Particulate matter generated from electrolysis processes: a review of pollution, formation, and control technologies

Abstract

The rupture of electrolysis bubbles at the gas-liquid interface generates electrolytic particulate matter (EPM). EPM poses a threat to both occupational health and ambient air quality. Understanding EPM pollution characteristics and developing effective control strategies are therefore critical for the green development of the electrolysis industry. This review summarizes research on EPM regarding workplace contamination, atmospheric emissions, formation mechanisms, and control technologies. Findings reveal severe contamination of electrolysis facilities by EPM, acid mist, and heavy metals, which collectively pose high cancer and non-cancer risks—even when individual component concentrations fall below exposure limits. However, industrial EPM emission levels remain poorly quantified, partly due to a lack of convenient and accurate measurement methods. Bubble characteristics, electrolyte properties, and electrode materials along with their physical characteristics significantly affect EPM formation. Based on the formation process and influencing factors, we summarize theoretical source reduction pathways, including: inhibiting electrochemical gas generation, reducing detached bubble size, and deploying physical barriers. Existing source control methods, while demonstrating high removal efficiency, often adversely affect energy consumption, product quality, or productivity. Finally, we identify key research gaps and propose future directions for characterizing EPM and developing targeted source reduction technologies.

Graphical abstract

Keywords

Electrolysis / Particulate matter / Generation mechanism / Pollution characteristics / Controlling methods

Highlight

	● Severe EPM pollution in electrolysis facilities poses significant health risks.
	● EPM was affected by the characteristics of bubbles, electrolytes, and electrodes.
	● Most control methods reduce EPMs effectively but may impact production efficiency.

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