Streamlining of commercial Berl saddles: A new material to improve the performance of microbial fuel cells

•Berl saddles were opportunely covered by a conductive carbon layer.•New and easy electrode preparation methods offer a low-cost solution for MFC anode.•Power density using coated Berl saddles is comparable to commercial materials.•Coated Berl saddles satisfy the electrical requirements and favor bacterial adhesion.•New electrode useful for scaled-up systems and continuous mode application of MFC.

Microbial fuel cell (MFC) is an upcoming technology that allows oxidizing organic matter to generate current by microorganism's activity. To render MFCs a cost-effective and energy sustainable technology, low-cost materials can be employed as support for bacteria growth and proliferation. With this purpose in mind, ceramic Berl saddles were opportunely covered by a thin and conductive carbon layer, thus obtaining an innovative low-cost anode material able to efficiently recover the electrons released by bacteria metabolisms. The conductive layer was obtained by using α-d-glucose deposition process within the following steps: impregnation, caramelization, and pyrolysis. In this way, a homogenous coating of polycrystalline graphitic carbon was successfully obtained and characterized by several methods. The carbon-coated Berl saddles were then tested as anode material in a two-compartment MFC prototype, in batch mode and using Saccharomyces cerevisiae as active microorganisms. The MFC performances were evaluated using electrochemical techniques. The carbon-coated Berl saddles showed a maximum power density of 130 mW m−2 (29.6 mA L−1) which is about 2–3 times higher than the values reported in literature by using commercial anode materials. In particular, we have carefully estimated the production and process costs of these carbon-coated Berl saddles used in our MFC prototype, obtaining a value comparable to the commercial carbon felt employed in the same MFC apparatus. All these results confirm that our innovative carbon-coated Berl saddles not only satisfy the electrical requirements, but also favor an optimal bacteria adhesion and can be produced as a low-cost anode for scaling-up MFC.