Organic electrosynthesis offers a sustainable path to decarbonize the chemical industry by integrating renewable energy in chemical manufacturing. However, achieving the selectivity and energy efficiency required for industrial applications is challenging due to the inherent mass transport limitations of most electro-organic reactions. Electrochemical reactions rely on transport of reactants to the electrode surface and become mass transport-limited when the reactant diffusion rate is lower than the reaction rate at the electrode. In organic electrosynthesis with several possible products, mass transport limitations can result in decreased selectivity towards the desired product as the various reaction pathways compete. Convection can mitigate mass transport limitations, but fundamental engineering guidelines for selecting and scaling up convection methods in electrochemical systems do not exist. As a result, the impact of convection on industrial-scale complex organic electrochemical processes remain poorly understood. Here we show that the Sherwood number (Sh)—the ratio of convective mass transport to diffusive mass transport—is a crucial metric to characterize mass transport, determine reactor performance, and enable effective scale-up. We investigate the interplay between mass transport and electrochemical reaction rates under convective flows in the context of the electrosynthesis of adiponitrile, one of the largest organic electrochemical processes in the industry. We use experiments and data-driven predictive models to demonstrate that forced liquid convection and bubble-induced convection produce nearly equivalent mass transport conditions when the corresponding Sherwood numbers are equal. This conclusion shows that the Sherwood number characterizes the mass transport condition independent of the underlying convection mechanism. Additionally, we show that the reactor performance scales with the Sherwood number for a given current density and reactant concentration. This scaling enables accurate prediction of performance irrespective of the convection method, and demonstrates that adiponitrile Faradaic efficiencies of >80% can be achieved for current densities of up to 200 mA/cm2 when Sh > 100. Our results provide guidelines for the design and selection of convection methods, from lab to industrial scale, and contribute to the development of more sustainable chemical manufacturing processes.
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