Process intensification for the continuous synthesis of high purity hydrogen peroxide using a micro-scale electrocatalytic reactor

The versatility of hydrogen peroxide (H2O2) as a chemical for a wide range of applications drives its heavy industrial production. Hydrogen peroxide is currently produced by the anthraquinone process, an energy-intensive and unsustainable process that relies on the use of the precious metal palladium. Therefore, there is great interest in finding alternative green, low-cost and low-energy methods, and electrocatalytic processes that exploit the reduction of molecular O2 are undoubtedly of great appeal. The focus of this proposal is to develop a method for the production of highly pure and green hydrogen peroxide in a microstructured device with integration of leading-edge catalysts, process intensification, state-of-the-art microreactor technology, electrochemistry and analytics. Environmental concerns and resulting legislation will increase the demand for H2O2 in the coming years. In particular, most applications require H2O2 to be produced in a pure water effluent. On-site, decentralized, sustainable electrochemical production of H2O2 is particularly attractive for this purpose. The recently reported electrochemical production of hydrogen peroxide over single-site metal-N-carbon catalysts will be used as a starting point for the construction of a microscale electrocatalytic reactor for on-site production of high-purity and green H2O2. The objectives of this proposal are: 1. To prepare and test N-doped carbon and graphene (and some other) materials as promising low-cost two-electron front-face oxygen reduction reaction (ORR) catalysts with high electrocatalytic activity. 2. Development of a microscale-based electrocatalytic reactor between two parallel plates coated with catalyst. 3. Model-based design and optimization of the heterogeneous catalytic microreactor system with the application of scale-up/numbering-up concept. 4. Development of effective H2O2 analysis and stabilization of H2O2. Our proposal aims to develop a revolutionary new production of high-purity H2O2 based on microreactor technology to meet the needs of end users, such as pure, dilute H2O2 solutions for pharmaceutical, medical, cosmetic, and water treatment applications. More generally, the process intensification of electrochemical production of H2O2 in microflow system is a fitting example of a broader trend that will transform the chemical industry. We believe that our project proposal is of great importance in view of the expected modern industrial trends in the coming years.