Designing large-format electrodes: challenges and solutions

Going from a lab electrode (~10 cm²) to industrial format (1-3 m²) is not a matter of simple geometric scaling. At large format, phenomena emerge that are invisible at small scale:

• Current distribution: longitudinal ohmic drop can create zones with 2× the nominal density.
• Gas management: H₂/O₂ bubbles obstruct flow unless the design channels evacuation.
• Mechanical stress: thermal expansion in 2.7 × 1.8 m plates generates stresses that deform thin coatings.

Our approach

Jolt Solutions validates each design on an intermediate-scale test bench (0.3 m²) before industrial scale-up, using coupled CFD and electrochemical models. Result: large-format electrodes with coating uniformity below 5% across 2.7 × 1.8 m.