Optimization of operational factors using statistical design and analysis of nanofiller incorporated polymer electrolyte membrane towards performance enhancement of microbial fuel cell

•Statistical approach proved effective in optimizing MFC performance in terms of power density.•Incorporation of SZnO NR nanofiller improved the proton conductivity of SPSEBS membrane.•RSM optimization on filler concentration, membrane thickness and anode area was performed.•Maximum power density obtained after optimization was 147 mW/m2. [Display omitted] Response Surface Methodology (RSM) coupled with Box–Behnken (BB) design is adopted to optimize Microbial Fuel Cell (MFC) performance statistically as a function of three selected operational factors such as filler concentration, membrane thickness and anode surface area. Various concentrations (2%, 4%, 6% and 8%) of Sulphonated Zinc Oxide Nano Rods (SZnO NR) with Sulphonated Polystyrene Ethylene Butylene Polystyrene (SPSEBS) are used as Proton Exchange Membranes (PEM) in a fabricated tubular MFC with a holding volume of 300 mL. The prepared nanocomposite membranes are analyzed for their water uptake, ion exchange capacity (IEC), oxygen crossover and proton conductivity to confirm the membrane suitability for MFC operation. The results indicate that SPSEBS + 6% SZnO NR possesses highest proton conductivity of 1.49 × 10-2 S/cm compared to other nanocomposite membranes and is thus selected for statistical analysis. Statistical analysis shows that STAT 15 with filler concentration of 6.5%, membrane thickness of 120 µm and anode surface area of 19.7 cm2 exhibits the highest maximum power density of 147 mW/m2. The results suggest a novel nanocomposite membrane that could be a suitable PEM and also gives a regression equation for optimizing factors which enhances electricity generation in MFC.