System Design Rules for Intensifying the Electrochemical Reduction of CO 2 to CO on Ag Nanoparticles

CO2 conversion to CO via plasma and electrolysis: a techno-economic and energy cost analysis

Electrification and carbon capture technologies are essential for achieving net-zero emissions in the chemical sector. A crucial strategy involves converting captured CO2 into CO, a valuable chemical feedstock. This study evaluates the feasibility of two innovative methods: plasma activation and electrolysis, using clean electricity and captured CO2. Specifically, it compares a gliding arc plasma reactor with an embedded novel carbon bed system to a modern zero-gap type low-temperature electrolyser. The plasma method stood out with an energy cost of 19.5 GJ per tonne CO, marking a 43% reduction compared to electrolysis and conventional methods. CO production costs for plasma- and electrolysis-based plants were $671 and $962 per tonne, respectively. However, due to high uncertainty regarding electrolyser costs, the CO production costs in electrolysis-based plants may actually range from $570 to $1392 per tonne. The carbon bed system in the plasma method was a key factor in facilitating additional CO generation from O2 and enhancing CO2 conversion, contributing to its cost-effectiveness. Challenges for electrolysis included high costs of equipment and low current densities. Addressing these limitations could significantly decrease production costs, but challenges arise from the mutual relationship between intrinsic parameters, such as CO2 conversion, CO2 input flow, or energy cost. In a future scenario with affordable feedstocks and equipment, costs could drop below $500 per tonne for both methods. While this may be more challenging for electrolysis due to complexity and expensive catalysts, plasma-based CO production appears more viable and competitive.

Tackling CO2 Loss in Electrocatalytic Carbon Dioxide Reduction by Advanced Material and Electrolyzer Design

Electrocatalytic CO2 reduction (ECO2R) has been considered as a promising approach to convert CO2 into valuable chemicals and fuels. CO2 loss in conventional alkaline electrolyzers has been recognized as a major obstacle that compromising the efficiency of the ECO2R system. This review firstly conducts an in-depth assessment of the origin and influence of CO2 loss. On this basis, this work summarizes electrolyzer configurations based on novel material and structure design that are capable of tackling CO2 loss, including acidic electrolyzer, bipolar membrane (BPM) derived electrolyzer, cascade electrolyzer, liquid-phase-anode electrolyzer, and liquid-fed electrolyzer. The design strategies and challenges of these carbon efficient electrolyzers have been deliberated in detail. By comparing and analyzing the advantages and limitations of various electrolyzer designs, this work aims to provide some guidelines for the development of efficient ECO2R technology toward large-scale industrial application.

Interfacial Engineering of Ag/C Catalysts for Practical Electrochemical CO2 Reduction to CO

Electrochemical CO2 reduction to value-added chemicals by renewable energy sources is a promising way to implement the artificial carbon cycle. During the reaction, especially at high current densities for practical applications, the complex interaction between the key intermediates and the active sites would affect the selectivity, while the reconfiguration of electrocatalysts could restrict the stability. This paper describes the fabrication of Ag/C catalysts with a well-engineered interfacial structure, in which Ag nanoparticles are partially encapsulated by C supports. The obtained electrocatalyst exhibits CO Faradaic efficiencies (FEs) of over 90 % at current densities even as high as 1.1 A/cm2. The strong interfacial interaction between Ag and C leads to highly localized electron density that promotes the rate-determining electron transfer step by enhancing the adsorption and the stabilization of the key *COO- intermediate. In addition, the partially encapsulated structure prevents the reconfiguration of Ag during the reaction. Stable performance for over 600 h at 500 mA/cm2 is achieved with CO FE maintaining over 95 %, which is among the best stability with such a high selectivity and current density. This work provides a novel catalyst design showing the potential for the practical application of electrochemical reduction of CO2.

Reaction Environment Regulation for Electrocatalytic CO2 Reduction in Acids

The electrocatalytic CO2 reduction reaction (CO2RR) is a sustainable route for converting CO2 into value-added fuels and feedstocks, advancing a carbon-neutral economy. The electrolyte critically influences CO2 utilization, reaction rate and product selectivity. While typically conducted in neutral/alkaline aqueous electrolytes, the CO2RR faces challenges due to (bi)carbonate formation and its crossover to the anolyte, reducing efficiency and stability. Acidic media offer promise by suppressing these processes, but the low Faradaic efficiency, especially for multicarbon (C2+) products, and poor electrocatalyst stability persist. The effective regulation of the reaction environment at the cathode is essential to favor the CO2RR over the competitive hydrogen evolution reaction (HER) and improve long-term stability. This review examines progress in the acidic CO2RR, focusing on reaction environment regulation strategies such as electrocatalyst design, electrode modification and electrolyte engineering to promote the CO2RR. Insights into the reaction mechanisms via in situ/operando techniques and theoretical calculations are discussed, along with critical challenges and future directions in acidic CO2RR technology, offering guidance for developing practical systems for the carbon-neutral community.

Direct formation of copper nanoparticles from atoms at graphitic step edges lowers overpotential and improves selectivity of electrocatalytic CO2 reduction

A key strategy for minimizing our reliance on precious metals is to increase the fraction of surface atoms and improve the metal-support interface. In this work, we employ a solvent/ligand/counterion-free method to deposit copper in the atomic form directly onto a nanotextured surface of graphitized carbon nanofibers (GNFs). Our results demonstrate that under these conditions, copper atoms coalesce into nanoparticles securely anchored to the graphitic step edges, limiting their growth to 2-5 nm. The resultant hybrid Cu/GNF material displays high selectivity in the CO2 reduction reaction (CO2RR) for formate production with a faradaic efficiency of ~94% at -0.38 V vs RHE and a high turnover frequency of 2.78 × 106 h-1. The Cu nanoparticles adhered to the graphitic step edges significantly enhance electron transfer to CO2. Long-term CO2RR tests coupled with atomic-scale elucidation of changes in Cu/GNF reveal nanoparticles coarsening, and a simultaneous increase in the fraction of single Cu atoms. These changes in the catalyst structure make the onset of the CO2 reduction potential more negative, leading to less formate production at -0.38 V vs RHE, correlating with a less efficient competition of CO2 with H2O for adsorption on single Cu atoms on the graphitic surfaces, revealed by density functional theory calculations.

Visualization of CO2 electrolysis using optical coherence tomography

Electrolysers offer an appealing technology for conversion of CO2 into high-value chemicals. However, there are few tools available to track the reactions that occur within electrolysers. Here we report an electrolysis optical coherence tomography platform to visualize the chemical reactions occurring in a CO2 electrolyser. This platform was designed to capture three-dimensional images and videos at high spatial and temporal resolutions. We recorded 12 h of footage of an electrolyser containing a porous electrode separated by a membrane, converting a continuous feed of liquid KHCO3 to reduce CO2 into CO at applied current densities of 50-800 mA cm-2. This platform visualized reactants, intermediates and products, and captured the strikingly dynamic movement of the cathode and membrane components during electrolysis. It also linked CO production to regions of the electrolyser in which CO2 was in direct contact with both membrane and catalyst layers. These results highlight how this platform can be used to track reactions in continuous flow electrochemical reactors.

CO2 Electrolyzers

CO2 electrolyzers have progressed rapidly in energy efficiency and catalyst selectivity toward valuable chemical feedstocks and fuels, such as syngas, ethylene, ethanol, and methane. However, each component within these complex systems influences the overall performance, and the further advances needed to realize commercialization will require an approach that considers the whole process, with the electrochemical cell at the center. Beyond the cell boundaries, the electrolyzer must integrate with upstream CO2 feeds and downstream separation processes in a way that minimizes overall product energy intensity and presents viable use cases. Here we begin by describing upstream CO2 sources, their energy intensities, and impurities. We then focus on the cell, the most common CO2 electrolyzer system architectures, and each component within these systems. We evaluate the energy savings and the feasibility of alternative approaches including integration with CO2 capture, direct conversion of flue gas and two-step conversion via carbon monoxide. We evaluate pathways that minimize downstream separations and produce concentrated streams compatible with existing sectors. Applying this comprehensive upstream-to-downstream approach, we highlight the most promising routes, and outlook, for electrochemical CO2 reduction.

Improving Stability of CO2 Electroreduction by Incorporating Ag NPs in N-Doped Ordered Mesoporous Carbon Structures

The electroreduction of carbon dioxide (eCO2RR) to CO using Ag nanoparticles as an electrocatalyst is promising as an industrial carbon capture and utilization (CCU) technique to mitigate CO2 emissions. Nevertheless, the long-term stability of these Ag nanoparticles has been insufficient despite initial high Faradaic efficiencies and/or partial current densities. To improve the stability, we evaluated an up-scalable and easily tunable synthesis route to deposit low-weight percentages of Ag nanoparticles (NPs) on and into the framework of a nitrogen-doped ordered mesoporous carbon (NOMC) structure. By exploiting this so-called nanoparticle confinement strategy, the nanoparticle mobility under operation is strongly reduced. As a result, particle detachment and agglomeration, two of the most pronounced electrocatalytic degradation mechanisms, are (partially) blocked and catalyst durability is improved. Several synthesis parameters, such as the anchoring agent, the weight percentage of Ag NPs, and the type of carbonaceous support material, were modified in a controlled manner to evaluate their respective impact on the overall electrochemical performance, with a strong emphasis on operational stability. The resulting powders were evaluated through electrochemical and physicochemical characterization methods, including X-ray diffraction (XRD), N2-physisorption, Inductively coupled plasma mass spectrometry (ICP-MS), scanning electron microscopy (SEM), SEM-energy-dispersive X-ray spectroscopy (SEM-EDS), high-angle annular dark field scanning transmission electron microscopy (HAADF-STEM), STEM-EDS, electron tomography, and X-ray photoelectron spectroscopy (XPS). The optimized Ag/soft-NOMC catalysts showed both a promising selectivity (∼80%) and stability compared with commercial Ag NPs while decreasing the loading of the transition metal by more than 50%. The stability of both the 5 and 10 wt % Ag/soft-NOMC catalysts showed considerable improvements by anchoring the Ag NPs on and into a NOMC framework, resulting in a 267% improvement in CO selectivity after 72 h (despite initial losses) compared to commercial Ag NPs. These results demonstrate the promising strategy of anchoring Ag NPs to improve the CO selectivity during prolonged experiments due to the reduced mobility of the Ag NPs and thus enhanced stability.

Recent insights on the use of modified Zn-based catalysts in eCO2RR

Converting CO2 into valuable chemicals can provide a new path to mitigate the greenhouse effect, achieving the aim of "carbon neutrality" and "carbon peaking". Among numerous electrocatalysts, Zn-based materials are widely distributed and cheap, making them one of the most promising electrocatalyst materials to replace noble metal catalysts. Moreover, the Zn metal itself has a certain selectivity for CO. After appropriate modification, such as oxide derivatization, structural reorganization, reconstruction of the surfaces, heteroatom doping, and so on, the Zn-based electrocatalysts can expose more active sites and adjust the d-band center or electronic structure, and the FE and stability of them can be effectively improved, and they can even convert CO2 to multi-carbon products. This review aims to systematically describe the latest progresses of modified Zn-based electrocatalyst materials (including organic and inorganic materials) in the electrocatalytic carbon dioxide reduction reaction (eCO2RR). The applications of modified Zn-based catalysts in improving product selectivity, increasing current density and reducing the overpotential of the eCO2RR are reviewed. Moreover, this review describes the reasonable selection and good structural design of Zn-based catalysts, presents the characteristics of various modified zinc-based catalysts, and reveals the related catalytic mechanisms for the first time. Finally, the current status and development prospects of modified Zn-based catalysts in eCO2RR are summarized and discussed.

Main group elements in electrochemical hydrogen evolution and carbon dioxide reduction

Main-group elements are renowned for their versatile reactivities in organometallic chemistry, including CO2 insertion and H2 activation. However, electrocatalysts comprising a main-group element active site have not yet been widely developed for activating CO2 or producing H2. Recently, research has focused on main-group element-based electrocatalysts that are active in redox systems related to fuel-forming reactions. These studies have determined that the catalytic performances of heavier main-group element-based electrocatalysts are often similar to those of transition-metal-based electrocatalysts. Our group has recently reported the scope of including the main-group elements in the design of molecular catalysts and explored their applications in redox catalysis, such as the generation of H2 upon coupling of two protons (H+) and two electrons (e-). This feature article summarizes our research efforts in developing molecular electrocatalysts comprising main-group elements at their active sites. Furthermore, we highlight their influence on the rate-determining step, thereby enhancing the reaction rate and product selectivity for multi-H+/multi-e- transfer catalysis. Particularly, we focus on the performance of our recently reported molecular Sn- or Sb-centered macrocycles for electrocatalytic H2 evolution reaction (HER) and on how their mechanisms resemble those of transition-metal-based electrocatalysts. Moreover, we discuss the CO2 reduction reaction (CO2RR), another promising fuel-forming reaction, and emphasize the recent progress in including the main-group elements in the CO2RR. Although the main-group elements are found at the active sites of the molecular catalysts and are embedded in the electrode materials for studying the HER, molecular catalysts bearing main-group elements are not commonly used for CO2RR. However, the main-group elements assist the CO2RR by acting as co-catalysts. For example, alkali and alkaline earth metal ions (e.g., Li+, Na+, K+, Rb+, Cs+, Mg2+, Ca2+, and Ba2+) are known for their Lewis acidities, which influence the thermodynamic landscape of the CO2RR and product selectivity. In contrast, the elements in groups 13, 14, and 15 are primarily used as dopants in the preparation of catalytic materials. Overall, this article identifies main-group element-based molecular electrocatalysts and materials for HER and CO2RR.

Fast and easy synthesis of silver, copper, and bimetallic nanoparticles on cellulose paper assisted by ultrasound

This work focuses on a systematic method to produce Ag, Cu, and Ag/Cu metallic nanoparticles (MNPs) in situ assisted with ultrasound on cellulose paper. By tuning the concentration of AgNO3 and CuSO4 salt precursors and ultrasound time, combined with a fixed concentration of ascorbic acid (AA) as a reducing agent, it was possible to control the size, morphology, and polydispersity of the resulting MNPs on cellulose papers. Notably, high yield and low polydispersity of MNPs and bimetallic nanoparticles are achieved by increasing the sonication time on paper samples pre-treated with salt precursors before reduction with AA. Moreover, mechanical analysis on paper samples presenting well-dispersed and distributed MNPs showed slightly decreasing values of Young's modulus compared to neat papers. The strain at break is substantially improved in papers containing solely Ag or Cu MNPs. The latter suggests that the elastic/plastic transition and deformation of papers are tuned by cellulose and MNPs interfacial interaction, as indicated by mechanical analysis. The proposed method provides insights into each factor affecting the sonochemistry in situ synthesis of MNPs on cellulose papers. In addition, it offers a straightforward alternative to scale up the production of MNPs on paper, ensuring an eco-friendly method.

Single-Atom Catalysts and Dual-Atom Catalysts for CO2 Electroreduction: Competition or Cooperation?

Developing highly active and selective electrocatalysts for electrochemical reduction of CO2 can reduce environmental pollution and mitigation of greenhouse gas emission. Owing to maximal atomic utilization, the atomically dispersed catalysts are broadly adopted in CO2 reduction reaction (CO2 RR). Dual-atom catalysts (DACs), with more flexible active sites, distinct electronic structures, and synergetic interatomic interactions compared to single-atom catalysts (SACs), may have great potential to enhance catalytic performance. Nevertheless, most of the existing electrocatalysts have low activity and selectivity due to their high energy barrier. Herein, 15 electrocatalysts are explored with noble metallic (Cu, Ag, and Au) active sites embedded in metal-organic hybrids (MOHs) for high-performance CO2 RR and studied the relationship between SACs and DACs by first-principles calculation. The results indicated that the DACs have excellent electrocatalytic performance, and the moderate interaction between the single- and dual-atomic center can improve catalytic activity in CO2 RR. Four among the 15 catalysts, including (CuAu), (CuCu), Cu(CuCu), and Cu(CuAu) MOHs inherited a capability of suppressing the competitive hydrogen evolution reaction with favorable CO overpotential. This work not only reveals outstanding candidates for MOHs-based dual-atom CO2 RR electrocatalysts but also provides new theoretical insights into rationally designing 2D metallic electrocatalysts.

Maximizing single-pass conversion does not result in practical readiness for CO2 reduction electrolyzers

The authors comment that maximizing product concentration is a more meaningful target for CO2 electrolyzers than maximizing single-pass conversion.

Integrated CO2 capture and electrochemical upgradation: the underpinning mechanism and techno-chemical analysis

Coupling post-combustion CO2 capture with electrochemical utilization (CCU) is a quantum leap in renewable energy science since it eliminates the cost and energy involved in the transport and storage of CO2. However, the major challenges involved in industrial scale implementation are selecting an appropriate solvent/electrolyte for CO2 capture, modeling an appropriate infrastructure by coupling an electrolyser with a CO2 point source and a separator to isolate CO2 reduction reaction (CO2RR) products, and finally selection of an appropriate electrocatalyst. In this review, we highlight the major difficulties with detailed mechanistic interpretation in each step, to find out the underpinning mechanism involved in the integration of electrochemical CCU to achieve higher-value products. In the past decades, most of the studies dealt with individual parts of the integration process, i.e., either selecting a solvent for CO2 capture, designing an electrocatalyst, or choosing an ideal electrolyte. In this context, it is important to note that solvents such as monoethanolamine, bicarbonate, and ionic liquids are often used as electrolytes in CO2 capture media. Therefore, it is essential to fabricate a cost-effective electrolyser that should function as a reversible binder with CO2 and an electron pool capable of recovering the solvent to electrolyte reversibly. For example, reversible ionic liquids, which are non-ionic in their normal forms, but produce ionic forms after CO2 capture, can be further reverted back to their original non-ionic forms after CO2 release with almost 100% efficiency through the chemical or thermal modulations. This review also sheds light on a focused techno-economic evolution for converting the electrochemically integrated CCU process from a pilot-scale project to industrial-scale implementation. In brief, this review article will summarize a state-of-the-art argumentation of challenges and outcomes over the different segments involved in electrochemically integrated CCU to stimulate urgent progress in the field.

Effects of Iron Species on Low Temperature CO2 Electrolyzers

Electrochemical energy conversion devices are considered key in reducing CO2 emissions and significant efforts are being applied to accelerate device development. Unlike other technologies, low temperature electrolyzers have the ability to directly convert CO2 into a range of value-added chemicals. To make them commercially viable, however, device efficiency and durability must be increased. Although their design is similar to more mature water electrolyzers and fuel cells, new cell concepts and components are needed. Due to the complexity of the system, singular component optimization is common. As a result, the component interplay is often overlooked. The influence of Fe-species clearly shows that the cell must be considered holistically during optimization, to avoid future issues due to component interference or cross-contamination. Fe-impurities are ubiquitous, and their influence on single components is well-researched. The activity of non-noble anodes has been increased through the deliberate addition of iron. At the same time, however, Fe-species accelerate cathode and membrane degradation. Here, we interpret literature on single components to gain an understanding of how Fe-species influence low temperature CO2 electrolyzers holistically. The role of Fe-species serves to highlight the need for considerations regarding component interplay in general.

Techno-economic Assessment of CO2 Electrolysis: How Interdependencies between Model Variables Propagate Across Different Modeling Scales

The production of base chemicals by electrochemical conversion of captured CO₂ has the potential to close the carbon cycle, thereby contributing to a future energy transition. With the feasibility of low-temperature electrochemical CO₂ conversion demonstrated at lab scale, research is shifting toward optimizing electrolyser design and operation for industrial applications, with target values based on techno-economic analysis. However, current techno-economic analyses often neglect experimentally reported interdependencies of key performance variables such as the current density, the faradaic efficiency, and the conversion. Aiming to understand the impact of these interdependencies on the economic outlook, we develop a model capturing mass transfer effects over the channel length for an alkaline, membrane electrolyser. Coupling the channel scale with the higher level process scale and embedding this multiscale model in an economic framework allows us to analyze the economic trade-off between the performance variables. Our analysis shows that the derived target values for the performance variables strongly depend on the interdependencies described in the channel scale model. Our analysis also suggests that economically optimal current densities can be as low as half of the previously reported benchmarks. More generally, our work highlights the need to move toward multiscale models, especially in the field of CO₂ electrolysis, to effectively elucidate current bottlenecks in the quest toward economically compelling system designs.

Carbon black supported Ag nanoparticles in zero-gap CO2 electrolysis to CO enabling high mass activity

In this study Ag nanoparticles supported on carbon black (Ag/C) were studied as catalysts for the electrochemical reduction of CO₂ to CO. The nanoparticles were synthesized on three carbon supports, namely Super P, Vulcan and Ketjenblack with surface areas from 50 to 800 m² g^-1 using cysteamine as a linker as proposed by Kim et al., J. Am. Chem. Soc., 2015, 137, 13844. Gas diffusion electrodes were fabricated with all three Ag/Cs and then characterized in a zero-gap electrolyzer. All three supported catalysts achieve high voltage efficiencies, mass activities, and faradaic efficiencies above 80% up to 200 mA cm^-2 with Ag loadings of ∼0.07 mg cm^-2. Using an IrO₂ anode, a partial CO current density of 196 mA cm^-2 at 2.95 V and a mass activity of 3920 mA mg^-1 at a cell voltage of 3.2 V was achieved. When changing the electrolyte from 0.1 M KOH to 0.1 M CsOH, it is possible to achieve 90% FE_CO at 300 mA cm^-2. This results in a mass activity up to 5400 mA mg^-1. Moreover, long-term tests at 300 mA cm^-2 with 0.1 M CsOH resulted in FE_CO remaining above 80% over 11 h. The electrochemical performance did not show a dependence on the carbon support, indicating that mass transport is limiting the cathode, rather than catalyst kinetics. It is worth noting that this may only apply to electrodes with PTFE binders as used in this study, and electrodes with ionomer binders may show a dependence on the catalyst support.

Upcycling air pollutants to fuels and chemicals via electrochemical reduction technology

The intensification of fossil fuel usage results in significant air pollution levels. Efforts have been put into developing efficient technologies capable of converting air pollution into valuable products, including fuels and valuable chemicals (e.g., CO₂ to hydrocarbon and syngas and NO_x to ammonia). Among the strategic efforts to mitigate the excessive concentration of CO₂ and NO_x pollutants in the atmosphere, the electrochemical reduction technology of CO₂ (CO₂RR) and NO_x (NO_xRR) emerges as one of the most promising approaches. It is even more attractive if CO₂RR and NO_xRR are paired with renewables to store intermittent electricity in the form of chemical feedstocks. This review provides an overview of the electrochemical reduction process to convert CO₂ to C₁ and/or C₂₊ chemicals and NO_x to ammonia (NH₃) with a focus on electrocatalysts, electrolytes, electrolyzer, and catalytic reactor designs toward highly selective electrochemical conversion of the desired products. While the attempts in these aspects are enormous, economic consideration and environmental feasibility for actual implementation are not comprehensively provided. We discuss CO₂RR and NO_xRR from the life cycle and techno-economic analyses to perceive the feasibility of the current achievements. The remaining challenges associated with the industrial implementation of electrochemical CO₂ and NO_x reduction are additionally provided.

Local hydrophobicity allows high-performance electrochemical carbon monoxide reduction to C2+ products

While CO can already be produced at industrially relevant current densities via CO₂ electrolysis, the selective formation of C₂₊ products seems challenging. CO electrolysis, in principle, can overcome this barrier, hence forming valuable chemicals from CO₂ in two steps. Here we demonstrate that a mass-produced, commercially available polymeric pore sealer can be used as a catalyst binder, ensuring high rate and selective CO reduction. We achieved above 70% faradaic efficiency for C₂₊ products formation at j = 500 mA cm^-2 current density. As no specific interaction between the polymer and the CO reactant was found, we attribute the stable and selective operation of the electrolyzer cell to the controlled wetting of the catalyst layer due to the homogeneous polymer coating on the catalyst particles' surface. These results indicate that sophistically designed surface modifiers are not necessarily required for CO electrolysis, but a simpler alternative can in some cases lead to the same reaction rate, selectivity and energy efficiency; hence the capital costs can be significantly decreased.

Applications of Metal-Organic Frameworks and Their Derivatives in Electrochemical CO2 Reduction

Electrochemically reducing CO2 to more reduced chemical species is a promising way that not only enables the conversion of intermittent energy resources to stable fuels, but also helps to build a closed-loop anthropogenic carbon cycle. Among various electrocatalysts for electrochemical CO2 reduction, multifunctional metal-organic frameworks (MOFs) have been employed as highly efficient and selective heterogeneous electrocatalysts due to their ultrahigh porosity and topologically diverse structures. Up to now, great progress has been achieved in the design and synthesis of highly active and selective MOF-related catalysts for electrochemical CO2 reduction reaction (CO2RR), and their corresponding reaction mechanisms have been thoroughly studied. In this review, we summarize the recent progress of applying MOFs and their derivatives in CO2RR, with a focus on the design strategies for electrocatalysts and electrolyzers. We first discussed the reaction mechanisms for different CO2RR products and introduced the commonly applied electrolyzer configurations in the current CO2RR system. Then, an overview of several categories of products (CO, HCOOH, CH4, CH3OH, and multi-carbon chemicals) generated from MOFs or their derivatives via CO2RR was discussed. Finally, we offer some insights and perspectives for the future development of MOFs and their derivatives in electrochemical CO2 reduction. We aim to provide new insights into this field and further guide future research for large-scale applications.

Strategies to Enhance CO2 Electrochemical Reduction from Reactive Carbon Solutions

CO₂ electrochemical reduction (CO₂ ER) from (bi)carbonate feed presents an opportunity to efficiently couple this process to alkaline-based carbon capture systems. Likewise, while this method of reducing CO₂ currently lags behind CO₂ gas-fed electrolysers in certain performance metrics, it offers a significant improvement in CO₂ utilization which makes the method worth exploring. This paper presents two simple modifications to a bicarbonate-fed CO₂ ER system that enhance the selectivity towards CO. Specifically, a modified hydrophilic cathode with Ag catalyst loaded through electrodeposition and the addition of dodecyltrimethylammonium bromide (DTAB), a low-cost surfactant, to the catholyte enabled the system to achieve a FE_CO of 85% and 73% at 100 and 200 mA·cm^-2, respectively. The modifications were tested in 4 h long experiments where DTAB helped maintain FE_CO stable even when the pH of the catholyte became more alkaline, and it improved the CO² utilization compared to a system without DTAB.

Operando characterization of continuous flow CO2 electrolyzers: current status and future prospects

The performance of continuous-flow CO₂ electrolyzers has substantially increased in recent years, achieving current density and selectivity (particularly for CO production) meeting the industrial targets. Further improvement is, however, necessary in terms of stability and energy efficiency, as well as in high-value multicarbon product formation. Accelerating this process requires deeper understanding of the complex interplay of chemical-physical processes taking place in CO₂ electrolyzer cells. Operando characterization can provide these insights under working conditions, helping to identify the reasons for performance losses. Despite this fact, only relatively few studies have taken advantage of such methods up to now, applying operando techniques to characterize practically relevant CO₂ electrolyzers. These studies include X-ray absorption- and Raman spectroscopy, fluorescent microscopy, scanning probe techniques, mass spectrometry, and radiography. Their objective was to characterize the catalyst structure, its microenviroment, membrane properties, etc., and relate them to the device performance (reaction rates and product distribution). Here we review the current state-of-the-art of operando methods, associated challenges, and also their future potential. We aim to motivate researchers to perform operando characterization in continuous-flow CO₂ electrolyzers, to understand the reaction mechanism and device operation under practically relevant conditions, thereby advancing the field towards industrialization.

Cracks as Efficient Tools to Mitigate Flooding in Gas Diffusion Electrodes Used for the Electrochemical Reduction of Carbon Dioxide

The advantage of employing gas diffusion electrodes (GDEs) in carbon dioxide reduction electrolyzers is that they allow CO₂ to reach the catalyst in gaseous state, enabling current densities that are orders of magnitude larger than what is achievable in standard H-type cells. The gain in the reaction rate comes, however, at the cost of stability issues related to flooding that occurs when excess electrolyte permeates the micropores of the GDE, effectively blocking the access of CO₂ to the catalyst. For electrolyzers operated with alkaline electrolytes, flooding leaves clear traces within the GDE in the form of precipitated potassium (hydrogen)carbonates. By analyzing the amount and distribution of precipitates, and by quantifying potassium salts transported through the GDE during operation (electrolyte perspiration), important information can be gained with regard to the extent and means of flooding. In this work, a novel combination of energy dispersive X-ray and inductively coupled plasma mass spectrometry based methods is employed to study flooding-related phenomena in GDEs differing in the abundance of cracks in the microporous layer. It is concluded that cracks play an important role in the electrolyte management of CO₂ electrolyzers, and that electrolyte perspiration through cracks is paramount in avoiding flooding-related performance drops.

CO2 Electroreduction in Organic Aprotic Solvents: A Mini Review

An annual increase of CO2 concentrations in the atmosphere causes global environmental problems, addressed by systematic research to develop effective technologies for capturing and utilizing carbon dioxide. Electrochemical catalytic reduction is one of the effective directions of CO2 conversion into valuable chemicals and fuels. The electrochemical conversion of CO2 at catalytically active electrodes in aqueous solutions is the most studied. However, the problems of low selectivity for target products and hydrogen evolution are unresolved. Literature sources on CO2 reduction at catalytically active cathodes in nonaqueous mediums, particularly in organic aprotic solvents, are analyzed in this article. Two directions of cathodic reduction of CO2 are considered—nonaqueous organic aprotic solvents and organic aprotic solvents containing water. The current interpretation of the cathodic conversion mechanism of carbon (IV) oxide into CO and organic products and the main factors influencing the rate of CO2 reduction, Faradaic efficiency of conversion products, and the ratio of direct cathodic reduction of CO2 are given. The influence of the nature of organic aprotic solvent is analyzed, including the topography of the catalytically active cathode, values of cathode potential, and temperature. Emphasis is placed on the role of water impurities in reducing CO2 electroreduction overpotentials and the formation of new CO2 conversion products, including formate and H2.

Surface Coverage as an Important Parameter for Predicting Selectivity Trends in Electrochemical CO2 Reduction

The electrochemical CO2 reduction reaction (CO2RR) is important for a sustainable future. Key insights into the reaction pathways have been obtained by density functional theory (DFT) analysis, but so far, DFT has been unable to give an overall understanding of selectivity trends without important caveats. We show that an unconsidered parameter in DFT models of electrocatalysts-the surface coverage of reacting species-is crucial for understanding the CO2RR selectivities for different surfaces. Surface coverage is a parameter that must be assumed in most DFT studies of CO2RR electrocatalysts, but so far, only the coverage of nonreacting adsorbates has been treated. Explicitly treating the surface coverage of reacting adsorbates allows for an investigation that can more closely mimic operating conditions. Furthermore, and of more immediate importance, the use of surface coverage-dependent adsorption energies allows for the extraction of ratios of adsorption energies of CO2RR intermediates (COOHads and HCOOads) that are shown to be predictive of selectivity and are not susceptible to systematic errors. This approach allows for categorization of the selectivity of several monometallic catalysts (Pt, Pd, Au, Ag, Zn, Cu, Rh, W, Pb, Sn, In, Cd, and Tl), even problematic ones such as Ag or Zn, and does so by only considering the adsorption energies of known intermediates. The selectivity of the further reduction of COOHads can now be explained by a preference for Tafel or Heyrovsky reactions, recontextualizing the nature of selectivity of some catalysts. In summary, this work resolves differences between DFT and experimental studies of the CO2RR and underlines the importance of surface coverage.

Electrolyte Effects on CO2 Electrochemical Reduction to CO

The electrochemical reduction of CO₂ (CO2RR) constitutes an alternative to fossil fuel-based technologies for the production of fuels and commodity chemicals. Yet the application of CO2RR electrolyzers is hampered by low energy and Faradaic efficiencies. Concomitant electrochemical reactions, like hydrogen evolution (HER), lower the selectivity, while the conversion of CO₂ into (bi)carbonate through solution acid–base reactions induces an additional concentration overpotential. During CO2RR in aqueous media, the local pH becomes more alkaline than the bulk causing an additional consumption of CO₂ by the homogeneous reactions. The latter effect, in combination with the low solubility of CO₂ in aqueous electrolytes (33 mM), leads to a significant depletion in CO₂ concentration at the electrode surface.

The nature of the electrolyte, in terms of pH and cation identity, has recently emerged as an important factor to tune both the energy and Faradaic efficiency. In this Account, we summarize the recent advances in understanding electrolyte effects on CO2RR to CO in aqueous solutions, which is the first, and crucial, step to further reduced products. To compare literature findings in a meaningful way, we focus on results reported under well-defined mass transport conditions and using online analytical techniques. The discussion covers the molecular-level understanding of the effects of the proton donor, in terms of the suppression of the CO₂ gradient vs enhancement of HER at a given mass transport rate and of the cation, which is crucial in enabling both CO2RR and HER. These mechanistic insights are then translated into possible implications for industrially relevant cell geometries and current densities.

Conversion of Reactive Carbon Solutions into CO at Low Voltage and High Carbon Efficiency

Electrolyzers are now capable of reducing carbon dioxide (CO₂) into products at high reaction rates but are often characterized by low energy efficiencies and low CO₂ utilization efficiencies. We report here an electrolyzer that reduces 3.0 M KHCO₃(aq) into CO(g) at a high rate (partial current density for CO of 220 mA cm^-2) and a CO₂ utilization efficiency of 40%, at a voltage of merely 2.3 V. These results were made possible by using: (i) a reactive carbon solution enriched in KHCO₃ as the feedstock instead of gaseous CO₂; (ii) a cation exchange membrane instead of an anion exchange membrane, which is common to the field; and (iii) the hydrogen oxidation reaction (HOR) at the anode instead of the oxygen evolution reaction (OER). The voltage reported here is the lowest reported for any CO₂ to CO electrolyzer that operates at high current densities (i.e., a partial current density for CO greater than 200 mA cm^-2) with a CO₂ utilization efficiency of greater than 20%. This study highlights how the choice of feedstock, membrane, and anode chemistries affects the rate and efficiency at which CO₂ is converted into products.

Intermittent Operation of CO2 Electrolyzers at Industrially Relevant Current Densities

We demonstrate the dynamic operation of CO₂ electrolyzer cells, with a power input mimicking the output of a solar photovoltaic power plant. The zero-gap design ensured efficient intermittent operation for a week, while avoiding significant performance loss.

Electroreduction of CO2 toward High Current Density

Carbon dioxide (CO2) electroreduction offers an attractive pathway for converting CO2 to valuable fuels and chemicals. Despite the existence of some excellent electrocatalysts with superior selectivity for specific products, these reactions are conducted at low current densities ranging from several mA cm−2 to tens of mA cm−2, which are far from commercially desirable values. To extend the applications of CO2 electroreduction technology to an industrial scale, long-term operations under high current densities (over 200 mA cm−2) are desirable. In this paper, we review recent major advances toward higher current density in CO2 reduction, including: (1) innovations in electrocatalysts (engineering the morphology, modulating the electronic structure, increasing the active sites, etc.); (2) the design of electrolyzers (membrane electrode assemblies, flow cells, microchannel reactors, high-pressure cells, etc.); and (3) the influence of electrolytes (concentration, pH, anion and cation effects). Finally, we discuss the current challenges and perspectives for future development toward high current densities.

Zero-Gap Bipolar Membrane Electrolyzer for Carbon Dioxide Reduction Using Acid-Tolerant Molecular Electrocatalysts

The scaling-up of electrochemical CO₂ reduction requires circumventing the CO₂ loss as carbonates under alkaline conditions. Zero-gap cell configurations with a reverse-bias bipolar membrane (BPM) represent a possible solution, but the catalyst layer in direct contact with the acidic environment of a BPM usually leads to H₂ evolution dominating. Here we show that using acid-tolerant Ni molecular electrocatalysts selective (>60%) CO₂ reduction can be achieved in a zero-gap BPM device using a pure water and CO₂ feed. At a higher current density (100 mA cm^-2), CO selectivity decreases, but was still >30%, due to reversible product inhibition. This study demonstrates the importance of developing acid-tolerant catalysts for use in large-scale CO₂ reduction devices.

Anode Catalysts in CO2 Electrolysis: Challenges and Untapped Opportunities

The field of electrochemical carbon dioxide reduction has developed rapidly during recent years. At the same time, the role of the anodic half-reaction has received considerably less attention. In this Perspective, we scrutinize the reports on the best-performing CO2 electrolyzer cells from the past 5 years, to shed light on the role of the anodic oxygen evolution catalyst. We analyze how different cell architectures provide different local chemical environments at the anode surface, which in turn determines the pool of applicable anode catalysts. We uncover the factors that led to either a strikingly high current density operation or an exceptionally long lifetime. On the basis of our analysis, we provide a set of criteria that have to be fulfilled by an anode catalyst to achieve high performance. Finally, we provide an outlook on using alternative anode reactions (alcohol oxidation is discussed as an example), resulting in high-value products and higher energy efficiency for the overall process.

Designing a Zn-Ag Catalyst Matrix and Electrolyzer System for CO2 Conversion to CO and Beyond

CO₂ emissions can be transformed into high-added-value commodities through CO₂ electrocatalysis; however, efficient low-cost electrocatalysts are needed for global scale-up. Inspired by other emerging technologies, the authors report the development of a gas diffusion electrode containing highly dispersed Ag sites in a low-cost Zn matrix. This catalyst shows unprecedented Ag mass activity for CO production: -614 mA cm^-2 at 0.17 mg of Ag. Subsequent electrolyte engineering demonstrates that halide anions can further improve stability and activity of the Zn-Ag catalyst, outperforming pure Ag and Au. Membrane electrode assemblies are constructed and coupled to a microbial process that converts the CO to acetate and ethanol. Combined, these concepts present pathways to design catalysts and systems for CO₂ conversion toward sought-after products.

Electroreduction of CO2/CO to C2 Products: Process Modeling, Downstream Separation, System Integration, and Economic Analysis

Direct electrochemical reduction of CO2 to C2 products such as ethylene is more efficient in alkaline media, but it suffers from parasitic loss of reactants due to (bi)carbonate formation. A two-step process where the CO2 is first electrochemically reduced to CO and subsequently converted to desired C2 products has the potential to overcome the limitations posed by direct CO2 electroreduction. In this study, we investigated the technical and economic feasibility of the direct and indirect CO2 conversion routes to C2 products. For the indirect route, CO2 to CO conversion in a high temperature solid oxide electrolysis cell (SOEC) or a low temperature electrolyzer has been considered. The product distribution, conversion, selectivities, current densities, and cell potentials are different for both CO2 conversion routes, which affects the downstream processing and the economics. A detailed process design and techno-economic analysis of both CO2 conversion pathways are presented, which includes CO2 capture, CO2 (and CO) conversion, CO2 (and CO) recycling, and product separation. Our economic analysis shows that both conversion routes are not profitable under the base case scenario, but the economics can be improved significantly by reducing the cell voltage, the capital cost of the electrolyzers, and the electricity price. For both routes, a cell voltage of 2.5 V, a capital cost of $10,000/m2, and an electricity price of <$20/MWh will yield a positive net present value and payback times of less than 15 years. Overall, the high temperature (SOEC-based) two-step conversion process has a greater potential for scale-up than the direct electrochemical conversion route. Strategies for integrating the electrochemical CO2/CO conversion process into the existing gas and oil infrastructure are outlined. Current barriers for industrialization of CO2 electrolyzers and possible solutions are discussed as well.

Probing the local activity of CO2 reduction on gold gas diffusion electrodes: effect of the catalyst loading and CO2 pressure

Large scale CO2 electrolysis can be achieved using gas diffusion electrodes (GDEs), and is an essential step towards broader implementation of carbon capture and utilization strategies. Different variables are known to affect the performance of GDEs. Especially regarding the catalyst loading, there are diverging trends reported in terms of activity and selectivity, e.g. for CO2 reduction to CO. We have used shear-force based Au nanoelectrode positioning and scanning electrochemical microscopy (SECM) in the surface-generation tip collection mode to evaluate the activity of Au GDEs for CO2 reduction as a function of catalyst loading and CO2 back pressure. Using a Au nanoelectrode, we have locally measured the amount of CO produced along a catalyst loading gradient under operando conditions. We observed that an optimum local loading of catalyst is necessary to achieve high activities. However, this optimum is directly dependent on the CO2 back pressure. Our work does not only present a tool to evaluate the activity of GDEs locally, it also allows drawing a more precise picture regarding the effect of catalyst loading and CO2 back pressure on their performance.

Efficiency and selectivity of CO2 reduction to CO on gold gas diffusion electrodes in acidic media

The electrochemical reduction of CO₂ to CO is a promising technology for replacing production processes employing fossil fuels. Still, low energy efficiencies hinder the production of CO at commercial scale. CO₂ electrolysis has mainly been performed in neutral or alkaline media, but recent fundamental work shows that high selectivities for CO can also be achieved in acidic media. Therefore, we investigate the feasibility of CO₂ electrolysis at pH 2–4 at indrustrially relevant conditions, using 10 cm² gold gas diffusion electrodes. Operating at current densities up to 200 mA cm⁻², we obtain CO faradaic efficiencies between 80–90% in sulfate electrolyte, with a 30% improvement of the overall process energy efficiency, in comparison with neutral media. Additionally, we find that weakly hydrated cations are crucial for accomplishing high reaction rates and enabling CO₂ electrolysis in acidic media. This study represents a step towards the application of acidic electrolyzers for CO₂ electroreduction.

Large scale CO₂ electrolysis to produce CO has mainly been performed in neutral and alkaline media. Here, we show that it can also be realized in acidic media, with faradaic efficiencies of 80–90%, and 30% better energy efficiency than obtained in neutral media.

The role of supported dual-atom on graphitic carbon nitride for selective and efficient CO2electrochemical reduction

The electrochemical reduction of CO₂into value-added fuels and chemicals using single atom (SACs) or dual-atom catalysts (DACs) has been extensively studied, but the reaction mechanism and design rules are still unclear. Here, we studied the role of dual-metal atoms on graphite carbon nitride (M₁M₂@g-CN, M₁M₂ = CuCu, FeFe, RuRu, RuCu, RuFe, CuFe) for selective and efficient CO₂electrochemical reduction based on density functional theory. Our results show that CO₂RR on RuRu@g-CN catalyst prefers the *COOH pathway, while for CuCu@g-CN, FeFe@g-CN, RuCu@g-CN, RuFe@g-CN, CuFe@g-CN catalysts, the *OCHO pathway is more suitable. Among all the DACs combinations, we found that RuCu@g-CN and RuFe@g-CN are the most promising electrocatalysts for CO₂RR with a lower limiting potential, which is attributed to the synergistic effect of different O- and C-affinity of the heterocenters in DACs. The selectivity of RuCu@g-CN and RuFe@g-CN to the production of CH₄is better than that of H₂evolution. In addition, we also found that the adsorption free energy of intermediate on heteroatomic DACs can be predicted by those on homoatomic DACs, which can be used to further predict the limiting potential.

Polymer-Supported Liquid Layer Electrolyzer Enabled Electrochemical CO2 Reduction to CO with High Energy Efficiency

The electrochemical conversion of carbon dioxide (CO2 ) to carbon monoxide (CO) is a favorable approach to reduce CO2 emission while converting excess sustainable energy to important chemical feedstocks. At high current density (>100 mA cm-2 ), low energy efficiency (EE) and unaffordable cell cost limit the industrial application of conventional CO2 electrolyzers. Thus, a crucial and urgent task is to design a new type of CO2 electrolyzer that can work efficiently at high current density. Here we report a polymer-supported liquid layer (PSL) electrolyzer using polypropylene non-woven fabric as a separator between anode and cathode. Ag based cathode was fed with humid CO2 and potassium hydroxide was fed to earth-abundant NiFe-based anode. In this configuration, the PSL provided high-pH condition for the cathode reaction and reduced the cell resistance, achieving a high full cell EE over 66 % at 100 mA cm-2 .

Investigation of Electrolyte-Dependent Carbonate Formation on Gas Diffusion Electrodes for CO2 Electrolysis

The electrochemical reduction of CO₂ (ECO₂R) is a promising method for reducing CO₂ emissions and producing carbon-neutral fuels if long-term durability of electrodes can be achieved by identifying and addressing electrode degradation mechanisms. This work investigates the degradation of gas diffusion electrodes (GDEs) in a flowing, alkaline CO₂ electrolyzer via the formation of carbonate deposits on the GDE surface. These carbonate deposits were found to impede electrode performance after only 6 h of operation at current densities ranging from -50 to -200 mA cm^-2. The rate of carbonate deposit formation on the GDE surface was determined to increase with increasing electrolyte molarity and became more prevalent in K⁺-containing as opposed to Cs⁺-containing electrolytes. Electrolyte composition and concentration also had significant effects on the morphology, distribution, and surface coverage of the carbonate deposits. For example, carbonates formed in K⁺-containing electrolytes formed concentrated deposit regions of varying morphology on the GDE surface, while those formed in Cs⁺-containing electrolytes appeared as small crystals, well dispersed across the electrode surface. Both deposits occluding the catalyst layer surface and those found within the microporous layer and carbon fiber substrate of the electrode were found to diminish performance in ECO₂R, leading to rapid loss of CO production after ∼50% of the catalyst layer surface was occluded. Additionally, carbonate deposits reduced GDE hydrophobicity, leading to increased flooding and internal deposits within the GDE substrate. Electrolyte engineering-based solutions are suggested for improved GDE durability in future work.

Operando cathode activation with alkali metal cations for high current density operation of water-fed zero-gap carbon dioxide electrolyzers

Continuous-flow electrolyzers allow CO2 reduction at industrially relevant rates, but long-term operation is still challenging. One reason for this is the formation of precipitates in the porous cathode from the alkaline electrolyte and the CO2 feed. Here we show that while precipitate formation is detrimental for the long-term stability, the presence of alkali metal cations at the cathode improves performance. To overcome this contradiction, we develop an operando activation and regeneration process, where the cathode of a zero-gap electrolyzer cell is periodically infused with alkali cation-containing solutions. This enables deionized water-fed electrolyzers to operate at a CO2 reduction rate matching that of those using alkaline electrolytes (CO partial current density of 420 ± 50 mA cm-2 for over 200 hours). We deconvolute the complex effects of activation and validate the concept with five different electrolytes and three different commercial membranes. Finally, we demonstrate the scalability of this approach on a multi-cell electrolyzer stack, with a 100 cm2 / cell active area.