Elena Alvarez1, Maria Romero-Fernandez2, Diego Iglesias3, Raul Martinez-Cuenca4, Obinna Okafor5, Astrid Delorme6, Pedro Lozano1, Ruth Goodridge5, Francesca Paradisi7, Darren A Walsh6, Victor Sans3. 1. Departamento de Bioquimica, Biologia Molecular e Inmunologia, Facultad de Quimica, Universidad de Murcia, Campus Reg Excelencia Int Mare Nostrum, E-30100 Murcia, Spain. 2. School of Chemistry, University of Nottingham, University Park, Nottingham NG7 2RD, United Kingdom. 3. Institute of Advanced Materials (INAM), Universitat Jaume I, Avda. Sos Baynat s/n, 12071 Castellon, Spain. 4. Department of Mechanical Engineering and Construction, Universitat Jaume I, Av. Vicent Sos Baynat s/n, 12071 Castellon, Spain. 5. Faculty of Engineering, University of Nottingham, University Park, Nottingham NG7 2RD, United Kingdom. 6. The GSK Carbon Neutral Laboratory for Sustainable Chemistry, Jubilee Campus, University of Nottingham, Triumph Road, Nottingham NG7 2TU, United Kingdom. 7. Department of Chemistry, Biochemistry and Pharmaceutical Sciences, University of Bern, Freiestrasse 3, 3012 Bern, Switzerland.
Abstract
Electrochemical continuous-flow reactors offer a great opportunity for enhanced and sustainable chemical syntheses. Here, we present a novel application of electrochemical continuous-flow oscillatory baffled reactors (ECOBRs) that combines advanced mixing features with electrochemical transformations to enable efficient electrochemical oxidations under continuous flow at a millimeter distance between electrodes. Different additive manufacturing techniques have been employed to rapidly fabricate reactors. The electrochemical oxidation of NADH, a very sensitive substrate key for the regeneration of enzymes in biocatalytic transformations, has been employed as a benchmark reaction. The oscillatory conditions improved bulk mixing, facilitating the contact of reagents to electrodes. Under oscillatory conditions, the ECOBR demonstrated improved performance in the electrochemical oxidation of NADH, which is attributed to improved mass transfer associated with the oscillatory regime.
Electrochemical continuous-flow reactors offer a great opportunity for enhanced and sustainable chemical syntheses. Here, we present a novel application of electrochemical continuous-flow oscillatory baffled reactors (ECOBRs) that combines advanced mixing features with electrochemical transformations to enable efficient electrochemical oxidations under continuous flow at a millimeter distance between electrodes. Different additive manufacturing techniques have been employed to rapidly fabricate reactors. The electrochemical oxidation of NADH, a very sensitive substrate key for the regeneration of enzymes in biocatalytic transformations, has been employed as a benchmark reaction. The oscillatory conditions improved bulk mixing, facilitating the contact of reagents to electrodes. Under oscillatory conditions, the ECOBR demonstrated improved performance in the electrochemical oxidation of NADH, which is attributed to improved mass transfer associated with the oscillatory regime.
Continuous-flow
synthetic methodologies are becoming a key technology
for sustainable and efficient chemical manufacturing.[1] Electrochemical flow reactors are gaining interest as alternative
methodologies to perform chemical transformations in a clean and efficient
fashion,[2−7] especially when considering that energy can be obtained from renewable
sources. This enables efficient transformations and reduces the amount
of waste generated by avoiding the need for additives and auxiliary
reagents to perform redox reactions. However, the performance of continuous-flow
electroreactors can be affected by mass-transfer limitations of reagents
and products to the electrodes if the reactor geometry is not carefully
controlled.[2] To address this, the electrodes
are typically held apart by a few hundreds of microns, which improves
mass transfer due to the small distances and it also minimizes Ohmic
losses.[6] These interelectrode distance
requirements impose considerable limitations in the design of reactor
architectures for continuous-flow electroreactors. Typically, flat
parallel electrode configurations are chosen.[3] Advanced reactor architectures could help to overcome these limitations
by improving mixing, thus enabling efficient performance at a higher
electrode distance. The higher reactor volume would, in turn, enable
the integration of other enabling technologies for novel applications.[8]In this regard, additive manufacturing
(AM), commonly known as
3D printing, can offer new opportunities for the development of continuous-flow
reactors,[9−11] advanced reactor architectures,[12] and other continuous-flow applications like crystallizers,[13,14] calorimeters,[15] or magnetic resonance
probes.[16] The digitalization of the fabrication
process enables the coupling of advanced and lean design techniques,
like computational fluid dynamics (CFD), to allow the generation of
optimized reactor structures[17] and the
production of reactor geometries that are easily adaptable to commercial
setups.[7] Moreover, with the aid of CFD
simulations, the shape of the reactor and the position of other elements
like static mixers can be fine-tuned to optimize flow dynamics and
consequently reactor performance before manufacturing.[18]A key advantage of flow chemistry is the
ability to finely control
mixing, which can be done by adding elements without moving parts
(passive),[19] or with the use of an external
energy source that produces changes in the flow resulting in better
mixing.[20] The use of AM to generate advanced
structures that enhance mixing in electrochemical flow systems is
gaining attention.[8,21,22] Indeed, the design of simple structures to improve mixing in parallel
plate continuous-flow electroreactors has been recently demonstrated,
showcasing the potential of AM to improve the performance of electrochemical
transformations under flow conditions.[23] Continuous-flow oscillatory baffled reactors (COBRs) are a specific
class of chemical reactors that combine both passive and active mixing:
the coupling of periodic constrictions and a mechanically generated
oscillatory flow enables the generation of a turbulent flow at low
Reynolds (Re) numbers.[24,25] The employment
of additive manufacturing to generate miniaturized continuous oscillatory
baffled reactors has been demonstrated previously by our group.[12]Here, we report, for the first time, the
design and fabrication
of an electrochemical oscillatory baffled continuous-flow reactor
(ECOBR), which combines enhanced mixing in electrochemical systems,
allowing for efficient anodic oxidations. The improved mixing was
demonstrated by CFD studies and preliminary work with the designed
reactor to show the effect of oscillation in improving cell performance.
Enhanced performance of the ECOBR can be comparable to a commercial
parallel plate flow cell for electrochemical oxidations of NADH under
continuous flow and opens the door to couple multiple enabling technologies,
like electrochemical transformations, continuous flow, and other enabling
technologies (e.g., biocatalysis).[26]
Experimental Section
Production of the Additively
Manufactured Electrochemical Flow
Reactor
Reactor
A baffled reactor was designed with CAD software
(Creo Parametrics) and fabricated by laser sintering from nylon polyamide
12 (PA12) with an EOS P100 selective laser sintering (SLS) printer.
Parts were built with a 21 W laser power (16 W contour), a 2500 mm/s
scan speed, a 0.25 mm scan spacing, a 172.5 °C build temperature,
with a removable platform at 150 °C.
Gaskets
Gaskets
were initially printed in Formlabs
Form 2 stereolithography (SLA) and Form 3 low force stereolithography
(LFS) 3D printers using commercially available resins (Formlabs Flexible).
Gaskets with the shape of the reactor and the baffles with a thickness
of 0.5–1 mm were successfully fabricated. Alternatively, 0.5
mm thick gaskets were fabricated using an Ultimaker S5 fused filament
printer, employing a red thermoplastic polyurethane (TPU95) filament
purchased from Ultimaker.
Outer Casing
Parts were modeled
using 3D design software
and fabricated using a Formlabs 3 low force stereolithography (LFS)
printer loaded with Formlabs Clear resin.
Proof-of-Concept
of the Additively Manufactured Electrochemical
Flow Reactor
Proof-of-concept experiments were carried out
using the AM electroreactor equipped with 6 × 6 cm2 electrodes (working electrode (WE): glassy carbon; counter electrode
(CE): stainless steel 316). Cell performance was monitored using potentiometry
with a two-electrode system on a μStat400 potentiostat (Metrohm
Dropsens) using the cables supplied by the manufacturer, at a flow
rate of 0.1 mL min–1 and a 15 μA cm–2 current, using 0.1 M aqueous 2-amino-2-(hydroxymethyl)propane-1,3-diol
hydrochloride (Tris–HCl) as an electrolyte, whose pH was adjusted
to ca. 6.7 with sodium hydroxide. Oscillatory flow regimes were generated
by a C3000 programmable pump (Tricontinent) equipped with a 5 mL syringe.
Electrochemical Oxidation of NADH
Cyclic voltammetry
(CV) for evaluating the electrochemical oxidation of NADH was recorded
using an Autolab PGSTAT302 (EcoChemie) with a three-electrode configuration
(WE: glassy Carbon; RE: silver; CE: platinum). The concentration of
Tris–HCl was 80 and 100 mM and NADH was 15 mM. The pH was varied
at 7 and 8.8.An Ammonite 8 spiral cell (100 × 0.2 ×
0.5 cm3) equipped with 8.5 cm electrodes (WE: carbon/PVDF;
CE: stainless steel) was used as a control experiment for the electrochemical
oxidation of an NADH enzymatic cofactor. The AM electroreactor was
equipped with square 6 × 6 cm2 electrodes (WE: glassy
carbon; CE: Stainless steel 316), and the oscillation was controlled
using a programmable Tricontinent C3000 pump equipped with a 5 mL
syringe. Experiments for both reactors were performed using an aqueous
solution of 1 mM NADH in Tris–HCl (10 mM, pH = 7), and the
electrical current was controlled using an Autolab PGSTAT302 (EcoChemie).
The current density (A cm–2) and normalized reactor
productivity (molNAD+·molNADH–1·min–1·cm–2) were calculated
as followswhere I is the intensity
of current set with the potentiostat; areaelec is the geometric
area of the electrode in contact with the reaction media; molNAD and molNADH are the mols of the
product and the reagent, respectively; tres is the residence time; and F is the Faraday constant
(96 485 C mol–1).
Quantification of the NAD+ Concentration
In a typical experiment, an NADH solution
in Tris–HCl was
pumped through the reactor to fully load it and to reach the steady-state
conditions. The residence time was calculated as the ratio between
the volumetric flow rate and the total volume of the reactor. The
NADH solution was pumped for the equivalent of two bed volumes, i.e.,
twice the residence time. Then, it was assumed that the steady state
had been reached. The cell was maintained at constant current through
this transient period and continued during the steady-state experiments.
Applied currents were chosen using the Faraday equation (eq S1) applied to the reaction conditions (flow
rate, concentration), with the aim of driving full conversion during
the residence time. The NADH cofactor oxidation was quantified through
its use in the enzymatic transformation of glucose into glucolactone
employing a commercially available glucose dehydrogenase (GDH) enzyme.
After the enzymatic reaction, the samples were analyzed in a UV–visible
spectrophotometer at 340 nm and quantified through a calibration curve
of NAD+ (Figures S1 and S2).
CFD Simulations
The flow dynamics were resolved using
the ANSYS-CFX 20 solver, based on the element-based finite volume
method.[27] Given the reduced Reynolds number
(Re)[27,28] of the flow, a transitional shear
stress transport (SST) k–ω model turbulence
model was used and the liquid was described as a Newtonian incompressible
fluid. Two tracers were added to the flow, with a molecular diffusivity
of 10–8 m2 s and a Schmidt number (ratio
between turbulent eddy viscosity and eddy mass diffusivity)[27,29] for turbulent dispersion of 0.9. The first tracer (inert tracer)
entered through the inlet side and served to characterize the inlet
flow mixing. The second tracer was generated as a mass flux, tracer
mass (mtracer) per unit area and time,
at the electrodes at a rate given byIn the simulations, Csat = 0.1 kg m–3 and k =
1 mg mm2 s–1. Ctracer was the tracer volume concentration right next to the
electrode and was calculated by the solver as it depends on the flow
conditions.Two transient simulations were performed to reproduce
the flow advancement through the reactor. The inlet was modeled as
an opening boundary condition so the fluid can enter and leave the
flow domain. The velocity at this boundary was set aswith the values Umean = 1 mm s–1 and T = 2 s. The amplitude
was set to 0 for the steady-state case and A = 10
for the pulsating one.
Results and Discussion
The initial
design of the baffled reactor was based on the modification
of a previously reported AM mCOBR reactor configuration.[12] The channels were designed with a square section
and open on both sides to accommodate the electrodes on the upper
and lower walls of the reactor (Figure A). The reactor module is sandwiched with the electrodes
on top and bottom, and the whole structure is completed with AM gaskets
and support structures that are bolted together (Figure B). The reactor modules were
printed by selective laser sintering (SLS) in polyamide 12 (PA12)
(Figure C). Nylon
is a robust, chemically resistant, and versatile material to generate
structures that could be subsequently modified to add functionality.[30] The structure is separated by gaskets fabricated
with thermoplastic polyurethane (TPU95, Ultimaker) employing fused
filament fabrication (FFF) technology (Figure D). The gaskets (0.5 mm thickness) were printed
with geometries matching the baffles. Alternatively, the gaskets were
fabricated with commercial flexible SLA resin (Flexible resin, Formlabs),
but they were damaged upon utilization in the electrochemical setup
(Figure S3). The design of the gaskets
was modified to adapt to the size of the different electrodes. Stainless
steel plates were cut to the size of the reactor chips and therefore
required flat gaskets of the same size. The glassy carbon electrodes
had narrower dimensions. Hence, the gaskets were modified to fill
the gap between the electrode and the reactor module, thus facilitating
the assembly of the ECOBR device, which was bolted together and tightened
until no leak was observed by pumping distilled water through the
reactor chamber at controlled flow rates. The pump flow rates were
calibrated in the assembled setup to ensure that there were no leaks.
Figure 1
(A) General
CAD design of the baffled section of the reactor (left),
with a detailed view of the baffles (right) including the characteristic
dimensions. (B) Schematic representation of ECOBR assembly. (C) Baffled
reactor section fabricated in nylon employing selective laser sintering
(SLS). (D) Gasket with tailored design matching baffles fabricated
in TPU95 employing fused filament fabrication (FFF). (E) ECOBR assembly
detail.
(A) General
CAD design of the baffled section of the reactor (left),
with a detailed view of the baffles (right) including the characteristic
dimensions. (B) Schematic representation of ECOBR assembly. (C) Baffled
reactor section fabricated in nylon employing selective laser sintering
(SLS). (D) Gasket with tailored design matching baffles fabricated
in TPU95 employing fused filament fabrication (FFF). (E) ECOBR assembly
detail.Proof-of-concept experiments were
performed using the ECOBR assembled
as previously described (Figure E), similarly to our previously reported method.[12] A potentiostat was employed to measure the difference
of electric potential under a constant current employing a two-electrode
system, glassy carbon was used as a working electrode and stainless
steel as a counter electrode (Figure S4). Oscillatory conditions were achieved by controlling the Tricontinent
C3000 pump with in-house developed code using Labview (Figure S5). The parameters controlled by the
user were frequency and amplitude of the oscillations, the latter
actually controlling how much volume is displaced back and forth;
it should be considered that due to the nature of the oscillatory
movement, the net flow of the oscillatory action is zero.The
observed variations of the cell potential were due to the impact
that oscillatory conditions have on the observed electrochemical process,
presumably the electrolysis of the electrolyte (Tris–HCl).
A flow of 0.1 mL min–1 was constantly pumped through
the ECOBR while a current of 4.1 μA cm–2 was
applied. Changes in potential were observed due to the differences
in the operation of the reactor associated to different mixing conditions.
We noted that when the cell was arranged with the cathode on top,
the cell started behaving erratically and large bubbles were observed
in the reactor outlet. Hence, the cathode was placed in the bottom
to prevent gas evolution. Initially, no oscillatory regime was induced
and the chamber was left to stabilize for 3 min. Afterward, a rapid
increase in the potential was initially observed, followed by a stabilization
period. The cell potential increased to above 2.2 V after 5000 s electrolysis
(Figure A). However,
once the syringe pump was activated and oscillatory conditions were
initiated, the potential suddenly dropped and then slowly stabilized
until it stabilized at below 2.0 V. If oscillation stopped, the potential
grew again until it reached values similar to the original ones (Figure A).
Figure 2
Chronoamperometry measurements
of the ECOBR showing the effect
of oscillatory conditions. (A) Activation and deactivation of the
conditions. (B) Potential drop for different parameter combinations
(amplitude: 250 μm for the red line and 500 μm for the
black line. Frequency: 1 Hz for dashed lines and 5 Hz for solid lines).
Chronoamperometry measurements
of the ECOBR showing the effect
of oscillatory conditions. (A) Activation and deactivation of the
conditions. (B) Potential drop for different parameter combinations
(amplitude: 250 μm for the red line and 500 μm for the
black line. Frequency: 1 Hz for dashed lines and 5 Hz for solid lines).The combined effect of oscillatory conditions and
the baffled design
of the reactor was expected to improve mass transport within the cell.[31] This means that the transformation promoted
by the ECOBR would be facilitated under oscillatory conditions.The effect of the oscillation parameters on ΔV, i.e., the difference of potential observed before the oscillation
started (V0) and the potential observed
upon stabilization under oscillatory conditions, was examined. As
shown in Table , an
increase in frequency from 1 to 5 Hz is correlated with a decrease
of the cell potentials (Table , entries 1 and 4). The effect of frequency achieved a maximum,
evidenced by the lack of significant improvement at 10 Hz (Table , entry 7), in line
with the behavior reported for COBRs in the literature.[12,25] This has been explained as once a threshold frequency is trespassed,
the effect of the oscillatory flow dominates over the net flow, the
continuous reactor operates more likely to a batch reactor, and mixing
is hindered.[32]
Table 1
Decrease
in Cell Potential for Different
Oscillation Parameter Combinations
entry
amplitude
(μm)
frequency
(Hz)
ΔVVo–1 (%)
1
125
1
5.1
2
250
1
7.5
3
500
1
12.0
4
125
5
10.2
5
250
5
11.0
6
500
5
14.0
7
250
10
11.0
Flow dynamics were simulated
in a virtual reactor with similar
dimensions and operating conditions as the one used in the experimental
part (Figure S7) to illustrate the enhanced
mixing provided by the oscillating flow. The results demonstrate that
the pulses of the oscillating conditions significantly enhance the
mixing of the flow, thus improving the contact of the fluid with the
walls of the reactor, which correspond to the electrodes. Figure shows the concentration
of the inert tracer across the reactor cross section. In the nonoscillating
state (Figure A),
the tracer remains close to the reactor axis (note the distribution
in the central cell). The tracer distribution in the oscillating state
is shown in Figure B. In this case, the tracer is distributed across the whole cell
section, reaching the walls in a higher proportion, which should favor
the electrochemical processes.
Figure 3
CFD simulation of the concentration of
the inert tracer for (A)
nonoscillating conditions and (B) oscillating conditions.
CFD simulation of the concentration of
the inert tracer for (A)
nonoscillating conditions and (B) oscillating conditions.The improved mixing is due to the change of the flow paths,
i.e.,
it is not related to flow induced turbulence. This can be noted in Figure , which shows the
CFD calculated velocity fields at four different times within half
an oscillating cycle. The flow in the nonoscillating case (Figure S8) is limited to the central region,
flowing smoothly from the cell inlet toward the cell outlet. As the
cell section is bigger than the tubular region, the flow slightly
spreads but cannot efficiently reach the electrodes. Figure A–D shows the flow at
different time steps under oscillatory conditions. These figures clearly
show the formation of mixing vortexes (Figure B,D) and strong flow-reversal conditions
(Figure C) near the
electrodes. This flow field enhances the mixing compared to the nonoscillatory
conditions (see Figure S7), characterized
by low speeds near the electrodes and an even flow distribution.
Figure 4
Results
from CFD simulations for the velocity fields under oscillatory
conditions. Color represents the flow speed and arrows indicate the
flow direction (arrow size scales with velocity). Images from (A)
to (D) correspond to different oscillation times inside the half cycle.
Results
from CFD simulations for the velocity fields under oscillatory
conditions. Color represents the flow speed and arrows indicate the
flow direction (arrow size scales with velocity). Images from (A)
to (D) correspond to different oscillation times inside the half cycle.Once the concept of the ECOBR was demonstrated,
the next step was
to evaluate its efficacy in a reaction process. The use of biocatalysts
in industrial environments has grown since they allow the use of environmentally
friendlier conditions and offer great selectivity. However, many enzymes
require cofactors in their catalytic pathways, and since the cost
of cofactors is usually high, their regeneration is essential.[33] The NADH/NAD+ is a cofactor redox
couple that intervenes in numerous interesting reactions, such as
those catalyzed by dehydrogenase enzymes.[34] Furthermore, the electrooxidation of NADH to NAD+ has
been thoroughly studied over the years[35−37] and used in applications
such as biosensors.[34] For all of these
reasons, the NADH oxidation was chosen to evaluate our proposed reactor.Before proceeding with the experiments using the reactor, cyclic
voltammetry was performed using 15 mM NADH in Tris–HCl buffer
to verify that the electrooxidation could take place in the reaction
medium (Figure A,
additional conditions and blank CVs are described in Figure S6). The voltammogram showed that NADH was oxidized
to NAD+ (Figure A) at 0.6 V as previous works using glassy carbon have established,[38] thus confirming that oxidation could be carried
out in the ECOBR.
Figure 5
(A) Cyclic voltammetry of the oxidation of 15 mM NADH
in 100 mM
Tris–HCl (pH 7.0). WE glassy carbon, CE platinum, reference
AgCl, and scan rate = 500 mV s–1. (B) Redox reaction
of NADH. (C) Degraded samples after applying a high current. (D) Graph
of yield vs current using the Ammonite 8 spiral reactor. Flow rate
= 0.01 mL min–1, tres = 100 min, room temperature, and [NADH] = 10 mM.
(A) Cyclic voltammetry of the oxidation of 15 mM NADH
in 100 mM
Tris–HCl (pH 7.0). WE glassy carbon, CE platinum, reference
AgCl, and scan rate = 500 mV s–1. (B) Redox reaction
of NADH. (C) Degraded samples after applying a high current. (D) Graph
of yield vs current using the Ammonite 8 spiral reactor. Flow rate
= 0.01 mL min–1, tres = 100 min, room temperature, and [NADH] = 10 mM.Initially, the testing under continuous-flow conditions was
undertaken
in a commercial Ammonite 8 electrochemical flow cell, which served
as a benchmark of the oxidation reaction, which later was performed
in the ECOBR. It is important to note that the reactor conditions
are not strictly comparable in terms of performance and productivity
due to the use of different current densities and electrode materials.
The design of the Ammonite 8 reactor features a circular cell with
a carved spiral pathway that the solution has to traverse while in
contact with electrodes placed on the top and bottom walls of the
reactor. The amount of NAD+ generated was quantified employing
an enzymatic method (see the Supporting Information for more details and Figures S1 and S2); this also demonstrated that the electrochemically oxidized/regenerated
cofactor is active in enzymatic reactions. Preliminary tests with
a solution of NADH (10 mM) were performed with the cell potential
fixed at 1 V, higher than required for the oxidation of NADH (Figure B), which caused
the current to increase to 0.18 A and presumably caused the observed
overoxidation (Figure C). The oxidation of NADH is a two-electron process, given a faradic
efficiency of 100%; the amount of charge transferred would be equal
to the amount of charge supplied of 2 F·mol–1 (F being 96 485 C). Hence, the current intensity
was set to a value calculated with eq S1, providing the required amount of charge for a complete conversion
during the residence time. For a residence time of 100 min and a molar
flow rate of 0.01 μmol·min–1 (calculated
as concentration × volumetric flow rate), eq S1 predicted a required current of 32 μA. Under these
conditions, a stable regime was observed and the steady state was
easily achieved. When a current above that calculated with eq S1 was applied, a negative effect on the yield
of NADH was observed (Figure D and Table S1). This is presumably
due to the overoxidation of the substrate at high current values.The normalized reactor productivity (NRP) parameter (eq ) was employed to compare the performance
of the different experiments. Here, the NRP was calculated as the
productivity of the reactor in terms of the molar flow rate of product
(mol NAD+·min–1) per mol of reagent
(NADH) and the electrode surface area along the reactor channels.
Different values of current and flow rates were evaluated for the
Ammonite 8 cell (Table , entries 1–3) and for the AM ECOBR without the oscillatory
regime (Table , entries
4–7). In both reactors, the highest yield was achieved with
the lowest flow rate, thus with longer residence time (Table , entry 1). The NRP of the Ammonite
8 reactor did not drop significantly as the flow rate was changed,
which suggests that mass transfer in the cell was relatively efficient.
It is important to keep in mind that the electrode distance is of
ca. 0.2 mm. Next, the AM reactor was evaluated without using oscillatory
conditions to find the optimum flow for this reactor. In this case,
the electrodes are placed about 3 mm from each other, which is an
order of magnitude higher than that in the commercial cell. This enables
the integration of supplementary features, like the baffles, which
can play additional roles for enhanced performance. Like for the commercial
reactor, the highest yield was obtained with the lowest flow rate
evaluated, corresponding to the highest residence time (Table , entry 4). The productivity
correlates the moles of the product formed with the residence time
of the reaction, representing the amount of the product generated
per unit of time. Hence, the productivity does not necessarily correlate
with the highest yield but with the highest reaction rate. Indeed,
it was achieved with a residence time of 46 min (Table , entry 6). Therefore, these
conditions were chosen for the oscillatory experiments.
Table 2
Results of the NADH Oxidation for
Different Continuous-Flow Conditions
To elucidate
the effect of the oscillations on the NRP, the current
density was selected based on eq S1, which,
as previously mentioned, calculates the stoichiometric amount of charge
required for a full conversion of the electrolyzed reagents and it
showed optimal performance with the Ammonite cell (see Figure D and Table S1, entry 2). Different combinations of amplitude and frequency
were set using the flow rate and current previously selected, and
their impact on the oxidation of NADH was evaluated in the ECOBR.
The NRP values observed were higher than those under nonoscillating
conditions for most of the combinations studied, except the one with
the lowest amplitude (Table , entry 2). The best performance was achieved at an amplitude
of 1 mm and a frequency of 0.5 Hz (Table , entry 3). The productivity observed was
2.2-fold higher than the same conditions without oscillating conditions.
Table 3
Results of NADH Oxidation for Different
Conditions Using the AM Flow Reactor with Different Oscillation Conditionsa
Entry
λ
(Hz)
A (μm)
Faradic
efficiency (%)
NRP × 104 (molNAD+molNADH–1min–1cm–2)
1
0
0
27
7.6
2
1
500
20
5.6
3
0.5
1000
60
16.9
4
1
1000
42
11.8
5
2
1000
31
8.7
6
1
1500
32
9.0
Reaction conditions: flow rate =
0.05 mL min–1, tres =
46 min, I = 160 μA, and current density = 20.8
μA cm–2.
Reaction conditions: flow rate =
0.05 mL min–1, tres =
46 min, I = 160 μA, and current density = 20.8
μA cm–2.The oscillatory regime of the ECOBR demonstrated an effect on the
yield of NAD+. Indeed, an increase in the frequency led
to lower yields (Figure A), while the amplitude did not show a defined trend (Figure B). The generation of oscillations
enhanced the performance of the ECOBR in terms of mols of NADH generated
per unit of time and the surface area of the electrode.
Figure 6
(A) Influence
of the oscillation frequency on the yield of the
AM ECOBR reactor (amplitude used: 1000 μm). (B) Influence of
the oscillation amplitude on the yield (frequency used: 1 Hz). (C)
Faradic efficiency and normalized reactor productivity (NRP) for the
ECOBR under oscillating (l = 0.5 Hz, A = 1 mm) and nonoscillating conditions; both experiments were performed
at following conditions: flow rate = 0.05 mL min–1, tres = 46 min, I = 160 μA, and
current density = 20.8 μA cm–2.
(A) Influence
of the oscillation frequency on the yield of the
AM ECOBR reactor (amplitude used: 1000 μm). (B) Influence of
the oscillation amplitude on the yield (frequency used: 1 Hz). (C)
Faradic efficiency and normalized reactor productivity (NRP) for the
ECOBR under oscillating (l = 0.5 Hz, A = 1 mm) and nonoscillating conditions; both experiments were performed
at following conditions: flow rate = 0.05 mL min–1, tres = 46 min, I = 160 μA, and
current density = 20.8 μA cm–2.Improving mass transport in the liquid phase can undoubtedly
improve
the performance of electrochemical flow reactors. In micro- and millireactors,
laminar flow is predominant so there are different strategies to solve
this problem; one of them is giving the reagents enough time to allow
mixing by either lowering the flow or increasing the pathway.[39] It is demonstrated that, as previously seen
in the CFD simulations, the oscillations generated in the baffled
reactor produce vortexes that improve the mixing, which could work
as a different strategy to improve performance in electrochemical
reactors (Figure C).
Conclusions
In the present work, an electrochemical continuous-flow oscillatory
baffled reactor was manufactured with different AM techniques. The
design features a pathway segmented by numerous baffles that under
a continuous oscillatory flow promote the generation of vortexes,
which improve the mixing in the reactor. Different parameters of the
amplitude and frequency of the oscillations, flow and current, were
evaluated for the oxidation of NADH. The ECOBR under oscillatory flow
conditions showed improved performance.The simplicity of this
reactor architecture paves the way for new
applications that may arise thanks to the easy tuning enabled by AM.
Additionally, the materials can be adapted to optimize each reaction
system and the different components can even be functionalized to
broaden their range of applications, thus envisioning the possibility
of efficiently combining multiple processes in integrated devices;
this offers novel windows of opportunity for sustainable chemical
manufacturing.