Project Se(L)ect(i)vity (PTDC/EQU-EQU/6193/2020)

The global transition to electric vehicles and renewable energy systems has heightened the demand for lithium-ion batteries (LIBs), creating an urgent need for sustainable battery recycling methods to recover critical raw materials, including lithium. Lithium-selective cation-exchange polymeric membranes are one of the emerging options to achieve such lithium recycling. To make this change even greener, instead of using traditional fossil-origin polymers to produce membranes, this research employed bacterial cellulose acetate (BCA), a bio-derived and eco-friendly polymer. By adding 5 wt% N-methyl-N-propylpiperidinium bis(trifluoromethanesulfonyl)imide (PP13–TFSI), an ionic liquid (IL) which is a plasticizer and lithium-ion conductor, and 20 wt% hydrogen manganese oxide (HMO), which is a lithium-selective inorganic filler, four BCA-based membranes (BCA, BCA-IL, BCA-HMO and BCA-IL-HMO) were prepared. The membranes were extensively characterized for their morphology, thermal stability, chemical, and mechanical properties. Subsequently, they were tested in diffusion cells (without applying any external driving force) for ionic conductivity, lithium selectivity, and lithium flux using binary salt mixtures and synthetic LIB leachate. The BCA-IL membrane outperformed other BCA-based membranes in terms of separation factors, achieving values of 10.50 (Li+/Mn2+), 11.75 (Li+/Ni2+), and 10.95 (Li+/Co2+) with a lithium flux of 0.12 mol m−2 h−1 when processing synthetic LIB leachate. Under the same conditions, the BCA-HMO membranes exhibited a higher lithium flux (0.51 mol m−2 h−1) but with lower separation factor values of 3.39 (Li+/Mn2+), 3.62 (Li+/Ni2+), and 3.36 (Li+/Co2+). The use of plant-derived cellulose acetate (CA) as an alternative to BCA was also assessed; however, despite promising ideal lithium selectivity values (for example, 112 for Li+/Ni2+ in the case of CA-HMO membrane), their conductivity was up to two orders of magnitude lower than that of BCA-based membranes. All these findings highlight the promising potential of BCA-based membranes for lithium recovery from lithium-ion battery leachates.

Flow electrode capacitive deionization (FCDI) is a desalination technology employing flowable carbon slurries to remove salt from an influent through the electro-sorption of ions at the surface of pores of activated carbon particles. This study presents an extensive morphological, electrochemical and rheological analysis of flow electrodes prepared using commercial (YP50F, YP80F, Norit, PAC) and lab-synthesized (KUA, PAC-OX) activated carbons. Simultaneous optimization of particle size, surface area, and surface chemistry of activated carbons is essential to enhance desalination efficiency in FCDI applications. The lab-made highly microporous activated carbon (KUA), prepared from a Spanish anthracite, exhibited a remarkably high specific surface area ( 2800 m2/g) but required first a particle size reduction through ball milling (from 56 μm to 12 μm) for the respective flow electrodes to achieve flowability. The slurry of milled fine KUA (designated as KUAF) shows a specific capacitance of 55 F/g, a 38-fold increase compared to its pristine form. The KUA-F flow electrode also achieved a maximum salt adsorption capacity of 185 mg/g, outperforming the leading commercial alternative (YP80F) by 26 %. The FCDI cell with the KUA-F flow electrode exhibited a desalination efficiency of 79 % at 15 wt% loading, surpassing YP80F by 29 %. In contrast, using PAC-OX (oxidized form of PAC), despite increasing oxygen functional groups and with relatively higher specific surface area, led only to a 2 % improvement in desalination performance, highlighting that oxidation alone at larger particle sizes and broader distribution is insufficient.

As billions of people suffer from water scarcity, finding sustainable water resources is imperative. Flow capacitive deionization (FCDI) is a highly promising desalination process that can produce clean water from saline streams such as brackish and seawater. Conventional FCDI systems employ Computerised Numerical Control (CNC)-milled graphite plates that serve as current collectors and flow electrode channels. However, they have drawbacks such as high manufacturing costs, waste generation, and the difficulty of producing complex geometries required for efficient flow electrode mixing. Here, we successfully demonstrate that 3D-printed flow electrode gaskets, made of non-conductive polyethylene terephthalate glycol (PET-G) or a carbon black-infused conductive polylactic acid (PLA), are viable alternatives to traditional graphite plates. In specific cases, the desalination and energy efficiency in FCDI cells with 3D-printed conductive gaskets were even 25 % and 10 % higher, respectively, compared to traditional CNC-milled current collectors. The transition to 3D printing offers notable benefits, such as the competence to fabricate complex designs that enhance internal mixing and charge percolation. This innovation represents a change of paradigm in the way FCDI cells should be designed and manufactured, using additive manufacturing, which represents an efficient, scalable, and cost-effective substitute for the conventional approach, contributing therefore for the advancement of FCDI desalination technology.

This study pioneers the application of deep eutectic solvents (DES) as electrolytes in flow electrode capacitive deionisation (FCDI) desalination systems, providing a novel and improved alternative to aqueous flow electrodes. The deep eutectic solvent, choline chloride-urea (ChCl-U), was selected for its wide electrochemical stability window, allowing voltages exceeding 1.23 V, which is the limit for aqueous flow electrodes. The effect of water doping on the viscosity and performance of the DES flow electrodes was also investigated. Cyclic voltammetry confirmed the electrochemical stability, while rheological and electrochemical impedance spectroscopy revealed that the addition of water reduced the viscosity and enhanced the conductivity of ChCl-U, making it suitable for use as an electrolyte in FCDI. Desalination experiments were performed within a potential range of up to 2.2 V. The ChCl-U flow electrode, containing 20 wt% water and 10 wt% activated carbon, achieved the best balance between desalination efficiency (83 %), desalination rate (0.17 mg/cm2.min), and effluent quality. Furthermore, 1H NMR analysis confirmed the absence of traces of the deep eutectic solvent in the dilute stream. The results highlight the potential of DES flow electrodes to enhance desalination processes by enabling higher operational voltages and improved performance, thereby paving the way for more efficient FCDI desalination systems.

Electromembrane processes are employed in critical applications such as desalination, lithium recovery, and salinity gradient energy conversion. However, issues like fouling and concentration polarisation may limit their effectiveness. Profiled ion-exchange membranes offer several advantages over flat membranes, including improved fluid mixing, enhanced mass transfer, lower pressure drop (thus, lower energy consumption), and elimination of the spacer’s shadow effect. Nonetheless, their preparation is considerably more complex than that of flat membranes. In this study, we pioneered the use of solvent-free fused deposition modelling (FDM) 3D printing to fabricate flat and profiled (chevron and stripe) cation-exchange membranes (CEMs). The functionalisation of the 3D-printed membranes into CEMs was achieved via sulfonation. The optimised electrical resistance and permselectivity of the prepared membranes were 10.7 ± 4 Ωcm2 and 97.3 ± 4 %, respectively, after 14 h of sulfonation, closely matching commercial alternatives (e.g., FUMASEP FKB-PK-130, 9.7 ± 3 Ωcm2 and 96.7 ± 1 %). Sulfonation durations exceeding 14 h increased the membranes’ electrical resistance due to the formation of sulfone cross-bridges that do not participate in cations’ exchange. Since FDM 3D printing is a solvent-free and additive manufacturing method, it significantly reduces waste during membrane fabrication, resulting in an E-factor value of 1.5. Therefore, this work opens a path toward customisable, scalable, and greener CEM production for electrochemical applications ranging from the recovery of critical raw materials and water desalination to renewable energy conversion.

Flow electrode capacitive deionization (FCDI) is an emerging desalination technology that utilises flowable electrodes and can be operated in diverse configuration modes. This study provides a systematic assessment of the three main configuration arrangements under a voltage range between 0.8 and 2.0 V: isolated closed-cycle (ICC), short-circuited closed-cycle (SCC), and single-cycle with separate concentrate chamber (SCSC). The ICC mode shows the highest specific energy consumption (up to 72.02 Wh/mol of NaCl at 2.0 V) and low operational stability manifested by extreme alteration of pH in the electrode compartments (anode compartment pH down to 2.17; cathode compartment pH up to 12.08), which leads to the need for frequent electrode regeneration or replacement. In comparison to the ICC mode, the SCC mode exhibited superior performance, with a 44.3 % increase in salt removal and up to 3.95 % higher current efficiency at 2.0 V, due to the regeneration of electrodes through short-circuiting, as it reduces the electrical resistance and minimises the side reactions. The SCSC mode emerged as the most stable and reliable among the three, with uniform current and conductivity profiles, as well as minimal pH fluctuations, which is critical to produce treated water within desired quality standards. These findings highlight the promising potential of SCSC mode as an optimal configuration for scalable, continuous and energy-efficient FCDI systems, providing a balanced solution for long-term desalination with reduced operational complexity and costs.

The recent growing demand for lithium worldwide, led by the Li-ion battery market, has sparked research into alternative sources of this material. In this context, selective lithium recovery from concentrated brines represents a sustainable and economical alternative to lithium mining activities. In this work, we developed a mathematical model of the recently implemented Lithium Membrane Flow Electrode Capacitive De-Ionization (Li-MFCDI) process, used to selectively extract lithium from a synthetic geothermal brine. The model was validated against the available experimental data and was used to perform a comprehensive parametric analysis. The model predicts the effects of the applied voltage, flow rates, and the adopted membranes on the process performance. These findings highlight the importance of the membrane conductivity-selectivity trade-off for process productivity. Furthermore, this simulation tool will substantially contribute to the development of this novel technology.

The rising lithium-ion battery market drives lithium demand and requires efficient and selective lithium recovery methods from aqueous sources. Membrane technologies can address environmental and inherent efficiency issues in conventional lithium extraction methods. This study presents the synthesis of novel lithium-selective mixed matrix membranes (MMMs) by integrating 0–30 wt% of a lithium selective filler named hydrogen manganese oxide (HMO) into a sulfonated polyethersulfone (SPES)-Nafion polymer matrix. The membranes were produced by casting and thoroughly examined to assess their chemical, physical, morphological, thermal, and mechanical characteristics. The transport of lithium across membranes was evaluated in diffusion and electro-diffusion studies. The membrane containing 20 wt% of HMO exhibited the highest ideal selectivity values, which were 1.05 for Li+/K+, 1.20 for Li+/Na+, and 13.36 for Li+/Mg2+; and more than 97% increase in lithium-ion conductivity when compared with the control membrane without HMO. In diffusion experiments, the binary separation factors for Li+/K+, Li+/Na+, and Li+/Mg2+ were 0.71, 1.52, and 11.83, respectively, while under electro-diffusion conditions, the corresponding values were 0.82, 1.55, and 9.88. Above 20 wt% of HMO, membranes lose their separation capacity as HMO aggregates inside the membrane structure. The higher selectivity of membranes towards Li+ in the presence of Mg2+ is due to magnesium's larger hydrated radius and higher hydration energy compared to lithium. Overall, the prepared membranes demonstrated a promising potential for green lithium recovery. This study facilitates the advancement of sustainable lithium-selective MMM synthesis.

Flow capacitive deionization (FCDI) is an emerging desalination technology at which flow electrodes (shear-thinning flowable carbon slurries) are used to remove ions from saline water. The geometry of flow electrode channels, which provide the path and ensure the distribution and mixing of the flow electrodes, is one of the most important aspects to be optimized. This work presents experimental and computational fluid dynamics (CFD) modelling analysis of the influence of the geometry of flow electrode channels on FCDI performance. Flow electrode gaskets (with open, serpentine (short) horizontal and serpentine (long) vertical channels) were 3D printed using a polyethylene terephthalate glycol (PET-G) filament. The FCDI cell with a vertical serpentine flow electrode channel exhibited the poorest performance due to channel blockage by carbon particles, while the best results were achieved with a horizontal serpentine flow electrode channel. CFD simulations aided in understanding this behaviour by showing that the channel geometry strongly affects the local shear rate, and thus the local viscosity of flow electrodes. Thus, it is recommended to design channels that induce flow disturbance aiming for increasing the shear rate and hence reducing flow electrode viscosity, therefore promoting their flowability and reducing clogging chances.

Mineral extraction from seawater brines has emerged as a viable solution to reduce Europe's reliance on imported Critical Raw Materials (CRM). However, the economic viability of this approach hinges on the local demand for sodium chloride, the primary product of such extraction processes. This study investigates the potential of residual brines, commonly known as "bitterns," generated during solar sea-salt extraction in traditional saltworks, as an alternative source of minerals. The Mediterranean region, encompassing South-European, North-African, Near East coasts, and parts of the Atlantic regions, is particularly conducive to exploring this prospect due to its extensive solar sea salt industry. Saltworks in the region, adopting various operational strategies based on feed quality or local climate conditions, produce different types of bitterns, each holding a latent resource potential that has remained largely unexplored. Within the framework of the EU-funded SEArcularMINE project, it was conducted an extensive analytical campaign to characterize bitterns collected from a diverse saltworks network. The analysis revealed the presence of sodium, potassium, magnesium, chloride, sulfate, and bromide in concentrations ranging from g/kg, while boron, calcium, lithium, rubidium, and strontium were found in the mg/kg range. Additionally, trace elements (TEs) such as cobalt, cesium, gallium, and germanium were detected at concentrations in the order of μg/kg. Detailed results on the composition of bitterns are presented, emphasizing the distinct characteristics observed at different sites. The estimated potential for mineral recovery from these bitterns is approximately 190 €/m3, considering the production capacity of about 9 Mm3 per year in the Mediterranean area. This finding underscores the significant contribution that mineral recovery from bitterns could make in securing access to CRMs for the European Union.

This work explores the application of Reverse Osmosis (RO) upcycled membranes, as Anion Exchange Membranes (AEMs) in Donnan Dialysis (DD) and related processes, such as the Ion Exchange Membrane Bioreactor (IEMB), for the removal of nitrate from contaminated water, to meet drinking water standards. Such upcycled membranes might be manufactured at a lower price than commercial AEMs, while their utilization reinforces the commitment to a circular economy transition. In an effort to gain a better understanding of such AEMs, confocal µ-Raman spectroscopy was employed, to assess the distribution of the ion-exchange sites through the thickness of the prepared membranes, and 2D fluorescence spectroscopy, to evaluate alterations in the membranes caused by fouling and chemical cleaning The best performing membrane reached a 56% average nitrate removal within 24 h in the DD and IEMB systems, with the latter furthermore allowing for simultaneous elimination of the pollutant by biological denitrification, thus avoiding its discharge into the environment. Overall, this work validates the technical feasibility of using RO upcycled AEMs in DD and IEMB processes for nitrate removal. This membrane recycling concept might also find applications for the removal and/or recovery of other target negatively charged species.

Environment-friendly production of power and clean water is one of the major goals of 2030 Agenda for Sustainable Development, and can be achieved by emerging electromembrane processes, such as reverse electrodialysis (RED) and membrane capacitive deionisation (MCDI). RED generates electricity from salinity gradient energy sources, while MCDI desalinates (mainly) brackish water. However, fouling, scaling, stack channels clogging and undesired uphill ionic transport can reduce the power output and salt removal efficiency in RED and MCDI, respectively. A practical overview of current problems and challenges of operating and monitoring these processes under real conditions is provided. Appropriate mitigation approaches, which might include feed water pre-treatment, in-situ cleaning strategies and/or development of new antifouling ion-exchange membranes (IEMs) are disclosed. First, a description, analysis and (when possible) normalised comparison of the performance of available RED and MCDI stacks, employing natural saline streams, is presented. Afterwards, it is discussed how fouling formation can be detected, monitored and characterised, which is essential to implement effective pre-treatment and cleaning strategies. Finally, sustainable ways for preparation of appropriate IEMs are selected and presented.

Profiled membranes (also known as corrugated membranes, micro-structured membranes, patterned membranes, membranes with designed topography or notched membranes) are gaining increasing academic and industrial attention and recognition as a viable alternative to flat membranes. So far, profiled ion exchange membranes have shown to significantly improve the performance of reverse electrodialysis (RED), and particularly, electrodialysis (ED) by eliminating the spacer shadow effect and by inducing hydrodynamic changes, leading to ion transport rate enhancement. The beneficial effects of profiled ion exchange membranes are strongly dependent on the shape of their profiles (corrugations/patterns) as well as on the flow rate and salts’ concentration in the feed streams. The enormous degree of freedom to create new profile geometries offers an exciting opportunity to improve even more their performance. Additionally, the advent of new manufacturing methods in the membrane field, such as 3D printing, is anticipated to allow a faster and an easier way to create profiled membranes with different and complex geometries.

Olive pomace is a semi-solid paste resulting from the two-phase olive oil production, being the most significant waste generated by this agro-industry. Olive pomace is reported as an environmental hazard due to its high content in phenolic compounds (phytotoxic). Nevertheless, these compounds, when recovered, can have impactful actions in different human physiological conditions, namely, skin protection, dysfunction treatment or diseases prevention. Therefore, their recovery from olive pomace is crucial for environmental and economical sustainability, without forgetting the functional challenge. In a previous work, lipid and aqueous fractions of olive pomace were studied regarding its major bioactive compounds. The present research aims to describe an environmentally friendly integrated approach to extract and concentrate (by a pressure-driven membrane processing) the phytotoxic compounds of olive pomace. Three types of polymeric composite membranes (NF90, NF270 and BW30) were tested. The composition of the resulting streams (permeates and concentrates) were compared and the process efficiency assessed based on: (1) antioxidant activity and total phenolic and flavonoid contents; (2) inorganic elemental composition (by Inductively Coupled Plasma Atomic Emission Spectroscopy); (3) pH, conductivity and total organic carbon; and (4) permeate flux, membranes' apparent target solutes rejection and fouling index. The BW30 membrane presented the lowest fouling index and was the most effective for extracts concentration, with no phenolic compounds in the permeates, preventing completely the loss of such compounds.

Highly porous monolithic alumina columns find a wide variety of applications, including in chromatography, due to increased surface area and good accessibility to the ligands and reduced diffusional hindrances. Several modelling approaches have been applied to describe experimentally observed flow behaviour in such materials, which morphology plays a key role in determining their hydrodynamic and mass transfer properties. In this work, a direct computational fluid dynamics (CFD) modelling approach is proposed to simulate flow behaviour in monolithic porous columns. The morphological structure of a fabricated alumina monolith was first reconstructed using 3D X-ray tomography data and, subsequently, OpenFOAM, an open-source CFD tool, was used to simulate the essential parameters for monoliths’ performance characterisation and optimisation, i.e. velocity and pressure fields, fluid streamlines, shear stress and residence time distribution (RTD). Moreover, the tortuosity of the monolith was estimated by a novel method, using the computed streamlines, and its value (∼1.1) was found to be in the same range of the results obtained by known experimental, analytical and numerical equations. Besides, it was observed (for the case of the monolith studied) that fluid transport was dominated by flow heterogeneities and advection, while the shear stress at pore mouths was significantly higher than in other regions. The proposed modelling approach, with expected high potential for designing target materials, was successfully validated by an experimentally obtained residence time distribution (RTD).

Salinity gradient energy is currently attracting growing attention among the scientific community as a renewable energy source. In particular, Reverse Electrodialysis (RED) is emerging as one of the most promising membrane-based technologies for renewable energy generation by mixing two solutions of different salinity. This work presents a critical review of the most significant achievements in RED, focusing on membrane development, stack design, fluid dynamics, process optimization, fouling and potential applications. Although RED technology is mainly investigated for energy generation from river water/seawater, the opportunities for the use of concentrated brine are considered as well, driven by benefits in terms of higher power density and mitigation of adverse environmental effects related to brine disposal. Interesting extensions of the applicability of RED for sustainable production of water and hydrogen when complemented by reverse osmosis, membrane distillation, bio-electrochemical systems and water electrolysis technologies are also discussed, along with the possibility to use it as an energy storage device. The main hurdles to market implementation, predominantly related to unavailability of high performance, stable and low-cost membrane materials, are outlined. A techno-economic analysis based on the available literature data is also performed and critical research directions to facilitate commercialization of RED are identified.

Spacer-less RED stacks using membranes with integrated spacer profiles have been investigated during the last years to eliminate the spacer shadow effect. The presence of spacers partially blocks the membrane surface and creates a tortuous and thus longer path for ions in the channel, meaning higher ohmic resistance. Consequently, power outputs are reduced. Profiled membranes may solve this problem as they provide flow channels for the feed streams, while the relief formed on their surfaces keeps the membranes separated. Although the geometry and arrangement of so far used profiles led to lower ohmic resistance, it did not grant an efficient fluid mixing. Recently, so-called chevron profiles, with enhanced mixing, were proposed based on computational fluid dynamics (CFD) simulations. In the present study, the performance of such chevron-profiled membranes, prepared by thermal pressing, was experimentally validated in a reverse electrodialysis (RED) stack. According to the obtained experimental values of non-ohmic resistance and total pressure drop across the RED stack, the chevron-profiled membranes assure efficient fluid mixing at comparatively low hydraulic losses. The net power density obtained with chevron-profiled membranes was the highest obtained for the present stack design. It outperformed the alternative RED stack configurations investigated in this study, such as channels with optimized spacers and channels formed by pillar-profiled membranes. To allow for an even more straightforward and efficient RED stack assembling with chevron-profiled membranes, recommendations for a further simplified design, consisting of diagonal ridges that are assembled perpendicularly, are provided.

Reverse electrodialysis (RED) is one of the emerging, membrane-based technologies for harvesting salinity gradient energy. In RED process, fouling is an undesirable operation constraint since it leads to a decrease of the obtainable net power density due to increasing stack electric resistance and pressure drop. Therefore, early fouling detection is one of the main challenges for successful RED technology implementation. In the present study, two-dimensional (2D) fluorescence spectroscopy was used, for the first time, as a tool for fouling monitoring in RED. Fluorescence excitation-emission matrices (EEMs) of ion-exchange membrane surfaces and of natural aqueous streams were acquired during one month of a RED stack operation. Fouling evolvement on the ion-exchange membrane surfaces was successfully followed by 2D fluorescence spectroscopy and quantified using principal components analysis (PCA). Additionally, the efficiency of cleaning strategy was assessed by measuring the membrane fluorescence emission intensity before and after cleaning. The anion-exchange membrane (AEM) surface in contact with river water showed to be significantly affected due to fouling by humic compounds, which were found to cross through the membrane from the lower salinity (river water) to higher salinity (sea water) stream. The results obtained show that the combined approach of using 2D fluorescence spectroscopy and PCA has a high potential for studying fouling development and membrane cleaning efficiency in ion exchange membrane processes.

Implementation of reverse electrodialysis (RED) is economically limited by the relatively high ion-exchange membranes price. Additionally, the shadow effect of non-conductive spacers reduces the membrane area available for counter-ion transport and increases the stack electric resistance. A promising alternative could be utilization of profiled membranes, since the reliefs formed on their surface keeps the membranes separated and provides channels for solutions flow. Herein, we have simulated, through computational fluid dynamics (CFD) tools, fluid behavior in channels formed by various profiled membranes. The highest net power density values were obtained for corrugations shape and arrangement in a form of chevrons due to the increase of the available membrane area and an excellent balance between enhancement of mass transfer and the increase of the pressure drop in the channel. When properly designed, corrugated membranes may offer a better performance even compared to the case of conductive spacers. The proposed membrane corrugation design in not limited to the RED application, and could be also extended to other electromembrane processes, such as electrodialysis and Donnan dialysis, in which high ionic mass transport rates are desirable at as low as possible energy costs.

The power density obtainable by a reverse electrodialysis (RED) stack decreases along its operating period due to fouling; however this effect is not accounted for by the so far proposed mechanistic models. Recently, it has been demonstrated that 2D fluorescence spectroscopy can capture the time evolvement of ion-exchange membrane fouling. In this work multivariate statistical modeling was performed, by using the projection to latent structure (PLS) approach, to predict relevant RED stack performance parameters: pressure drop, stack electric resistance and net power density. Several PLS models, with and without 2D fluorescence data as models inputs, were developed. It was found that inclusion of fluorescence data considerably improved the models fitting, because the otherwise missing information about the dynamic state of ion-exchange membranes was added. Additionally, the coefficients of the optimized models revealed important contributions of some of the input parameters to the predicted outputs and allowed to mathematically confirm the qualitative observations that fouling of anion-exchange membranes facing river water is the main factor affecting the RED stack performance. This work confirms the applicability of 2D fluorescence spectroscopy for monitoring of fouling in RED stacks and demonstrates the ability of simple, statistically based models to follow RED performance.

Power generation by reverse electrodialysis (RED) depends on ionic mass transfer through alternately arranged cation- and anion-exchange membranes. Chronopotentiometric measurements were carried out in an EDR-Z Mini stack (MEGA a.s.), equipped with Ralex heterogeneous membranes, separated by either sheet flow spacers or mesh-free gaskets. Various concentrations of model NaCl solutions were used to study the ohmic and non-ohmic resistances in the stack under different hydrodynamic conditions. In order to eliminate the uncertainties associated with a non-uniform distribution of the applied current over the membrane surface, the relaxation zone of the obtained chronopotentiograms was used to estimate the diffusion boundary layer thickness. It was found that this approach provide more accurate data under RED operating conditions, which are strongly influenced by entrance effects on mass transfer, especially for a spacer-free channel configuration. For shorter flow channels, since the salt concentration profile across the diffusion boundary layer is not yet fully developed, more power can be obtained than in the case of longer channels. The presence of spacers was found to reduce the boundary layer thickness, but also increased the ohmic resistance, due to their shadow effect over the membrane surface. The description of the impact of flow entrance effects on mass transfer, and therefore on diffusion boundary layer thickness, can be useful for characterization and further design and/or optimization of RED stacks performance.

Reverse electrodialysis (RED) is a sustainable technology for salinity gradient energy harvesting. In order to make the process economically competitive, it is desirable to operate it at the highest possible net power density, which depends on the RED stack geometry and on the pressure drop along its pathways and, thus, on the energy spent for solutions pumping. The fluid flow in RED stacks generally occurs in rectangular compartment channels, equipped with spacers. The effects of spacers design and properties have been studied extensively in recent years. However, the other possible causes for a RED stack and their relative impact on the process performance have not yet been systematically studied. In this study the partial pressure drops in (1) distribution ducts, (2) branches, (3) beams, (4) due to sudden section expansion between the beam and the compartment channel and (5) in the compartment channel were taken into consideration. A model for the total pressure drop inside a RED stack, with a parallel fluid flow distribution through the compartments, is proposed and experimentally validated for lab-scale RED stacks with sheet flow spacers and compared with an open channel (spacer-free) design. The importance of each partial pressure drop was then evaluated quantitatively through model simulations for industrial-scale stacks with an increasing number of cell pairs. It was found that the net power density decreases when the cell-pair number increases, since the partial pressure drop in the branches becomes dominant. Moreover, the possible reasons for a non-uniform fluid flow distribution are discussed, thus making the proposed model useful for planning and/or optimization of RED stacks design.