We developed a technique based on the use of microsensors to measure pH and H₂ gradients during microbial electrosynthesis. The use of 3D electrodes in (bio)electrochemical systems likely results in the occurrence of gradients from the bulk conditions into the electrode. Since these gradients, e.g., with respect to pH and reactant/product concentrations determine the performance of the electrode, it is essential to be able to accurately measure them. Apart from these parameters, also local oxidation-reduction potential and electric field potential were determined in the electrolyte and throughout the 3D porous electrodes. Key was the realization that the presence of an electric field disturbed the measurements obtained by the potentiometric type of microsensor. To overcome the interference on the pH measure, a method was validated where the signal was corrected for the local electric field measured with the electric potential microsensor. The developed method provides a useful tool for studies about electrode design, reactor engineering, measuring gradients in electroactive biofilms, and flow dynamics in and around 3D porous electrodes of (bio)electrochemical systems.

Microbial electrosynthesis is an uprising concept for the combined carbon dioxide reduction and electricity storage in the form of green chemical compounds. Although several proof of principle studies show great promise, mass-transfer limitations of substrates, protons and products remains one of the issues that needs to be addressed to bring the systems towards greater scale applications. A previously tested solution formed force flow-through catholyte recirculation, but this set-up encountered difficulties with gas accumulation during start-up at higher current densities (∼ −10 kA/m ³), creating the need for a bypass to release gas. In this study, start-up at high current density was achieved without a bypass by using an alternating flow-through regime. This regime decreased the operating energy input from 221 to 136 kWh per kg of produced hydrogen and reached acetate production within 10 days after start-up at high current density and elongation to n-caproate after 45 days. Mass-transfer studies were included by microsensor measurements of local conditions (hydrogen concentration, pH) combined with thermodynamic calculations at the start and end of 60-days biotic experiments. The microorganisms on the cathode decreased pH gradients and consumed the formed hydrogen. The presence of Clostridium sensu stricto 12 and Peptococcaceae species were related to chain elongation activity, and the presence of Methanobrevibacter was linked to methanogenesis activity. By identifying the effects of different flow-through strategies on local concentrations and functional microbial groups, this work provides insights on the optimal conditions for microbial CO ₂ conversion and highlight the application potential of microbial electrosynthesis.

In microbial electrosynthesis (MES), microorganisms grow on a cathode electrode as a biofilm, or in the catholyte as planktonic biomass, and utilize CO₂for their growth and metabolism. Modification of the cathode with metals can improve MES performance, due to their catalytic activity for H2 production, which can be consumed by microorganisms, or via modifying the cathode properties. On the other hand, metals can have an inhibiting effect on MES. While these single roles of metals and their oxides have been identified, an investigation of the simultaneous effects on MES is still lacking. Here, we modify activated carbon (AC) electrodes with nickel (Ni) at high (5%) and low (0.01%) loadings, to investigate its combined effects on MES. Upon Ni impregnation, multiple factors explained the MES performance, including electrocatalytic H2 production, trace element availability, metal toxicity, Ni leaching and redeposition/bio-crystalization. Instead, the electrode surface properties (i.e., surface area and pore structure) were not affected by Ni addition. Compared to unmodified AC, low Ni loading did not improve abiotic H2 production, whereas at high Ni loading a 6-fold increase was observed. During biological experiments, low Ni loading resulted in over a 3-fold increase of acetate production and 35% higher planktonic growth, compared to unmodified AC. Instead, high Ni loading resulted in 25-fold increase of acetate production, 21% decrease of planktonic growth, and improved biofilm growth. Unmodified AC, and low and high Ni loading each resulted in unique microbial community composition. The effect of Ni on MES is therefore concentration-dependent, with apparently different mechanisms of interaction being prevalent at low or high Ni loadings.

Electrocatalytic metals and microorganisms can be combined for CO2 conversion in microbial electrosynthesis (MES). However, a systematic investigation on the nature of interactions between metals and MES is still lacking. To investigate this nature, we integrated a copper electrocatalyst, converting CO2 to formate, with microorganisms, converting CO2 to acetate. A co-catalytic (i. e. metabolic) relationship was evident, as up to 140 mg L-1 of formate was produced solely by copper oxide, while formate was also evidently produced by copper and consumed by microorganisms producing acetate. Due to non-metabolic interactions, current density decreased by over 4 times, though acetate yield increased by 3.3 times. Despite the antimicrobial role of copper, biofilm formation was possible on a pure copper surface. Overall, we show for the first time that a CO2 -reducing copper electrocatalyst can be combined with MES under biological conditions, resulting in metabolic and non-metabolic interactions.

Carbon dioxide (CO₂) can be converted to valuable products using different catalysts, including metal or biological catalysts (e. g. microorganisms). Some products formed by metal electrocatalysts can be further utilized by microorganisms, and therefore catalytic cooperation can be envisioned. To prevent cumbersome separations, it is beneficial when both catalyst work under the same conditions, or at least in the same reaction medium. Here, we will show that a formate-producing copper electrocatalyst can function in a biological medium. Furthermore, we will show that the effluent of the copper-containing reactor can be used without purification as the sole medium for a bio-reactor, inoculated with a mixed culture of microorganisms. In that second reactor, formate, H₂ and CO₂ are consumed by the microorganisms, forming acetate and methane. Compared to simple buffer electrolyte, catalytic activity of copper was improved in the presence of microbial growth medium, likely due to EDTA (Ethylenediaminetetraacetic acid) present in the latter.

Microbial electrosynthesis (MES) allows carbon-waste and renewable electricity valorization into industrially-relevant chemicals. MES has received much attention in laboratory-scale research, although a techno-economic-driven roadmap towards validation and large-scale demonstration of the technology is lacking. In this work, two main integrated systems were modelled, centered on (1) MES-from-CO₂ and (2) MES from short-chain carboxylates, both for the production of pure, or mixture of, acetate, n–butyrate, and n–caproate. Twenty eight key parameters were identified, and their impact on techno-economic feasibility of the systems assessed. The main capital and operating costs were found to be the anode material cost (59%) and the electricity consumption (up to 69%), respectively. Under current state-of-the-art MES performance and economic conditions, these systems were found non-viable. However, it was demonstrated that sole improvement of MES performance, independent of improvement of non-technological parameters, would result in profitability. In otherwise state-of-the-art conditions, an improved electron selectivity (≥36%) towards n-caproate, especially at the expense of acetate, was showed to result in positive net present values (i.e. profitability; NPV). Cell voltage, faradaic efficiency, and current density also have significant impact on both the capital and operating costs. Variation in electricity cost on overall process feasibility was also investigated, with a cost lower than 0.045 € kWh⁻¹ resulting in positive NPV of the state-of-the-art scenario. Maximum purification costs were also determined to assess the integration of a product's separation unit, which was showed possible at positive NPV. Finally, we briefly discuss CO₂ electroreduction versus MES, and their potential market complementarities.