced H₂ can be a key advantage of microbial electrosynthesis over traditional gas fermentation. However, the technical details of how to supply large amounts of electric current per volume in a biocompatible manner remain unresolved. Here, we explored for the first time the flexibility of complex 3D-printed custom electrodes to fine tune H₂ delivery during microbial electrosynthesis. Using a model system for H₂-mediated electromethanogenesis comprised of 3D fabricated carbon aerogel cathodes plated with nickel-molybdenum and Methanococcus maripaludis, we showed that novel 3D-printed cathodes facilitated sustained and efficient electromethanogenesis from electricity and CO₂ at an unprecedented volumetric production rate of 2.2 L_CH4 /L_catholyte/day and at a coulombic efficiency of 99%. Importantly, our experiments revealed that the efficiency of this process strongly depends on the current density. At identical total current supplied, larger surface area cathodes enabled higher methane production and minimized escape of H₂. Specifically, low current density (<1 mA/cm²) enabled by high surface area cathodes was found to be critical for fast start-up times of the microbial culture, stable steady state performance, and high coulombic efficiencies. Our data demonstrate that 3D-printing of electrodes presents a promising design tool to mitigate effects of bubble formation and local pH gradients within the boundary layer and, thus, resolve key critical limitations for in situ electron delivery in microbial electrosynthesis.

Waste valorization using solid-phase microbial fuel cells (SMFCs): Recent trends and status

This review article discusses the use of solid waste processed in solid-phase microbial fuel cells (SMFCs) as a source of electrical energy. Microbial Fuel Cells (MFCs) are typically operated in the liquid phase because the ion transfer process is efficient in liquid media. Nevertheless, some researchers have considered the potential for MFCs in solid phases (particularly for treating solid waste). This has promise if several important factors are optimized, such as the type and amount of substrate, microorganism community, system configuration, and type and number of electrodes, which increases the amount of electricity generated. The critical factor that affects the SMFC performance is the efficiency of electron and proton transfer through solid media. However, this limitation may be overcome by electrode system enhancements and regular substrate mixing. The integration of SMFCs with other conventional solid waste treatments could be used to produce sustainable green energy. Although SMFCs produce relatively small amounts of energy compared with other waste-to-energy treatments, SMFCs are still promising to achieve zero-emission treatment. Therefore, this article addresses the challenges and fills the gaps in SMFC research and development.

Developing 3D-Printable Cathode Electrode for Monolithically Printed Microbial Fuel Cells (MFCs)

Microbial Fuel Cells (MFCs) employ microbial electroactive species to convert chemical energy stored in organic matter, into electricity. The properties of MFCs have made the technology attractive for bioenergy production. However, a challenge to the mass production of MFCs is the time-consuming assembly process, which could perhaps be overcome using additive manufacturing (AM) processes. AM or 3D-printing has played an increasingly important role in advancing MFC technology, by substituting essential structural components with 3D-printed parts. This was precisely the line of work in the EVOBLISS project, which investigated materials that can be extruded from the EVOBOT platform for a monolithically printed MFC. The development of such inexpensive, eco-friendly, printable electrode material is described below. The electrode in examination (PTFE_FREE_AC), is a cathode made of alginate and activated carbon, and was tested against an off-the-shelf sintered carbon (AC_BLOCK) and a widely used activated carbon electrode (PTFE_AC). The results showed that the MFCs using PTFE_FREE_AC cathodes performed better compared to the PTFE_AC or AC_BLOCK, producing maximum power levels of 286 μW, 98 μW and 85 μW, respectively. In conclusion, this experiment demonstrated the development of an air-dried, extrudable (3D-printed) electrode material successfully incorporated in an MFC system and acting as a cathode electrode.

Complete Microbial Fuel Cell Fabrication Using Additive Layer Manufacturing

Improving the efficiency of microbial fuel cell (MFC) technology by enhancing the system performance and reducing the production cost is essential for commercialisation. In this study, building an additive manufacturing (AM)-built MFC comprising all 3D printed components such as anode, cathode and chassis was attempted for the first time. 3D printed base structures were made of low-cost, biodegradable polylactic acid (PLA) filaments. For both anode and cathode, two surface modification methods using either graphite or nickel powder were tested. The best performing anode material, carbon-coated non-conductive PLA filament, was comparable to the control modified carbon veil with a peak power of 376.7 µW (7.5 W m⁻³) in week 3. However, PLA-based AM cathodes underperformed regardless of the coating method, which limited the overall performance. The membrane-less design produced more stable and higher power output levels (520−570 µW, 7.4−8.1 W m⁻³) compared to the ceramic membrane control MFCs. As the final design, four AM-made membrane-less MFCs connected in series successfully powered a digital weather station, which shows the current status of low-cost 3D printed MFC development.

A review of 3D printing techniques for environmental applications

With a wide variety of techniques and compatible materials, three-dimensional (3D) printing is becoming increasingly useful in environmental applications in air, water, and energy. Through the advantages of quick production, cost-effectiveness, customizable design, the ability to produce complex geometries, and more, 3D printing has supported improvements to air quality monitors, filters, membranes, separation devices for water treatment, microbial fuel cells, solar cells, and wind turbines. It also supports sustainable manufacturing through reduced material waste, energy use, and carbon emissions. Applications of 3D printing within four environmental disciplines are described in this article: sustainable manufacturing, air quality, water and wastewater, and alternative energy sources.

Utilisation of waste medicine wrappers as an efficient low-cost electrode material for microbial fuel cell

Waste generation from healthcare facilities now has become a concerning issue as it contain plastic and metals. Medicine wrappers are one of the major portions of healthcare solid waste, which impel intensive solid waste management practice due to fewer possibilities of deriving by-products. However, it can be recycled and used as an electrode material in microbial fuel cells (MFCs). An electrode material for application in MFCs is a crucial component, which governs total fabrication cost as well as power recovery, thus a cost-effective, stable and durable electrode is essential. In this endeavour, a new metallic (aluminium) waste material, a waste medicine wrapper (WMW), was evaluated for feasibility to be used as anode/cathode in MFCs. Based on the stability test under corrosive environment (1 N KCl), the WMW electrode sustained a maximum current of 46 mA during cyclic voltammetry (CV) and noted only 14% reduction in current at an applied voltage of +0.4 V after 2500 s in chronoamperometry, indicating its good stability. Power recovery from MFC using WMW was higher than the MFC using bare carbon felt as an anode (27 vs. 21 mW/m²). The entire analytical test results viz. CV, electrochemical impedance spectroscopy and power performance established WMW as an excellent anode rather than cathode material.

A novel microbial fuel cell with exchangeable membrane – application of additive manufacturing technology for device fabrication

Research about exploitation the potential of waste and sludge increased drastically in the recent years. One of the most promising alternative methods of waste management is Microbial Fuel Cell (MFC), which generate clean bio-electricity using microorganisms. Organic compounds, sewage, municipal solid waste could be used as a source for microbial nutrition. The construction of MFC is one of the most important parameter in laboratory studies and during scale-up. The efficiency of MFC depends on many factors including type of membrane. To obtain optimization in terms of various operating conditions, a prototype of Microbial Fuel Cell with exchangeable membrane was projected and fabricated by additive manufacturing (AM) technology. This novel device allows to research effects of different types of separator membranes. Preliminary research showed possibility to produce 3D printed MFC systems.

Electrochemical Characterisation of Bio-Bottle-Voltaic (BBV) Systems Operated with Algae and Built with Recycled Materials

Photobioelectrochemical systems are an emerging possibility for renewable energy. By exploiting photosynthesis, they transform the energy of light into electricity. This study evaluates a simple, scalable bioelectrochemical system built from recycled plastic bottles, equipped with an anode made from recycled aluminum, and operated with the green alga Chlorella sorokiniana. We tested whether such a system, referred to as a bio-bottle-voltaic (BBV) device, could operate outdoors for a prolonged time period of 35 days. Electrochemical characterisation was conducted by measuring the drop in potential between the anode and the cathode, and this value was used to calculate the rate of charge accumulation. The BBV systems were initially able to deliver ~500 mC·bottle⁻¹·day⁻¹, which increased throughout the experimental run to a maximum of ~2000 mC·bottle⁻¹·day⁻¹. The electrical output was consistently and significantly higher than that of the abiotic BBV system operated without algal cells (~100 mC·bottle⁻¹·day⁻¹). The analysis of the rate of algal biomass accumulation supported the hypothesis that harvesting a proportion of electrons from the algal cells does not significantly perturb the rate of algal growth. Our finding demonstrates that bioelectrochemical systems can be built using recycled components. Prototypes of these systems have been displayed in public events; they could serve as educational toolkits in schools and could also offer a solution for powering low-energy devices off-grid.

Additive Manufacturing: Unlocking the Evolution of Energy Materials

The global energy infrastructure is undergoing a drastic transformation towards renewable energy, posing huge challenges on the energy materials research, development and manufacturing. Additive manufacturing has shown its promise to change the way how future energy system can be designed and delivered. It offers capability in manufacturing complex 3D structures, with near-complete design freedom and high sustainability due to minimal use of materials and toxic chemicals. Recent literatures have reported that additive manufacturing could unlock the evolution of energy materials and chemistries with unprecedented performance in the way that could never be achieved by conventional manufacturing techniques. This comprehensive review will fill the gap in communicating on recent breakthroughs in additive manufacturing for energy material and device applications. It will underpin the discoveries on what 3D functional energy structures can be created without design constraints, which bespoke energy materials could be additively manufactured with customised solutions, and how the additively manufactured devices could be integrated into energy systems. This review will also highlight emerging and important applications in energy additive manufacturing, including fuel cells, batteries, hydrogen, solar cell as well as carbon capture and storage.

Microbial fuel cells: From fundamentals to applications. A review

In the past 10-15 years, the microbial fuel cell (MFC) technology has captured the attention of the scientific community for the possibility of transforming organic waste directly into electricity through microbially catalyzed anodic, and microbial/enzymatic/abiotic cathodic electrochemical reactions. In this review, several aspects of the technology are considered. Firstly, a brief history of abiotic to biological fuel cells and subsequently, microbial fuel cells is presented. Secondly, the development of the concept of microbial fuel cell into a wider range of derivative technologies, called bioelectrochemical systems, is described introducing briefly microbial electrolysis cells, microbial desalination cells and microbial electrosynthesis cells. The focus is then shifted to electroactive biofilms and electron transfer mechanisms involved with solid electrodes. Carbonaceous and metallic anode materials are then introduced, followed by an explanation of the electro catalysis of the oxygen reduction reaction and its behavior in neutral media, from recent studies. Cathode catalysts based on carbonaceous, platinum-group metal and platinum-group-metal-free materials are presented, along with membrane materials with a view to future directions. Finally, microbial fuel cell practical implementation, through the utilization of energy output for practical applications, is described.

Long term testing of Microbial Fuel Cells: Comparison of different anode materials

This paper focuses on the long term operation and testing of three Microbial Fuel Cells (MFC) having three different anode materials: commercial carbon felt (C-FELT), polyaniline-deposited carbon felt (C-PANI) and carbon-coated Berl saddles (C-SADDLES). A mixed consortium from seawater was used as inoculum and acetate was used as substrate. Tests were conducted for four months under 1000Ω external load. The maximum power generation was obtained by C-SADDLES (102mWm(-2)) followed by C-FELT and C-PANI, respectively. A similar trend was obtained with the evaluation of electrical energy produced: C-SADDLES (2222J), C-PANI (2183J) and C-FELT (2114J). However, the performance of C-PANI decreased over time, most evidently due to degradation or deactivation of deposited polyaniline by the microorganisms' activity. These results provide evidence that the three-dimensional structure, C-SADDLES, offers excellent biocompatibility, high specific surface area, high conductivity and most importantly these properties are maintained for a long period of time.

Big Area Additive Manufacturing of High Performance Bonded NdFeB Magnets

Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm³, and the room temperature magnetic properties are: intrinsic coercivity H_ci = 688.4 kA/m, remanence B_r = 0.51 T, and energy product (BH)_max = 43.49 kJ/m³ (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. The present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.