Recent
studies have shown that electrochemically producing
hydrogen
peroxide (H2O2) with gas diffusion electrodes
(GDEs) directly in the water to be treated by H2O2-based advanced oxidation processes (AOPs) is problematic in practical
applications because of the quick deterioration of GDE stability by
oxidation with strong oxidants (e.g., hydroxyl radicals) and fouling
by complex water constituents (e.g., Ca2+ and Mg2+). Therefore, this study tested the electrosynthesis of H2O2 with GDEs in electrolyte solutions in a separate reactor
as an alternative for on-site H2O2 production
in water treatment. Results show that many reactor configurations
and operational parameters (e.g., electrode distance, current densities,
electrolytes, and GDE backpressure) intertwine to have complex influences
on the overall performance of H2O2 production
in terms of H2O2 production rates and current
efficiencies, GDE stability, operating cost, and GDE capital cost.
Under optimized conditions determined in this study (4 mm electrode
distance, 150–200 mA/cm2 current densities, 1 M
Na2SO4, and 30 kPa GDE backpressure), ∼29,000–34,000
mg/L of H2O2 could be produced with production
rates of 57.3–68.3 mg/h/cm2 and apparent current
efficiencies of 55%–61% during H2O2 electrosynthesis
with a divided cell, and the GDEs maintained stable H2O2 production over ∼350–1000 h before water penetrated
the GDEs due to the electrocapillary effect. The operating cost, including
the electricity, electrolytes, water, and oxygen consumed in the process,
was ∼1.32–1.48 $/kgH2O2, and the capital
cost was ∼0.30–0.46 $/kgH2O2. The results
of this study suggest that it is technoeconomically feasible to scale
up H2O2 electrosynthesis with GDEs in electrolytes
to produce H2O2 on site in some water treatment
applications, e.g., micropollutant removal in drinking water treatment
by H2O2-based AOPs. Additional studies are needed
to further extend the GDE lifetime by improving GDE fabrications and
operations to prevent water penetration during H2O2 electrosynthesis.