Laser-Microstructured Copper Reveals Selectivity Patterns in the Electrocatalytic Reduction of CO2

Scaling CO2 Electrolyzer Cell Area from Bench to Pilot

To contribute meaningfully to carbon dioxide (CO2) emissions reduction, CO2 electrolyzer technology will need to scale immensely. Bench-scale electrolyzers are the norm, with active areas <5 cm2. However, cell areas on the order of 100s or 1000s of cm2 will be required for industrial deployment. Here, we study the effects of increasing cell area, scaling over 2 orders of magnitude from a 5 cm2 lab-scale cell to an 800 cm2 pilot plant-scale cell. A direct scaling of the bench-scale cell architecture to the larger area results in a ∼20% drop in ethylene (C2H4) selectivity and an increase in the parasitic hydrogen (H2) evolution reaction (HER). We instrument an 800 cm2 electrolyzer cell to serve as a diagnostic tool and determine that nonuniformities in electrode compression and flow-influenced local CO2 availability are the key drivers of performance loss upon scaling. Machining of an initial 800 cm2 cell results in a standard deviation in MEA compression that is 7-fold that of a similarly produced 5 cm2 cell (0.009 mm). Using these findings, we redesign an 800 cm2 cell for compression tolerance and increased CO2 transport and achieve an H2 FE in the revised 800 cm2 cell similar to that of the 5 cm2 case (16% at 200 mA cm-2). These results demonstrate that by ensuring uniform compression and fluid flow, the CO2 electrolyzer area can be scaled over 100-fold and retain C2H4 selectivity (within 10% of small-scale selectivity).

Self-enhanced localized alkalinity at the encapsulated Cu catalyst for superb electrocatalytic nitrate/nitrite reduction to NH3 in neutral electrolyte

The electrocatalytic nitrate/nitrite reduction reaction (eNOx-RR) to ammonia (NH3) is thermodynamically more favorable than the eye-catching nitrogen (N2) electroreduction. To date, the high eNOx-RR-to-NH3 activity is limited to strong alkaline electrolytes but cannot be achieved in economic and sustainable neutral/near-neutral electrolytes. Here, we construct a copper (Cu) catalyst encapsulated inside the hydrophilic hierarchical nitrogen-doped carbon nanocages (Cu@hNCNC). During eNOx-RR, the hNCNC shell hinders the diffusion of generated OH- ions outward, thus creating a self-enhanced local high pH environment around the inside Cu nanoparticles. Consequently, the Cu@hNCNC catalyst exhibits an excellent eNOx-RR-to-NH3 activity in the neutral electrolyte, equivalent to the Cu catalyst immobilized on the outer surface of hNCNC (Cu/hNCNC) in strong alkaline electrolyte, with much better stability for the former. The optimal NH3 yield rate reaches 4.0 moles per hour per gram with a high Faradaic efficiency of 99.7%. The strong-alkalinity-free advantage facilitates the practicability of Cu@hNCNC catalyst as demonstrated in a coupled plasma-driven N2 oxidization with eNOx-RR-to-NH3.

Solar fuels design: Porous cathodes modeling for electrochemical carbon dioxide reduction in aqueous electrolytes

The reduction of carbon dioxide emissions is crucial to reduce the atmospheric greenhouse effect, fighting climate change and global warming. Electrochemical CO2 reduction is one of the most promising carbon capture and utilization technologies, that can be powered by solar energy and used to make added-value chemicals and green fuels, providing grid-stability, energy security, and environmental benefits. A two-dimensional finite-elements model for porous electrodes was developed and validated against experimental data, allowing the design and performance improvement of a porous zinc cathode morphology and its operational conditions for an electrolyzer producing syngas via the co-electrolysis of CO2 and water. Porosity, pore length, fiber geometric shape, inlet pressure, system temperature, and catholyte flow rate were explored, and these parameters were thoroughly tuned by using the smart-search Nelder-Mead's multi-parameter optimization algorithm to achieve pronouncedly higher, industrial-relevant current density values than those previously reported, up to 263.6 mA/cm2 at an applied potential of -1.1 V vs. RHE.

CO2 Electroreduction To Syngas With Tunable Composition In An Artificial Leaf

Artificial leaves (a-leaves) can reduce carbon dioxide into syngas using solar power and could be combined with thermo- and biocatalytic technologies to decentralize the production of valuable products. By providing variable CO : H2 ratios on demand, a-leaves could facilitate optimal combinations and control the distribution of products in most of these hybrid systems. However, the current design procedures of a-leaves concentrate on achieving high performance for a predetermined syngas composition. This study demonstrates that incorporating the electrolyte flow as a design variable enables flexible production without compromising performance. The concept was tested on an a-leaf using a commercial cell, a Cu2 O:Inx cathodic catalyst, and an inexpensive amorphous silicon thin-film photovoltaic module. Syngas with CO : H2 ratio in the range of 1.8-2.3 could be attained with only 2 % deviation from the optimal cell voltage and controllable solely by catholyte flow. These features could be beneficial for downstream technologies such as Fischer-Tropsch synthesis and anaerobic fermentation.

Cu-based catalyst designs in CO2 electroreduction: precise modulation of reaction intermediates for high-value chemical generation

The massive emission of excess greenhouse gases (mainly CO2) have an irreversible impact on the Earth's ecology. Electrocatalytic CO2 reduction (ECR), a technique that utilizes renewable energy sources to create highly reduced chemicals (e.g. C2H4, C2H5OH), has attracted significant attention in the science community. Cu-based catalysts have emerged as promising candidates for ECR, particularly in producing multi-carbon products that hold substantial value in modern industries. The formation of multi-carbon products involves a range of transient intermediates, the behaviour of which critically influences the reaction pathway and product distribution. Consequently, achieving desirable products necessitates precise regulation of these intermediates. This review explores state-of-the-art designs of Cu-based catalysts, classified into three categories based on the different prospects of the intermediates' modulation: heteroatom doping, morphological structure engineering, and local catalytic environment engineering. These catalyst designs enable efficient multi-carbon generation in ECR by effectively modulating reaction intermediates.

Tailoring Cu Electrodes for Enhanced CO2 Electroreduction through Plasma Electrolysis in Non-Conventional Phosphorus-Oxoanion-Based Electrolytes

This study presents a green, ultra-fast, and facile technique for the fabrication of micro/nano-structured and porous Cu electrodes through in-liquid plasma electrolysis using phosphorous-oxoanion-based electrolytes. Besides the preferential surface faceting, the Cu electrodes exhibit unique surface structures, including octahedral nanocrystals besides nanoporous and microporous structures, depending on the employed electrolyte. The incorporation of P-atoms into the Cu surfaces is observed. The modified Cu electrodes display increased roughness, leading to higher current densities for CO2 electroreduction reaction. The selectivity of the modified Cu electrodes towards C2 products is highest for the Cu electrodes treated in Na2 HPO3 and Na3 PO4 electrolytes, whereas those treated in Na2 H2 PO2 produce the most H2 . The Cu electrode treated in Na3 PO4 produces ethylene (23 %) at -1.1 V vs. RHE, and a comparable amount of acetaldehyde (15 %) that is typically observed for Cu(110) single crystals. The enhanced selectivity is attributed to several factors, including the surface morphology, the incorporation of phosphorus into the Cu structure, and the formation of Cu(110) facets. Our results not only advance our understanding of the influence of the electrolyte's nature on the plasma electrolysis of Cu electrodes, but also underscores the potential of in-liquid plasma treatment for developing efficient Cu electrocatalysts for sustainable CO2 conversion.

NMR-based quantification of liquid products in CO2 electroreduction on phosphate-derived nickel catalysts

Recently discovered phosphate-derived Ni catalysts have opened a new pathway towards multicarbon products via CO₂ electroreduction. However, understanding the influence of basic parameters such as electrode potential, pH, and buffer capacity is needed for optimized C₃₊ product formation. To this end, rigorous catalyst evaluation and sensitive analytical tools are required to identify potential new products and minimize increasing quantification errors linked to long-chain carbon compounds. Herein, we contribute to enhance testing accuracy by presenting sensitive ¹H NMR spectroscopy protocols for liquid product assessment featuring optimized water suppression and reduced experiment time. When combined with an automated NMR data processing routine, samples containing up to 12 products can be quantified within 15 min with low quantification limits equivalent to Faradaic efficiencies of 0.1%. These developments disclosed performance trends in carbon product formation and the detection of four hitherto unreported compounds: acetate, ethylene glycol, hydroxyacetone, and i-propanol.

How Temperature Affects the Selectivity of the Electrochemical CO2 Reduction on Copper

Copper is a unique catalyst for the electrochemical CO₂ reduction reaction (CO2RR) as it can produce multi-carbon products, such as ethylene and propanol. As practical electrolyzers will likely operate at elevated temperatures, the effect of reaction temperature on the product distribution and activity of CO2RR on copper is important to elucidate. In this study, we have performed electrolysis experiments at different reaction temperatures and potentials. We show that there are two distinct temperature regimes. From 18 up to ∼48 °C, C2+ products are produced with higher Faradaic efficiency, while methane and formic acid selectivity decreases and hydrogen selectivity stays approximately constant. From 48 to 70 °C, it was found that HER dominates and the activity of CO2RR decreases. Moreover, the CO2RR products produced in this higher temperature range are mainly the C1 products, namely, CO and HCOOH. We argue that CO surface coverage, local pH, and kinetics play an important role in the lower-temperature regime, while the second regime appears most likely to be related to structural changes in the copper surface.

Femtosecond laser-induced nano- and microstructuring of Cu electrodes for CO2 electroreduction in acetonitrile medium

The dependency of CO₂ reduction rate in acetonitrile-Bu₄NClO₄ solution on cathodes, which were modified by laser induction of a copper surface, was studied. The topography of laser-induced periodic surface structures (LIPSS) → grooves → spikes was successively formed by a certain number of pulses. It was proved that for a higher number of laser pulses, the surface area of the copper cathode increases and preferred platy orientation of the copper surface on [022] crystallografic direction and larger fluence values increase. At the same time, the content of copper (I) oxide on the surface of the copper cathode increases. Also, the tendency to larger fluency values is observed. It promotes the increase of cathodic current density for CO₂ reduction, which reaches values of 14 mA cm^-2 for samples with spikes surface structures at E = - 3.0 V upon a stable process.

Enhancing CO2 Electroreduction Selectivity toward Multicarbon Products via Tuning the Local H2O/CO2 Molar Ratio

Mass transfer plays an important role in controlling the surface coverage of reactants and the kinetics of surface reactions, thus significantly adjusting the catalytic performance. Herein, we reported that H₂O diffusion was modulated by controlling the thicknesses of the carbon black (CB) layer between the gas diffusion electrode (GDE) of Cu and the electrolyte. As a consequence, the product distribution over the GDE of Cu was effectively regulated during CO₂ electroreduction. Interestingly, a volcano-type relationship between the thickness of the CB layer and the faradaic efficiency (FE) for multicarbon (C₂₊) products was observed over the GDE of Cu. Especially, when the applied total current density was set as 800 mA cm^-2, the FE for the C₂₊ products over the GDE of Cu coated by a CB layer with a thickness of 6.6 μm reached 63.2%, which was 2.8 times higher than that (16.8%) over the GDE of Cu without a CB layer.

A review of catalytic hydrogenation of carbon dioxide: From waste to hydrocarbons

With the rapid development of industrial society and humankind’s prosperity, the growing demands of global energy, mainly based on the combustion of hydrocarbon fossil fuels, has become one of the most severe challenges all over the world. It is estimated that fossil fuel consumption continues to grow with an annual increase rate of 1.3%, which has seriously affected the natural environment through the emission of greenhouse gases, most notably carbon dioxide (CO₂). Given these recognized environmental concerns, it is imperative to develop clean technologies for converting captured CO₂ to high-valued chemicals, one of which is value-added hydrocarbons. In this article, environmental effects due to CO₂ emission are discussed and various routes for CO₂ hydrogenation to hydrocarbons including light olefins, fuel oils (gasoline and jet fuel), and aromatics are comprehensively elaborated. Our emphasis is on catalyst development. In addition, we present an outlook that summarizes the research challenges and opportunities associated with the hydrogenation of CO₂ to hydrocarbon products.

Model structures of molten salt-promoted MgO to probe the mechanism of MgCO3 formation during CO2 capture at a solid-liquid interface

MgO is a promising solid oxide-based sorbent to capture anthropogenic CO2 emissions due to its high theoretical gravimetric CO2 uptake and its abundance. When MgO is coated with alkali metal salts such as LiNO3, NaNO3, KNO3, or their mixtures, the kinetics of the CO2 uptake reaction is significantly faster resulting in a 15 times higher CO2 uptake compared to bare MgO. However, the underlying mechanism that leads to this dramatic increase in the carbonation rate is still unclear. This study aims to determine the most favourable location for the nucleation and growth of MgCO3 and more specifically, whether the carbonation occurs preferentially at the buried interface, the triple phase boundary (TPB), and/or inside the molten salt of the NaNO3-MgO system. For this purpose, a model system consisting of a MgO single crystal that is structured by ultra-short pulse laser ablation and coated with NaNO3 as the promoter is used. To identify the location of nucleation and growth of MgCO3, micro X-ray computed tomography, scanning electron microscopy, Raman microspectroscopy and optical profilometry were applied. We found that MgCO3 forms at the NaNO3/MgO interface and not inside the melt. Moreover, there was no preferential nucleation of MgCO3 at the TPB when compared to the buried interface. Furthermore, it is found that there is no observable CO2 diffusion limitation in the nucleation step. However, it was observed that CO2 diffusion limits MgCO3 crystal growth, i.e. the growth rate of MgCO3 is approximately an order of magnitude faster in shallow grooves compared to that in deep grooves.

Modeling Operando Electrochemical CO2 Reduction

Since the seminal works on the application of density functional theory and the computational hydrogen electrode to electrochemical CO₂ reduction (eCO₂R) and hydrogen evolution (HER), the modeling of both reactions has quickly evolved for the last two decades. Formulation of thermodynamic and kinetic linear scaling relationships for key intermediates on crystalline materials have led to the definition of activity volcano plots, overpotential diagrams, and full exploitation of these theoretical outcomes at laboratory scale. However, recent studies hint at the role of morphological changes and short-lived intermediates in ruling the catalytic performance under operating conditions, further raising the bar for the modeling of electrocatalytic systems. Here, we highlight some novel methodological approaches employed to address eCO₂R and HER reactions. Moving from the atomic scale to the bulk electrolyte, we first show how ab initio and machine learning methodologies can partially reproduce surface reconstruction under operation, thus identifying active sites and reaction mechanisms if coupled with microkinetic modeling. Later, we introduce the potential of density functional theory and machine learning to interpret data from Operando spectroelectrochemical techniques, such as Raman spectroscopy and extended X-ray absorption fine structure characterization. Next, we review the role of electrolyte and mass transport effects. Finally, we suggest further challenges for computational modeling in the near future as well as our perspective on the directions to follow.

CO2 Electroreduction on Silver Foams Modified by Ionic Liquids with Different Cation Side Chain Length

Ionic liquids (ILs) are capable of tuning the kinetics of electroreduction processes by modifying a catalyst interface. In this work, a group of hydrophobic imidazolium-based ILs were immobilized on Ag foams by using a procedure known as "solid catalyst with ionic liquid layer" (SCILL). The derived electrocatalysts demonstrated altered selectivity and CO production rates for the electrochemical reduction of CO₂ compared to the unmodified Ag foam. The activity change caused by the IL was dependent on the length of the N-alkyl substituent. The rate of CO production is optimized at moderate chain length and IL loadings. The observed trends are attributed to a local enrichment of CO₂-based species in the proximity of the catalyst and a modification of the environment of its active sites. On the contrary, high loadings or long IL chains render the surface inaccessible and favor the hydrogen evolution reaction.

Mechanistic insight into electrocatalytic glyoxal reduction on copper and its relation to CO2 reduction

Copper electrodes produce several industrially relevant chemicals and fuels during the electrochemical CO₂ reduction reaction (CO₂RR). Knowledge about the reaction pathways can help tune the reaction selectivity toward higher-value products. To probe the uncertain role of the C₂ molecule glyoxal, we electrochemically reduced it on polycrystalline Cu and quantified its liquid-phase products, namely, ethanol, ethylene glycol, and acetaldehyde. The gas phase contained hydrogen and traces of ethylene. In contrast with previous hypothesis, a one-to-one comparison with CO₂RR on Cu indicates that glyoxal is neither a major intermediate in the pathway toward ethylene nor in the pathway toward ethanol. In addition, great possibilities for the selective, low-temperature production of ethylene glycol are open, as computational modelling shows that ethylene glycol and ethanol are produced on different active sites. Thus, apart from the mechanistic insight into CO₂RR, this study gives new directions to facilitate the electrification of chemical processes at refineries.

Glyoxal is not likely a key intermediate of CO₂ reduction to C₂ species, but its electroreduction on Cu yields the commodity chemicals ethylene glycol and ethanol, produced at Cu terraces and defects, respectively.

Electrochemical CO2 Reduction on Cu: Synthesis-Controlled Structure Preference and Selectivity

The electrochemical CO2 reduction reaction (ECO2 RR) on Cu catalysts affords high-value-added products and is therefore of great practical significance. The outcome and kinetics of ECO2 RR remain insufficient, requiring essentially the optimized structure design for the employed Cu catalyst, and also the fine synthesis controls. Herein, synthesis-controlled structure preferences and the modulation of intermediate's interactions are considered to provide synthesis-related insights on the design of Cu catalysts for selective ECO2 RR. First, the origin of ECO2 RR intermediate-dominated selectivity is described. Advanced structural engineering approaches, involving alloy/compound formation, doping/defect introduction, and the use of specific crystal facets/amorphization, heterostructures, single-atom catalysts, surface modification, and nano-/microstructures, are then reviewed. In particular, these structural engineering approaches are discussed in association with diversified synthesis controls, and the modulation of intermediate generation, adsorption, reaction, and additional effects. The results pertaining to synthetic methodology-controlled structural preferences and the correspondingly motivated selectivity are further summarized. Finally, the current opportunities and challenges of Cu catalyst fabrication for highly selective ECO2 RR are discussed.

3D-Printable Fluoropolymer Gas Diffusion Layers for CO2 Electroreduction

The electrosynthesis of value-added multicarbon products from CO₂ is a promising strategy to shift chemical production away from fossil fuels. Particularly important is the rational design of gas diffusion electrode (GDE) assemblies to react selectively, at scale, and at high rates. However, the understanding of the gas diffusion layer (GDL) in these assemblies is limited for the CO₂ reduction reaction (CO₂ RR): particularly important, but incompletely understood, is how the GDL modulates product distributions of catalysts operating in high current density regimes > 300 mA cm^-2 . Here, 3D-printable fluoropolymer GDLs with tunable microporosity and structure are reported and probe the effects of permeance, microstructural porosity, macrostructure, and surface morphology. Under a given choice of applied electrochemical potential and electrolyte, a 100× increase in the C₂ H₄ :CO ratio due to GDL surface morphology design over a homogeneously porous equivalent and a 1.8× increase in the C₂ H₄ partial current density due to a pyramidal macrostructure are observed. These findings offer routes to improve CO₂ RR GDEs as a platform for 3D catalyst design.

Geometry assessment of ultra-short pulsed laser drilled micro-holes

Ultra-short pulsed laser ablation enables a defined generation of micro-holes. A parameter study on the ablation characteristics of copper clearly reveals a benefit for green wavelength with lower threshold fluence, simultaneously increasing the Rayleigh length. The use of a circular drilling method allows a defined manufacturing of micro boreholes and micro through-holes with 35 μm diameter of up to 165 μm and 300 μm length. Introducing high-resolution micro-computed X-ray tomography studying the micro-hole evolution and adjacent geometrical transformations reveals micrometer resolution and high usability. The conical geometry evolving up to an aspect ratio of 5:1 fits well to established models known for percussion drilling. However, increasing the number of pulses leads to non-conical geometry evolution, and this resulting geometry is studied for the first time. Henceforth, the exact geometrical evolution from conical to cylindrical shape upon laser drilling can be resolved revealing the impact of multiple reflections at the generated steep flanks.