Electrochemical CO2 reduction - The macroscopic world of electrode design, reactor concepts & economic aspects

ICP-MS Assisted EDX Tomography: A Robust Method for Studying Electrolyte Penetration Phenomena in Gas Diffusion Electrodes Applied to CO2 Electrolysis

A carbon paper-based gas diffusion electrode (GDE) is used with a bismuth(III) subcarbonate active catalyst phase for the electrochemical reduction of CO2 in a gas/electrolyte flow-by configuration electrolyser at high current density. It is demonstrated that in this configuration, the gas and catholyte phases recombine to form K2CO3/KHCO3 precipitates to an extent that after electrolyses, vast amount of K+ ions is found by EDX mapping in the entire GDE structure. The fact that the entirety of the GDE gets wetted during electrolysis should, however, not be interpreted as a sign of flooding of the catalyst layer, since electrolyte perspiring through the GDE can largely be removed with the outflow gas, and the efficiency of electrolysis (toward the selective production of formate) can thus be maintained high for several hours. For a full spatial scale quantitative monitoring of electrolyte penetration into the GDE, (relying on K+ ions as tracer) the method of inductively coupled plasma-mass spectrometry (ICP-MS) assisted energy dispersive X-ray (EDX) tomography is introduced. This new, cheap and robust tomography of non-uniform aspect ratio has a large planar span that comprises the entire GDE surface area and a submicrometer depth resolution, hence it can provide quantitative information about the amount and distribution of K+ remnants inside the GDE structure, in three dimensions.

Sensitivity Analysis of One-Dimensional Multiphysics Simulation of CO2 Electrolysis Cell

Electrochemical (EC) carbon dioxide (CO2) reduction, where CO2 is converted to value-added products such as fuel precursors, plays a key role in helping the world's energy system reach net-zero carbon emissions. Simulations of EC cells provide valuable insight into their operation since detailed experimental results on short length and time scales are difficult to obtain. In this work, we construct a 1D simulation of a membrane-electrode-assembly EC cell for CO2 reduction, using a porous silver gas diffusion cathode. We run the simulation under different electrolyte conditions, showing how the cell performance is affected. We then perform a sensitivity analysis of all input parameters to the simulation, which has not been presented before in the literature. We show that the CO partial current density (i CO) is significantly affected by each input parameter of the simulation. i CO is most sensitive to EC kinetic parameters (i 0/α) of all EC reactions, with a 1% change in α resulting in up to 6% change in i CO. Since there is uncertainty associated with the value of each input parameter, this indicates that infidelity between experiment and simulation is likely, and thus, caution should be practiced when comparing experimental results to simulation results. Further, we show that the large range of conditions simulated in literature helps to explain the large variance in reported values of i 0 and α. The results of this paper demonstrate the potential of sensitivity analysis methods to quickly optimize aspects of cell performance (CO2 utilization, Faradaic efficiency, etc.).

In Situ Generated CO Enables High-Current CO2 Reduction to Methanol in a Molecular Catalyst Layer

Molecular catalysts such as cobalt phthalocyanine (CoPc) exhibit remarkable electrochemical activity in methanol production from CO2 or CO, but fast conversion with a high current density is still yet to be realized. While adopting flow cells with gas diffusion electrodes is a common approach to enhanced reaction rates, the current scientific and engineering knowledge primarily centers on metal particle-based catalysts like Cu. This focus overlooks the emerging heterogenized molecular catalysts with distinct physical and chemical properties. In this work, we observe that the partial current density of CO reduction to methanol catalyzed by tetraamine-substituted CoPc (CoPc-NH2) supported on carbon nanotubes (CNTs) remains below 30 mA cm-2, even with systematic optimization of structural and operational parameters of the flow cell. A comparative analysis with a Cu metal catalyst reveals that the porous and electrolyte-philic nature of CoPc-NH2/CNT leaves a large fraction of active sites deprived of CO under reaction conditions. To address this microenvironmental challenge, we directly use CO2 as the reactant, leveraging its faster diffusion rate in water compared to CO. Effective CO2 reduction generates CO in situ to feed the catalytic sites, achieving an unprecedently high partial current density for methanol of 129 mA cm-2. This research underscores the necessity for new insights and approaches in the development of molecular catalyst-based electrodes.

Study of CuSb bimetallic flow-through gas diffusion electrodes for efficient electrochemical CO2 reduction to CO

Electrochemical CO2 reduction (eCO2R) to industrially important feedstock has received great attention, but it faces different challenges. Among them, the poor CO2 mass transport due to low intrinsic CO2 solubility significantly limits the rate of reduction reactions, leading to lower catalytic performance; thereby, commercially relevant current densities can't be achieved. Moreover, the poor activity and selectivity of high-cost monometallic catalysts, including Cu, Zn, Ag, and Au, undermine the efficiency of eCO2R. Flow-through gas diffusion electrodes (FTGDE), a newly developed class of GDEs, can potentially solve the issue of poor CO2 mass transport because they directly feed the CO2 to the catalyst layer. In addition, abundant surface area, porous structure, and improved triple-phase interface make them an excellent candidate for extremely high rate eCO2R. Antimony, a low-cost and abundant metalloid, can be effectively tuned with Cu to produce useful products such as CO, formate, and C2H4 through eCO2R. Herein, a series of porous binary CuSb FTGDEs with different Sb compositions are fabricated for the electrocatalytic reduction of CO2 to CO. The results show that the catalytic performance of CuSb FTGDEs improved with increasing Sb content up to a certain threshold, beyond which it started to decrease. The CuSb FTGDE with 5.4 g of antimony demonstrated higher current density (206.4 mA/cm2) and faradaic efficiency (72.82 %) at relatively lower overpotentials. Compared to gas diffusion configuration, the poor catalytic activity and selectivity achieved by CuSb FTGDE in non-gas diffusion configuration signifies the importance of improved local CO2 concentration and improved triple-phase interface formation in GDE configuration. The several hours stable operation of CuSb FTGDEs during eCO2R demonstrates its potential for efficient electrocatalytic conversion applications.

Developing electrochemical hydrogenation towards industrial application

Electrochemical hydrogenation reactions gained significant attention as a sustainable and efficient alternative to conventional thermocatalytic hydrogenations. This tutorial review provides a comprehensive overview of the basic principles, the practical application, and recent advances of electrochemical hydrogenation reactions, with a particular emphasis on the translation of these reactions from lab-scale to industrial applications. Giving an overview on the vast amount of conceivable organic substrates and tested catalysts, we highlight the challenges associated with upscaling electrochemical hydrogenations, such as mass transfer limitations and reactor design. Strategies and techniques for addressing these challenges are discussed, including the development of novel catalysts and the implementation of scalable and innovative cell concepts. We furthermore present an outlook on current challenges, future prospects, and research directions for achieving widespread industrial implementation of electrochemical hydrogenation reactions. This work aims to provide beginners as well as experienced electrochemists with a starting point into the potential future transformation of electrochemical hydrogenations from a laboratory curiosity to a viable technology for sustainable chemical synthesis on an industrial scale.

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.

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.

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.

Effective perspiration is essential to uphold the stability of zero-gap MEA-based cathodes used in CO2 electrolysers

The application of gas diffusion electrodes (GDEs) for the electrochemical reduction of CO₂ to value-added products creates the possibility of achieving current densities of a few hundred mA cm^-2. To achieve stable operation at such high reaction rates remains, however, a challenging task, due to the flooding of the GDE. In order to mitigate flooding in a zero-gap membrane-electrode assembly (MEA) configuration, paths for effective electrolyte perspiration inside the GDE structure have to be kept open during the electrolysis process. Here we demonstrate that apart from the operational parameters of the electrolysis and the structural properties of the supporting gas diffusion layers, also the chemical composition of the applied catalyst inks can play a decisive role in the electrolyte management of GDEs used for CO₂ electroreduction. In particular, the presence of excess amounts of polymeric capping agents (used to stabilize the catalyst nanoparticles) can lead to a blockage of micropores, which hinders perspiration and initiates the flooding of the microporous layer. Here we use a novel ICP-MS analysis-based approach to quantitatively monitor the amount of perspired electrolyte that exits a GDE-based CO₂ electrolyser, and we show a direct correlation between the break-down of effective perspiration and the appearance of flooding-the latter ultimately leading to a loss of electrolyser stability. We recommend the use of an ultracentrifugation-based approach by which catalyst inks containing no excess amount of polymeric capping agents can be formulated. Using these inks, the stability of electrolyses can be ensured for much longer times.

Copper and silver nanowires for CO2 electroreduction

Copper and silver nanowires have been extensively investigated as the next generation of transparent conductive electrodes (TCEs) due to their ability to form percolating networks. Recently, they have been exploited as electrocatalysts for CO2 reduction. In this review, we present the most recent advances in this field summarizing different strategies used for the synthesis and functionalization/activation of copper and silver nanowires, as well as, the state of the art of their electrochemical performance with particular emphasis on the effect of the nanowire morphology. Novel perspectives for the development of highly efficient, selective, and stable electrocatalysts for CO2 reduction arise from the translation of NW-based TCEs in this challenging field.

Recent Progress in Surface-Defect Engineering Strategies for Electrocatalysts toward Electrochemical CO2 Reduction: A Review

Climate change, caused by greenhouse gas emissions, is one of the biggest threats to the world. As per the IEA report of 2021, global CO2 emissions amounted to around 31.5 Gt, which increased the atmospheric concentration of CO2 up to 412.5 ppm. Thus, there is an imperative demand for the development of new technologies to convert CO2 into value-added feedstock products such as alcohols, hydrocarbons, carbon monoxide, chemicals, and clean fuels. The intrinsic properties of the catalytic materials are the main factors influencing the efficiency of electrochemical CO2 reduction (CO2-RR) reactions. Additionally, the electroreduction of CO2 is mainly affected by poor selectivity and large overpotential requirements. However, these issues can be overcome by modifying heterogeneous electrocatalysts to control their morphology, size, crystal facets, grain boundaries, and surface defects/vacancies. This article reviews the recent progress in electrochemical CO2 reduction reactions accomplished by surface-defective electrocatalysts and identifies significant research gaps for designing highly efficient electrocatalytic materials.

Selective and high-rate CO2 electroreduction by metal-doped covalent triazine frameworks: a computational and experimental hybrid approach

The electrochemical CO₂ reduction reaction (CO₂RR) has attracted intensive attention as a technology to achieve a carbon-neutral society. The use of gas diffusion electrodes (GDEs) enables the realization of high-rate CO₂RRs, which is one of the critical requirements for social implementation. Although both a high reaction rate and good selectivity are simultaneously required for electrocatalysts on GDEs, no systematic study of the relationship among active metal centers in electrocatalysts, reaction rate, and selectivity under high-rate CO₂RR conditions has been reported. In the present study, we employed various metal-doped covalent triazine frameworks (M-CTFs) as platforms for CO₂ reduction reaction (CO₂RR) electrocatalysts on GDEs and systematically investigated them to deduce sophisticated design principles using a combined computational and experimental approach. The Ni-CTF showed both high selectivity (faradaic efficiency (FE) > 98% at -0.5 to -0.9 V vs. reversible hydrogen electrode) and a high reaction rate (current density < -200 mA cm^-2) for CO production. By contrast, the Sn-CTF exhibited selective formic acid production, and the FE and partial current density reached 85% and 150 mA cm^-2, respectively. These results for the CO₂RR activity and selectivity at high current density with respect to metal centers correspond well with predictions based on first-principles calculations. This work is the first demonstration of a clear relationship between the computational adsorption energy of intermediates depending on metal species and the experimental high-rate gaseous CO₂RR.

The oxygen dilemma: The challenge of the anode reaction for microbial electrosynthesis from CO2

Microbial electrosynthesis (MES) from CO2 provides chemicals and fuels by driving the metabolism of microorganisms with electrons from cathodes in bioelectrochemical systems. These microorganisms are usually strictly anaerobic. At the same time, the anode reaction of bioelectrochemical systems is almost exclusively water splitting through the oxygen evolution reaction (OER). This creates a dilemma for MES development and engineering. Oxygen penetration to the cathode has to be excluded to avoid toxicity and efficiency losses while assuring low resistance. We show that this dilemma derives a strong need to identify novel reactor designs when using the OER as an anode reaction or to fully replace OER with alternative oxidation reactions.