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.

The scale-up of crystallization processes is a challenging step in production of active pharmaceutical ingredients (APIs). When moving from lab to industrial scale, the mixing conditions tend to modify due to the different geometry and agitation performance, which is particularly important in anti-solvent crystallizations where the size of the crystals depends on the mixing and incorporation of the anti-solvent in the solution. In this work, the results obtained in anti-solvent lab-scale crystallization experiments were used to develop multivariate statistical models predicting Particle Size Distribution (PSD) parameters (Dv10, Dv50 and Dv90) in function of predictors such as percentage of volume, power per volume and tip speed. Firstly, the collinearity among the predictors was assessed by Variance Inflation Factor (VIF) diagnosis. Subsequently, least squares method was employed to find correlations among the predictors and output variables. The optimization of the models was executed by testing quadratic, logarithmic and square root terms of the predictors and removing the least statistically significant regression coefficient. The quality of the fitting was evaluated in terms of adjusted R2 (R2adj). The modelled Dv10, Dv50 and Dv90 values presented a good fitting to the experimental data, with R2adj higher than 0.79, either when using power per volume or tip speed along the percentage of volume as predictors. Afterwards, the particle size distribution parameters of industrial scale production were predicted using the previously developed models. The deviations between predicted and experimental values were lower than 17%. This demonstrates that multivariate statistical models developed in lab-scale conditions can be successfully used to predict particle size distribution in industrial-size vessels.

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.