Assessment of pillar-array electrodes for electrochemical flow reactors using a novel hydrodynamic electrode performance factor

• Derivation of a new performance factor based on mass transfer and pumping power. • Agreement between experimental and simulated data for pillar array electrodes. • Pillar diameter and interpillar distance determine the performance of the arrays. • Hydrodynamic resistance and dimensionless numbers determine the flow regime. • Performance factor permits to compare pillar arrays and reported porous electrodes. This work introduces and validates a Hydrodynamic Electrode Performance Factor (HEPF) for flow reactors. Traditional approaches to electrode optimization often rely on separated mass transfer and pressure drop metrics, hindering comparisons. We address this issue by combining electrochemical and hydrodynamic parameters through a new mathematical expression. This formulation draws inspiration from established equations in heat transfer and the widely recognized Chilton-Colburn analogy, aiming to develop a quantification method independent of the experimental arrangement. The HEPF is complementary to the well-established volumetric mass transfer coefficient and to Storck’s energetic effectiveness postulates for electrochemical reactors. Additionally, this study validates the proposed equation experimentally and then applies it to evaluate pillar array electrodes using 2D computational fluid dynamics simulations for laminar flow conditions. Both experimental and simulation approaches are used to analyze the hydrodynamic behaviour of the electrodes, utilizing the Forchheimer and Hagen-Poiseuille numbers. Notably, preliminary turbulence effects are observed at Reynolds numbers as low as 50 to 125. Visualization of velocity streamlines revealed distinct wake formation behind the pillars at these low Reynolds numbers. This study also explores how reactor inlets, outlets, and tubing pressure losses affect electrode performance. Results emphasize the importance of considering pressure drop, which is integral to the new hydrodynamic performance factor. Analysis of pillar array electrodes demonstrates that reducing both interpillar distance and pillar radius leads to improved electrochemical performance