To enhance the performance of an existing planar-type prototype reactor for bioelectrochemical hydrogen production from industrial wastewater by applying a digital twin-based modelling approach.

Development of an integrated MET model combining computational fluid dynamics (CFD) and microbial growth based on thermodynamic fundamentals using COMSOL Multiphysics; iterative feedback loops between reactor performance data and 3D simulations to optimise reactor design.

That modelling and simulation of flow regime, mass transfer, and ohmic losses can identify and overcome process limitations, leading to improved biological activity and reactor performance.

An existing planar-type pilot microbial electrolysis cell (MEC) reactor treating industrial wastewater.

A comprehensive digital model of the system, improved reactor design, and more than 50% increase in reactor performance (current density, COD removal rate, and hydrogen production rate), along with general design recommendations for planar-type MET reactors.

Accurate integration of microbial thermodynamics with CFD modelling, validation of simulation results, and effective implementation of design improvements in the real system. In addition, high cathode density in bioelectrochemical reactors creates a trade-off: more surface area improves reactions but disrupts flow, causing boundary-layer resistance and stagnant zones. Solving this often requires mixing or recirculation, which adds energy costs and can compromise plug-flow performance.

HELMHOLTZ-ZENTRUM FUR UMWELTFORSCHUNG (UFZ) for modelling support using COMSOL to integrate microbial thermodynamics and mass transfer.