Industrial scale-up is an exercise in maximizing sustainable current density (j). To achieve this, we must manipulate hydrodynamics to thin the Nernst diffusion layer.

Electrochemical Reactor Scale-Up Performance

Comparing Current Density vs. Daily Productivity across hydrodynamic regimes.

Beaker-Type Cell

Batch Operation

Mass Transport

Low

Current Density (j)

~10-40 mA/cm²

Area/Volume

Suboptimal

Projected Prod.

~0.1-1.0 kg/d

Parallel Plate Cell

Recirculating Flow

Mass Transport

High (Laminar)

Current Density (j)

~100-150 mA/cm²

Electrode Gap

Narrow (1-3mm)

Projected Prod.

~1.0-2.5 kg/d

Rotating Cylinder

Single-Pass Flow

Mass Transport

Extreme

Current Density (j)

~200-300+ mA/cm²

Conversion

Full (Single-Pass)

Projected Prod.

~2.0-4.0 kg/d

Lehnherr, Dan, and Longrui Chen. "Overview of recent scale-ups in organic electrosynthesis (2000–2023)." Organic Process Research & Development 28.2 (2024): 338-366.