Intermediate enrichment effect of porous Cu catalyst for CO2 electroreduction to C2 fuels

Critical Role of Cu Nanoparticle-Loaded Cu(100) Surface Structures on Structured Copper-Based Catalysts in Boosting Ethanol Generation in CO2 Electroreduction

Presently, realizing high ethanol selectivity in CO2 electroreduction remains challenging due to difficult C-C coupling and fierce product competition. In this work, we report an innovative approach for improving the efficiency of Cu-based electrocatalysts in ethanol generation from electrocatalytic CO2 reduction using a crystal plane modification strategy. These novel Cu-based electrocatalysts were fabricated by electrochemically activating three-dimensional (3D) flower-like CuO micro/nanostructures grown in situ on copper foils and modifying with surfactants. It was demonstrated that the fabricated Cu-based electrocatalyst featured a predominantly exposed Cu(100) surface loaded with high-density Cu nanoparticles (NPs). The optimal Cu-based electrocatalyst displayed considerably improved CO2 electroreduction performance, with a Faraday efficiency of 37.9% for ethanol and a maximum Faraday efficiency of 68.0% for C2+ products at -1.4 V vs RHE in an H-cell, accompanied by a high current density of 69.9 mA·cm-2, much better than the particulate Cu-based electrocatalyst. It was unveiled that the Cu(100)-rich surface of nanoscale petals with abundant under-coordinated copper atoms from CuNPs was conducive to the formation and stabilization of key *CH3CHO and *OC2H5 intermediates, thereby promoting ethanol generation. This study highlighted the critical role of CuNP-loaded Cu(100) surface structures on structured Cu-based electrocatalysts in enhancing ethanol production for the CO2 electroreduction process.

Catalysts and electrolyzers for the electrochemical CO2 reduction reaction: from laboratory to industrial applications

To cope with the urgent environmental pressure and tight energy demand, using electrocatalytic methods to drive the reduction of carbon dioxide molecules and produce a variety of fuels and chemicals, is one of the effective pathways to achieve carbon neutrality. In recent years, many significant advances in the study of the electrochemical carbon dioxide reduction reaction (CO2RR) have been made, but most of the works exhibit low current density, small electrode area and poor long-term stability, which are not suitable for large-scale industrial applications. Herein, combining the research achievements obtained in laboratories and the practical demand of industrial production, we summarize recent frontier progress in the field of the electrochemical CO2RR, including the fundamentals of catalytic reactions, catalyst design and preparation, and the construction of electrolyzers. In addition, we discuss the bottleneck problem of industrial CO2 electrolysis, and further present the prospect of the essential issues to be solved by the available technology for industrial electrolysis. This review can provide some basic understanding and knowledge accumulation for the development and practical application of electrochemical CO2RR technology.

Insight into the Electrochemical CO2-to-Ethanol Conversion Catalyzed by Cu2S Nanocrystal-Decorated Cu Nanosheets

Ethanol (C₂H₅OH) is an economically ideal C₂ product in electrochemical CO₂ reduction. However, the CO₂-to-C₂H₅OH conversion yield has been rather low and the underlying catalytic mechanism remains vague or unexplored in most cases. Herein, by decorating small Cu₂S nanocrystals uniform ly on Cu nanosheets, three desirable features are integrated into the electrocatalyst, including a relatively high positive local charge on Cu (Cu^δ+), abundant interfaces between Cu^δ+ and zero-valence Cu⁰, and a non-flat, stepped catalyst surface, leading to the promoted affinity of *CO, decreased *COCO formation barrier, and thermodynamically preferred *CH₂CHO-to-*CH₃CHO conversion. As a result, a high partial current density of ∼20.7 mA cm^-2 and a Faraday efficiency of 46% for C₂H₅OH are delivered at -1.2 V vs reversible hydrogen electrode in an H-cell containing a 0.1 M KHCO₃ solution. This work proposes an efficient strategy for the high-yield CO₂-to-C₂H₅OH conversion, emphasizing the promise for the industrial production of alcohol and related products from CO₂.

Low-Temperature Transient Liquid Phase Bonding Technology via Cu Porous-Sn58Bi Solid-Liquid System under Formic Acid Atmosphere

This study proposes a low-temperature transient liquid phase bonding (TLPB) method using Sn58Bi/porous Cu/Sn58Bi to enable efficient power-device packaging at high temperatures. The bonding mechanism is attributed to the rapid reaction between porous Cu and Sn58Bi solder, leading to the formation of intermetallic compounds with high melting point at low temperatures. The present paper investigates the effects of bonding atmosphere, bonding time, and external pressure on the shear strength of metal joints. Under formic acid (FA) atmosphere, Cu₆Sn₅ forms at the porous Cu foil/Sn58Bi interface, and some of it transforms into Cu₃Sn. External pressure significantly reduces the micropores and thickness of the joint interconnection layer, resulting in a ductile fracture failure mode. The metal joint obtained under a pressure of 10 MPa at 250 °C for 5 min exhibits outstanding bonding mechanical performance with a shear strength of 62.2 MPa.

Copper-Based Catalysts for Electrochemical Reduction of Carbon Dioxide to Ethylene

Electrochemical reduction of CO₂ into high energy density multi-carbon chemicals or fuels (e. g., ethylene) via new renewable energy storage has extraordinary implications for carbon neutrality. Copper (Cu)-based catalysts have been recognized as the most promising catalysts for the electrochemical reduction of CO₂ to ethylene (C₂ H₄ ) due to their moderate CO adsorption energy and moderate hydrogen precipitation potential. However, the poor selectivity, low current density and high overpotential of the CO₂ RR into C₂ H₄ greatly limit its industrial applications. Meanwhile, the complex reaction mechanism is still unclear, which leads to blindness in the design of catalysts. Herein, we systematically summarized the latest research, proposed possible conversion mechanisms and categorized the general strategies to adjust of the structure and composition for CO₂ RR, such as tip effect, defect engineering, crystal plane catalysis, synergistic effect, nanoconfinement effect and so on. Eventually, we provided a prospect of the future challenges for further development and progress in CO₂ RR. Previous reviews have summarized catalyst designs for the reduction of CO₂ to multi-carbon products, while lacking in targeting C₂ H₄ alone, an important industrial feedstock. This Review mainly aims to provide a comprehensive understanding for the design strategies and challenges of electrocatalytic CO₂ reduction to C₂ H₄ through recent researches and further propose some guidelines for the future design of copper-based catalysts for electroreduction of CO₂ to C₂ H₄ .

Hetero-Interfaces on Cu Electrode for Enhanced Electrochemical Conversion of CO2 to Multi-Carbon Products

Electrochemical CO₂ reduction reaction (CO₂RR) to multi-carbon products would simultaneously reduce CO₂ emission and produce high-value chemicals. Herein, we report Cu electrodes modified by metal-organic framework (MOF) exhibiting enhanced electrocatalytic performance to convert CO₂ into ethylene and ethanol. The Zr-based MOF, UiO-66 would in situ transform into amorphous ZrO_x nanoparticles (a-ZrO_x), constructing a-ZrO_x/Cu hetero-interface as a dual-site catalyst. The Faradaic efficiency of multi-carbon (C2+) products for optimal UiO-66-coated Cu (0.5-UiO/Cu) electrode reaches a high value of 74% at - 1.05 V versus RHE. The intrinsic activity for C2+ products on 0.5-UiO/Cu electrode is about two times higher than that of Cu foil. In situ surface-enhanced Raman spectra demonstrate that UiO-66-derived a-ZrO_x coating can promote the stabilization of atop-bound CO* intermediates on Cu surface during CO₂ electrolysis, leading to increased CO* coverage and facilitating the C-C coupling process. The present study gives new insights into tailoring the adsorption configurations of CO₂RR intermediate by designing dual-site electrocatalysts with hetero-interfaces.

The site pair matching of a tandem Au/CuO-CuO nanocatalyst for promoting the selective electrolysis of CO2 to C2 products

Tandem catalysis, in which a CO₂-to-C₂ process is divided into a CO₂-to-CO/*CO step and a CO/*CO-to-C₂ step, is promising for enhancing the C₂ product selectivity when using Cu-based electrochemical CO₂ reduction catalysts. In this work, a nanoporous hollow Au/CuO–CuO tandem catalyst was used for catalyzing the eCO₂RR, which exhibited a C₂ product FE of 52.8% at −1.0 V vs. RHE and a C₂ product partial current density of 78.77 mA cm⁻² at −1.5 V vs. RHE. In addition, the C₂ product FE stably remained at over 40% over a wide potential range, from −1.0 V to −1.5 V. This superior performance was attributed to good matching in terms of the optimal working potential and charge-transfer resistance between CO/*CO-production sites (Au/CuO) and CO/*CO-reduction sites (CuO). This site pair matching effect ensured sufficient supplies of CO/*CO and electrons at CuO sites at the working potentials, thus dramatically enhancing the formation rate of C₂ products.

C₂ product FE of 52.8% was achieved in eCO₂RR at −1.0 V vs. RHE using a nanoporous hollow Au/CuO–CuO tandem catalyst due to the matching of optimal working potentials and charge-transfer resistances of the CO-production sites and CO-reduction sites.