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Microbial fuel cells (MFCs) have garnered significant attention due to their capacity to generate electricity using renewable and carbon-neutral energy sources such as wastewater. Extensive experimental work and modeling techniques have been employed to dissect these processes and understand their respective impacts on electricity generation. The driving force is to enhance MFC performance for practical applications commercially. Among the various statistical modeling approaches, one particularly robust tool is the Design of Experiments (DoE). It serves to establish the relationships between different variables that influence MFC performance and allows for the optimization of the MFC configuration and operation for scaled-up performances in terms of bioelectricity generation. This study focused on optimizing microbial fuel cells (MFCs) for bioelectricity production using industrial wastewater treatment, employing the Box–Behnken design (BBD) methodology. Through an analysis of response surface models and ANOVA tests, it was found that a combined approach of reduced quadratic, reduced two-factor interaction, and linear models yielded sound results, particularly in voltage yield, COD removal, and current density. Second-order regression models predicted optimal conditions for various parameters, with surface area, temperature, and catholyte dosage identified as critical input variables for optimization. Under these conditions, conducted by the four-factor and three-level Box–Behnken design methodology in a double-chamber MFC unit considering eight output variables—CCV yield, % COD removal, current density, power density, % TSS removal, % CE, and % P O 4 3 − —the optimum values were 700 mV, 54.4%, 54.4 mA/m2, 73.7 mW/m2, 99%, 21.2%, and 100%, respectively. At optimum operating conditions, the results revealed a desirability of 76.6% out of a total of 92 iterations. The paper highlights the effectiveness of statistical ANOVA fit-statistics modeling and optimization in enhancing DCMFC performance, recommending its use as a sustainable bioenergy source. Furthermore, validation results supported the above optimization output response findings and confirmed the viability of biorefinery wastewater as an anolyte for scaling up DCMFC bioelectricity generation. [ABSTRACT FROM AUTHOR]

In this present study, the potential application of DCMFC for the treatment of three different sourced industrial wastewater streams: biorefinery, dairy and mixed streams was investigated. Operating conditions were optimised using the Box Behnken design in response surface methodology (RSM) with three validation experimental runs. The effect of process variables, i.e., HRT (48 h), catholyte dose (0.1 gmol/L) and electrode surface area (three carbon rods argumentation-m2) on the production of electricity as voltage yield (mV), power density (mW/m2), current density (mA/m2), Columbic efficiency (%) CE and Gibbs free energy correlation with the electromotive force of the DCMFC system. Experimental results obtained were a positive response towards the predictive values according to the DoE numerical optimisation sequence. At numerical optimum MFC conditions stated above, validation experimental responses of voltage yield by biorefinery wastewater were 645.2 mV, mixed wastewater was 549 mV, and dairy wastewater was 358 mV maximum yields. The power densities and current densities were attained, for biorefinery, mixed wastewater and dairy wastewater sources respectively as; 62 mW/m2, 50 mW/m2 and 27.2 mW/m2, then current densities of 50 mA/m2, 44,008 mA/m2 and 18 mA/m2. The coulombic efficiencies of 0.34%, 0.75% and 0.22%, respectively, were achieved. The validation of predicted optimum operating conditions was successfully attained, especially through the biorefinery wastewater organic substrate. This article articulates that it is highly imperative to choose the most suitable wastewater source as the viable electron donor towards scaling up and maximising the efficiency of generating electricity in the double chamber microbial fuel cell (DCMFC). Moreover, the findings of the current study demonstrate that the DCMFC can be further upscaled through a series connection in a fed-batch mode of operation using a well-designed and simulated process control system that has been computationally designed and modelled using first order MFC model bioenergy generating models MATLAB Simulink and Simscape electrical software. These findings of the simulations were successful and illustrated that an MFC power output can be successfully stepped to be a viable bio-electrochemical technology for both industrial wastewater (IWW) treatment and simultaneous sustainable power generation. [ABSTRACT FROM AUTHOR]