Review—The Design, Performance and Continuing Development of Electrochemical Reactors for Clean Electrosynthesis

A critical review of classical and improved electrodes, electrocatalysts and reactors is provided. The principles governing the selection of electrochemical flow reactor or progression of a particular design for laboratory or pilot scale are reviewed integrating the principles of electrochemistry and electrochemical engineering with practical aspects. The required performance, ease of assembly, maintenance schedule and scale-up plans must be incorporated. Reactor designs can be enhanced by decorating their surfaces with nanostructured electrocatalysts. The simple parallel plate geometry design, often in modular, filter-press format, occupies a prominent position, both in the laboratory and in industry and may incorporates porous, 3D or structured electrode surfaces and bipolar electrical connections considering the reaction environment, especially potential- and current-distributions, uniformity of flow, mass transport rates, electrode activity, side reactions and current leakage. Specialised electrode geometries include capillary gap and thin film cells, rotating cylinder electrodes, 3-D porous electrodes, fluidised bed electrodes and bipolar trickle tower reactors. Applications span inorganic, organic electrosynthesis and environmental remediation. Recent developments in cell design: 3D printing, nanostructured, templating 3D porous electrodes, microchannel flow, combinatorial electrocatalyst studies, bioelectrodes and computational modelling. Figures of merit describing electrochemical reactor performance and their use are illustrated. Future research and development needs are suggested.