Fig. 1: Details of the structure and arrangement of our dedicated zero-gap flow-through cell, using a high uniform forced upstream electrolyte flow.

a Flow and pumping direction of both anolyte and catholyte and the position of the bi-layer foam electrodes. The area of the rectangular 4.5 × 9.5 cm2 Zirfon diaphragm exposed to the electrolyte is enclosed by dashed lines. It is larger than the fluid domain (2 cm width) to prevent leakage; b integration of 3-D electrodes using a bi-layer configuration consisting of a fine, 1.6 mm thin 450 µm pore size foam in contact with a coarse, 4 mm thick 3000 µm pore size foam as porous transport layer, the combination being flow-engineered to enhance gas removal; c application of a Ni-based coating on the fine foam and its activation into Raney Ni in both the anodic and cathodic parts, resulting in catalytically highly active electrodes free of Pt group metals. The coating exposed surface is facing the 500 µm thick Zirfon diaphragm.