Sbir fast-track: direct electrochemical generation of caustic peroxide in a porous solid electrolyte reactor for onsite applications

The National Science Foundation (NSF) awarded Solidec Inc. a $1.555 million Cooperative Agreement under the Technology, Innovation, and Partnerships (TIP) program (CFDA 47.084) effective September 1, 2025, through August 31, 2028. The award funds development of a novel electrochemical porous solid electrolyte reactor system capable of directly producing high-concentration hydrogen peroxide (H2O2) and sodium hydroxide (NaOH) through coproduction from air, water, and salt. The technology eliminates post-processing requirements and enables onsite chemical manufacturing, addressing critical needs for decentralized, low-emission production of essential industrial chemicals.

The project delivers a platform technology that substantially reduces transportation and storage risks associated with hazardous chemical handling while achieving up to 90% emission reductions compared to centralized production methods. By supporting domestic chemical manufacturing and supply chain resilience, the initiative aligns with national security and economic competitiveness objectives. The underlying electrochemical innovation is designed to be extensible beyond hydrogen peroxide and sodium hydroxide production, potentially addressing a broader chemicals market while creating employment opportunities. The work is performed in Houston, Texas, and represents NSF TIP's strategic investment in breakthrough technologies that translate scientific innovation into practical marketplace solutions addressing societal and economic challenges.

Abstract

The broader/commercial impact of this small business innovation research (sbir) fast-track pilot project is the transformation of chemical manufacturing through on-site, low-emission production of hydrogen peroxide and sodium hydroxide. These substances are two essential industrial chemicals, but their traditional production and distribution methods pose significant safety, environmental, and economic challenges. Transporting and storing these reactive chemicals introduces risks of spills and exposure, while centralized production processes consume large amounts of energy and generate carbon emissions. This project introduces a clean, decentralized electrochemical approach that eliminates the need for transporting hazardous chemicals, reduces energy requirements for manufacturing, and reduces emissions by up to 90%. In addition, the decentralized model supports national goals for domestic manufacturing and resilience of chemical supply chains. A domestic supply of chemicals is critical for minimizing dependency on foreign nations for national security purposes. Finally, this project develops a platform technology that could be extended beyond hydrogen peroxide and sodium hydroxide. This solution is a safer, more cost-effective, and environmentally responsible alternative to the industrial status QUO, which could address a large chemicals market and could create high-quality jobs for years to come. The core technical innovation of this project is a novel electrochemical porous solid electrolyzer reactor that enables the coproduction of hydrogen peroxide (H2O2) and sodium hydroxide (naoh) from air, water, and salt. The technology comprises a unique electrolyzer architecture that enables high-concentration chemical products to be directly produced from the electrolyzer, without any post-processing steps. This technology also enables onsite CO-production of these chemicals, which are used in industry for bleaching and odor control, at the point of use. In doing so IT replaces two energy-intensive legacy processes: the anthraquinone process for H2O2 and the chlor-alkali process for naoh. Phase i research will validate the ability to produce H2O2 and naoh at tunable ratios, to demonstrate stable operation over 100 hours, and to determine shelf stability of the chemical mixture. Successful development will lay the groundwork for phase II, which aims to optimize energy efficiency, demonstrate 1000-hour durability, and scale the reactor in preparation for commercial deployment. This platform offers a pathway to decentralize chemical manufacturing while offering cost, operation, and environmental benefits across multiple industries. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the foundation's intellectual merit and broader impacts review criteria.- subawards are not planned for this award.