Analytical modelling of CO2 reduction in gas-diffusion electrode catalyst layers

Finite Element Analysis of Local pH Variations in Electrolysis with Porous Electrodes, Considering Water Self-Ionization

A finite element model was developed to simulate ion fluxes and local pH changes within and around porous electrodes during the H2 evolution reaction (HER) in acidic electrolytes. This model is particularly characterized by its ability to simulate scenarios in which the local pH inside and near the cathode exceeds 7, even under bulk acidic conditions (e.g., pH = 1), by considering the self-ionization of water. Steady-state calculations using meshes with an appropriate spatial distribution inside and near the cathode revealed that the relationship between the local pH and the double-layer potential at the interface between the porous catalyst layer and the electrolyte domains changed notably when the local pH exceeded the threshold of 7. By comparing the fluxes of H+ and OH- ions at the interface and using the thickness of the catalyst layer as a variable, we determined that the presence of H+ ions within the pores or the supply of OH- ions from the pores to the interface was responsible for the characteristic change in the local pH observed for the porous electrode. The porous electrode model constructed in this study can potentially serve as a basis that can be extended to a wide range of electrolysis systems, including not only the HER, but also the reduction of CO2, H2O2, and O2, and even oxidation reactions such as the O2 evolution reaction.

Rational Designing Microenvironment of Gas-Diffusion Electrodes via Microgel-Augmented CO2 Availability for High-Rate and Selective CO2 Electroreduction to Ethylene

Efficient electrochemical CO2 reduction reaction (CO2RR) requires advanced gas-diffusion electrodes (GDEs) with tunned microenvironment to overcome low CO2 availability in the vicinity of catalyst layer. Herein, for the first time, pyridine-containing microgels-augmented CO2 availability is presented in Cu2O-based GDE for high-rate CO2 reduction to ethylene, owing to the presence of CO2-phil microgels with amine moieties. Microgels as three-dimensional polymer networks act as CO2 micro-reservoirs to engineer the GDE microenvironment and boost local CO2 availability. The superior ethylene production performance of the GDE modified by 4-vinyl pyridine microgels, as compared with the GDE with diethylaminoethyl methacrylate microgels, indicates the bifunctional effect of pyridine-based microgels to enhance CO2 availability, and electrocatalytic CO2 reduction. While the Faradaic efficiency (FE) of ethylene without microgels was capped at 43% at 300 mA cm-2, GDE with the pyridine microgels showed 56% FE of ethylene at 700 mA cm-2. A similar trend was observed in zero-gap design, and GDEs showed 58% FE of ethylene at -4.0 cell voltage (>350 mA cm-2 current density), resulting in over 2-fold improvement in ethylene production. This study showcases the use of CO2-phil microgels for a higher rate of CO2RR-to-C2+, opening an avenue for several other microgels for more selective and efficient CO2 electrolysis.

Contrasting Views of the Electric Double Layer in Electrochemical CO2 Reduction: Continuum Models vs Molecular Dynamics

In the field of electrochemical CO2 reduction, both continuum models and molecular dynamics (MD) models have been used to understand the electric double layer (EDL). MD often focuses on the region within a few nm of the electrode, while continuum models can span up to the device level (cm). Still, both methods model the EDL, and for a cohesive picture of the CO2 electrolysis system, the two methods should agree in the regions where they overlap length scales. To this end, we make a direct comparison between state-of-the-art continuum models and classical MD simulations under the conditions of CO2 reduction on a Ag electrode. For continuum modeling, this includes the Poisson-Nernst-Planck formulation with steric (finite ion size) effects, and in MD the electrode is modeled with the constant potential method. The comparison yields numerous differences between the two modeling methods. MD shows cations forming two adsorbed layers, including a fully hydrated outer layer and a partial hydration layer closer to the electrode surface. The strength of the inner adsorbed layer increases with cation size (Li+ < Na+ < K+ < Cs+) and with more negative applied potentials. Continuum models that include steric effects predict CO2 to be mostly excluded within 1 nm of the cathode due to tightly packed cations, yet we find little evidence to support these predictions from the MD results. In fact, MD shows that the concentration of CO2 increases within a few Å of the cathode surface due to interactions with the Ag electrode, a factor not included in continuum models. The EDL capacitance is computed from the MD results, showing values in the range of 7-9 μF cm-2, irrespective of the electrolyte concentration, cation identity, or applied potential. The direct comparison between the two modeling methods is meant to show the areas of agreement and disagreement between the two views of the EDL, so as to improve and better align these models.

Quantifying mass transport limitations in a microfluidic CO2 electrolyzer with a gas diffusion cathode

A gas diffusion electrode (GDE) based CO2 electrolyzer shows enhanced CO2 transport to the catalyst surface, significantly increasing current density compared to traditional planar immersed electrodes. A two-dimensional model for the cathode side of a microfluidic CO2 to CO electrolysis device with a GDE is developed. The model, validated against experimental data, examines key operational parameters and electrode materials. It predicts an initial rise in CO partial current density (PCD), peaking at 75 mA cm-2 at -1.3 V vs RHE for a fully flooded catalyst layer, then declining due to continuous decrease in CO2 availability near the catalyst surface. Factors like electrolyte flow rate and CO2 gas mass flow rate influence PCD, with a trade-off between high CO PCD and CO2 conversion efficiency observed with increased CO2 gas flow. We observe that a significant portion of the catalyst layer remains underutilized, and suggest improvements like varying electrode porosity and anisotropic layers to enhance mass transport and CO PCD. This research offers insights into optimizing CO2 electrolysis device performance.

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.

Non-invasive current collectors for improved current-density distribution during CO2 electrolysis on super-hydrophobic electrodes

Electrochemical reduction of CO2 presents an attractive way to store renewable energy in chemical bonds in a potentially carbon-neutral way. However, the available electrolyzers suffer from intrinsic problems, like flooding and salt accumulation, that must be overcome to industrialize the technology. To mitigate flooding and salt precipitation issues, researchers have used super-hydrophobic electrodes based on either expanded polytetrafluoroethylene (ePTFE) gas-diffusion layers (GDL's), or carbon-based GDL's with added PTFE. While the PTFE backbone is highly resistant to flooding, the non-conductive nature of PTFE means that without additional current collection the catalyst layer itself is responsible for electron-dispersion, which penalizes system efficiency and stability. In this work, we present operando results that illustrate that the current distribution and electrical potential distribution is far from a uniform distribution in thin catalyst layers (~50 nm) deposited onto ePTFE GDL's. We then compare the effects of thicker catalyst layers (~500 nm) and a newly developed non-invasive current collector (NICC). The NICC can maintain more uniform current distributions with 10-fold thinner catalyst layers while improving stability towards ethylene (≥ 30%) by approximately two-fold.

Pathways to enhance electrochemical CO2 reduction identified through direct pore-level modeling

Electrochemical conversion of CO2 to fuels and valuable products is one pathway to reduce CO2 emissions. Electrolyzers using gas diffusion electrodes (GDEs) show much higher current densities than aqueous phase electrolyzers, yet models for multi-physical transport remain relatively undeveloped, often relying on volume-averaged approximations. Many physical phenomena interact inside the GDE, which is a multiphase environment (gaseous reactants and products, liquid electrolyte, and solid catalyst), and a multiscale problem, where "pore-scale" phenomena affect observations at the "macro-scale". We present a direct (not volume-averaged) pore-level transport model featuring a liquid electrolyte domain and a gaseous domain coupled at the liquid-gas interface. Transport is resolved, in 2D, around individual nanoparticles comprising the catalyst layer, including the electric double layer and steric effects. The GDE behavior at the pore-level is studied in detail under various idealized catalyst geometries configurations, showing how the catalyst layer thickness, roughness, and liquid wetting behavior all contribute to (or restrict) the transport necessary for CO2 reduction. The analysis identifies several pathways to enhance GDE performance, opening the possibility for increasing the current density by an order of magnitude or more. The results also suggest that the typical liquid-gas interface in the GDE of experimental demonstrations form a filled front rather than a wetting film, the electrochemical reaction is not taking place at a triple-phase boundary but rather a thicker zone around the triple-phase boundary, the solubility reduction at high electrolyte concentrations is an important contributor to transport limitations, and there is considerable heterogeneity in the use of the catalyst. The model allows unprecedented visualization of the transport dynamics inside the GDE across multiple length scales, making it a key step forward on the path to understanding and enhancing GDEs for electrochemical CO2 reduction.

Direct Imaging of Local pH Reveals Bubble-Induced Mixing in a CO2 Electrolyzer

Electrochemical CO2 reduction poses a promising pathway to produce hydrocarbon chemicals and fuels without relying on fossil fuels. Gas diffusion electrodes allow high selectivity for desired carbon products at high current density by ensuring a sufficient CO2 mass transfer rate to the catalyst layer. In addition to CO2 mass transfer, the product selectivity also strongly depends on the local pH at the catalyst surface. In this work, we directly visualize for the first time the two-dimensional (2D) pH profile in the catholyte channel of a gas-fed CO2 electrolyzer equipped with a bipolar membrane. The pH profile is imaged with operando fluorescence lifetime imaging microscopy (FLIM) using a pH-sensitive quinolinium-based dye. We demonstrate that bubble-induced mixing plays an important role in the Faradaic efficiency. Our concentration measurements show that the pH at the catalyst remains lower at -100 mA cm-2 than at -10 mA cm-2, implying that bubble-induced advection outweighs the additional OH- flux at these current densities. We also prove that the pH buffering effect of CO2 from the gas feed and dissolved CO2 in the catholyte prevents the gas diffusion electrode from becoming strongly alkaline. Our findings suggest that gas-fed CO2 electrolyzers with a bipolar membrane and a flowing catholyte are promising designs for scale-up and high-current-density operation because they are able to avoid extreme pH values in the catalyst layer.

Assessment of the technological viability of photoelectrochemical devices for oxygen and fuel production on Moon and Mars

Human deep space exploration is presented with multiple challenges, such as the reliable, efficient and sustainable operation of life support systems. The production and recycling of oxygen, carbon dioxide (CO₂) and fuels are hereby key, as a resource resupply will not be possible. Photoelectrochemical (PEC) devices are investigated for the light-assisted production of hydrogen and carbon-based fuels from CO₂ within the green energy transition on Earth. Their monolithic design and the sole reliance on solar energy makes them attractive for applications in space. Here, we establish the framework to evaluate PEC device performances on Moon and Mars. We present a refined Martian solar irradiance spectrum and establish the thermodynamic and realistic efficiency limits of solar-driven lunar water-splitting and Martian carbon dioxide reduction (CO₂R) devices. Finally, we discuss the technological viability of PEC devices in space by assessing the performance combined with solar concentrator devices and explore their fabrication via in-situ resource utilization.

Inhomogeneities in the Catholyte Channel Limit the Upscaling of CO2 Flow Electrolysers

The use of gas diffusion electrodes that supply gaseous CO₂ directly to the catalyst layer has greatly improved the performance of electrochemical CO₂ conversion. However, reports of high current densities and Faradaic efficiencies primarily come from small lab scale electrolysers. Such electrolysers typically have a geometric area of 5 cm², while an industrial electrolyser would require an area closer to 1 m². The difference in scales means that many limitations that manifest only for larger electrolysers are not captured in lab scale setups. We develop a 2D computational model of both a lab scale and upscaled CO₂ electrolyser to determine performance limitations at larger scales and how they compare to the performance limitations observed at the lab scale. We find that for the same current density larger electrolysers exhibit much greater reaction and local environment inhomogeneity. Increasing catalyst layer pH and widening concentration boundary layers of the KHCO₃ buffer in the electrolyte channel lead to higher activation overpotential and increased parasitic loss of reactant CO₂ to the electrolyte solution. We show that a variable catalyst loading along the direction of the flow channel may improve the economics of a large scale CO₂ electrolyser.

What It Takes for Imidazolium Cations to Promote Electrochemical Reduction of CO2

Imidazolium cations enhance the performance of several electrodes in converting CO₂ to CO in non-aqueous media. In this publication, we elucidate the origin of the function of imidazolium cations when exposed to Au electrodes in anhydrous acetonitrile in CO₂ atmosphere. We demonstrate that imidazolium cations lead to unprecedentedly low overpotentials for CO₂ reduction to CO on Au, with ∼100% Faradaic efficiency. By modification of the N₁ and N₃ functionality of the imidazolium cation, we show a direct correlation between the performance in CO₂ reduction and the C₂-H acidity of the cation. Based on NMR analyses, DFT calculations, and isotopic labeling, showing an inverse kinetic isotope effect, we demonstrate that the mechanism involves a concerted proton-electron transfer to the electrode-adsorbed CO₂ intermediate. The demonstrated mechanism provides guidelines for improvement in the energy efficiency of non-aqueous electrochemical CO₂ reduction, by a tailored design of electrolyte cations.

Continuum Modeling of Porous Electrodes for Electrochemical Synthesis

Electrochemical synthesis possesses substantial promise to utilize renewable energy sources to power the conversion of abundant feedstocks to value-added commodity chemicals and fuels. Of the potential system architectures for these processes, only systems employing 3-D structured porous electrodes have the capacity to achieve the high rates of conversion necessary for industrial scale. However, the phenomena and environments in these systems are not well understood and are challenging to probe experimentally. Fortunately, continuum modeling is well-suited to rationalize the observed behavior in electrochemical synthesis, as well as to ultimately provide recommendations for guiding the design of next-generation devices and components. In this review, we begin by presenting an historical review of modeling of porous electrode systems, with the aim of showing how past knowledge of macroscale modeling can contribute to the rising challenge of electrochemical synthesis. We then present a detailed overview of the governing physics and assumptions required to simulate porous electrode systems for electrochemical synthesis. Leveraging the developed understanding of porous-electrode theory, we survey and discuss the present literature reports on simulating multiscale phenomena in porous electrodes in order to demonstrate their relevance to understanding and improving the performance of devices for electrochemical synthesis. Lastly, we provide our perspectives regarding future directions in the development of models that can most accurately describe and predict the performance of such devices and discuss the best potential applications of future models.