Two-step electrochemical reduction of CO2 towards multi-carbon products at high current densities

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.

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.

Recent Advances in Electrocatalytic Hydrogenation Reactions on Copper-Based Catalysts

Hydrogenation reactions play a critical role in the synthesis of value-added products within the chemical industry. Electrocatalytic hydrogenation (ECH) using water as the hydrogen source has emerged as an alternative to conventional thermocatalytic processes for sustainable and decentralized chemical synthesis under mild conditions. Among the various ECH catalysts, copper-based (Cu-based) nanomaterials are promising candidates due to their earth-abundance, unique electronic structure, versatility, and high activity/selectivity. Herein, recent advances in the application of Cu-based catalysts in ECH reactions for the upgrading of valuable chemicals are systematically analyzed. The unique properties of Cu-based catalysts in ECH are initially introduced, followed by design strategies to enhance their activity and selectivity. Then, typical ECH reactions on Cu-based catalysts are presented in detail, including carbon dioxide reduction for multicarbon generation, alkyne-to-alkene conversion, selective aldehyde conversion, ammonia production from nitrogen-containing substances, and amine production from organic nitrogen compounds. In these catalysts, the role of catalyst composition and nanostructures toward different products is focused. The co-hydrogenation of two substrates (e.g., CO2 and NOx n, SO3 2-, etc.) via C─N, C─S, and C─C cross-coupling reactions are also highlighted. Finally, the critical issues and future perspectives of Cu-catalyzed ECH are proposed to accelerate the rational development of next-generation catalysts.

Two-Membrane Dual Non-Aqueous/Aqueous Electrolyte Flow Cell Operation for Electrochemical Conversion of CO2 to Methyl Formate

Recently, tandem cathodic reactions have been demonstrated in non-aqueous solvents to couple CO2 reduction to a secondary reaction to create novel species that are not produced in aqueous CO2 electrolysis. One reaction that can be performed with high selectivity and durability is the electrochemical conversion of CO2 to formic acid and in-situ esterification with methanol to produce methyl formate. However, the translation to a high-performance flow electrolyzer is far from trivial, as the non-aqueous catholyte leads to reactor challenges including flooding the gas diffusion electrode. Here, a two-membrane flow electrolyzer with both anion and cation exchange membranes was used with flowing methanol catholyte and aqueous anolyte. This design prevented methanol from flooding the cathode, which was a pervasive limiting issue for electrolyzers with a single membrane. Methyl formate production at 42.9 % faradaic efficiency was achieved with pure methanol in a flow electrolyzer with stable performance beyond 80 min. However, low-water-content catholyte compositions also led to increased cell resistance and lower operating current densities. Thus, with the present ionomer materials there is a tradeoff between methyl formate selectivity and current density depending on water concentration, highlighting a need for new ionomers tailored for desirable non-aqueous solvents such as methanol.

Multiscale effects in tandem CO2 electrolysis to C2+ products

CO2 electrolysis is a sustainable technology capable of accelerating global decarbonisation through the production of high-value alternatives to fossil-derived products. CO2 conversion can generate critical multicarbon (C2+) products such as drop-in chemicals ethylene and ethanol, however achieving high selectivity from single-component catalysts is often limited by the competitive formation of C1 products. Tandem catalysis can overcome C2+ selectivity limitations through the incorporation of a component that generates a high concentration of CO, the primary reactant involved in the C-C coupling step to form C2+ products. A wide range of approaches to promote tandem CO2 electrolysis have been presented in recent literature that span atomic-scale manipulation to device-scale engineering. Therefore, an understanding of multiscale effects that contribute to selectivity alterations are required to develop effective tandem systems. In this review, we use relevant examples to highlight the complex and interlinked contributions to selectivity and provide an outlook for future development of tandem CO2 electrolysis systems.

Gerhardtite as a Precursor to an Efficient CO-to-Acetate Electroreduction Catalyst

Carbon-carbon coupling electrochemistry on a conventional copper (Cu) catalyst still undergoes low selectivity among many different multicarbon (C2+) chemicals, posing a grand challenge to achieve a single C2+ product. Here, we demonstrate a laser irradiation synthesis of a gerhardtite mineral, Cu2(OH)3NO3, as a catalyst precursor to make a Cu catalyst with abundant stacking faults under reducing conditions. Such structural perturbation modulates electronic microenvironments of Cu, leading to improved d-electron back-donation to the antibonding orbital of *CO intermediates and thus strengthening *CO adsorption. With increased *CO coverage on the defect-rich Cu, we report an acetate selectivity of 56 ± 2% (compared to 31 ± 1% for conventional Cu) and a partial current density of 222 ± 7 mA per square centimeter in CO electroreduction. When run at 400 mA per square centimeter for 40 h in a flow reactor, this catalyst produces 68.3 mmol of acetate throughout. This work highlights the value of a Cu-containing mineral phase in accessing suitable structures for improved selectivity to a single desired C2+ product.

A CO2 electrolyzer tandem cell system for CO2-CO co-feed valorization in a Ni-N-C/Cu-catalyzed reaction cascade

Coupled tandem electrolyzer concepts have been predicted to offer kinetic benefits to sluggish catalytic reactions thanks to their flexibility of reaction environments in each cell. Here we design, assemble, test, and analyze the first complete low-temperature, neutral-pH, cathode precious metal-free tandem CO2 electrolyzer cell chain. The tandem system couples an Ag-free CO2-to-CO2/CO electrolyzer (cell-1) to a CO2/CO-to-C2+ product electrolyzer (cell-2). Cell-1 and cell-2 incorporate selective Ni-N-C-based and Cu-based Gas Diffusion Cathodes, respectively, and operate at sustainable neutral pH conditions. Using our tandem cell system, we report strongly enhanced rates for the production of ethylene (by 50%) and alcohols (by 100%) and a sharply increased C2+ energy efficiency (by 100%) at current densities of up to 700 mA cm-2 compared to the single CO2-to-C2+ electrolyzer cell system approach. This study demonstrates that coupled tandem electrolyzer cell systems can offer kinetic and practical energetic benefits over single-cell designs for the production of value-added C2+ chemicals and fuels directly from CO2 feeds without intermediate separation or purification.

Electrochemical Manufacturing Routes for Organic Chemical Commodities

Electrochemical synthesis of organic chemical commodities provides an alternative to conventional thermochemical manufacturing and enables the direct use of renewable electricity to reduce greenhouse gas emissions from the chemical industry. We discuss electrochemical synthesis approaches that use abundant carbon feedstocks for the production of the largest petrochemical precursors and basic organic chemical products: light olefins, olefin oxidation derivatives, aromatics, and methanol. First, we identify feasible routes for the electrochemical production of each commodity while considering the reaction thermodynamics, available feedstocks, and competing thermochemical processes. Next, we summarize successful catalysis and reaction engineering approaches to overcome technological challenges that prevent electrochemical routes from operating at high production rates, selectivity, stability, and energy conversion efficiency. Finally, we provide an outlook on the strategies that must be implemented to achieve large-scale electrochemical manufacturing of major organic chemical commodities.

Competition of CO and Acetaldehyde Adsorption and Reduction on Copper Electrodes and Its Impact on n-Propanol Formation

Selective synthesis of n-propanol from electrocatalytic CO₂/CO reduction on copper remains challenging and the impact of the local interfacial effects on the production of n-propanol is not yet fully understood. Here, we investigate the competition between CO and acetaldehyde adsorption and reduction on copper electrodes and how it affects the n-propanol formation. We show that n-propanol formation can be effectively enhanced by modulating the CO partial pressure or acetaldehyde concentration in solution. Upon successive additions of acetaldehyde in CO-saturated phosphate buffer electrolytes, n-propanol formation was increased. Oppositely, n-propanol formation was the most active at lower CO flow rates in a 50 mM acetaldehyde phosphate buffer electrolyte. In a conventional carbon monoxide reduction reaction (CORR) test in KOH, we show that, in the absence of acetaldehyde in solution, an optimum ratio of n-propanol/ethylene formation is found at intermediate CO partial pressure. From these observations, we can assume that the highest n-propanol formation rate from CO₂RR is reached when a suitable ratio of CO and acetaldehyde intermediates is adsorbed. An optimum ratio was also found for n-propanol/ethanol formation but with a clear decrease in the formation rate for ethanol at this optimum, while the n-propanol formation rate was the highest. As this trend was not observed for ethylene formation, this finding suggests that adsorbed methylcarbonyl (adsorbed dehydrogenated acetaldehyde) is an intermediate for the formation of ethanol and n-propanol but not for ethylene. Finally, this work may explain why it is challenging to reach high faradaic efficiencies for n-propanol, as CO and the intermediates for n-propanol synthesis (like adsorbed methylcarbonyl) compete for active sites on the surface, where CO adsorption is favored.

Coverage-driven selectivity switch from ethylene to acetate in high-rate CO2/CO electrolysis

Tuning catalyst microenvironments by electrolytes and organic modifications is effective in improving CO₂ electrolysis performance. An alternative way is to use mixed CO/CO₂ feeds from incomplete industrial combustion of fossil fuels, but its effect on catalyst microenvironments has been poorly understood. Here we investigate CO/CO₂ co-electrolysis over CuO nanosheets in an alkaline membrane electrode assembly electrolyser. With increasing CO pressure in the feed, the major product gradually switches from ethylene to acetate, attributed to the increased CO coverage and local pH. Under optimized conditions, the Faradaic efficiency and partial current density of multicarbon products reach 90.0% and 3.1 A cm^-2, corresponding to a carbon selectivity of 100.0% and yield of 75.0%, outperforming thermocatalytic CO hydrogenation. The scale-up demonstration using an electrolyser stack achieves the highest ethylene formation rate of 457.5 ml min^-1 at 150 A and acetate formation rate of 2.97 g min^-1 at 250 A.

Utilizing CO2 as a Reactant for C3 Oxygenate Production via Tandem Reactions

One possible solution to closing the loop on carbon emissions is using CO₂ as the carbon source to generate high-value, multicarbon products. In this Perspective, we describe four tandem reaction strategies for converting CO₂ into C₃ oxygenated hydrocarbon products (i.e., propanal and 1-propanol), using either ethane or water as the hydrogen source: (1) thermocatalytic CO₂-assisted dehydrogenation and reforming of ethane to ethylene, CO, and H₂, followed by heterogeneous hydroformylation, (2) one-pot conversion of CO₂ and ethane using plasma-activated reactions in combination with thermocatalysis, (3) electrochemical CO₂ reduction to ethylene, CO, and H₂, followed by thermocatalytic hydroformylation, and (4) electrochemical CO₂ reduction to CO, followed by electrochemical CO reduction to C₃ oxygenates. We discuss the proof-of-concept results and key challenges for each tandem scheme, and we conduct a comparative analysis of the energy costs and prospects for net CO₂ reduction. The use of tandem reaction systems can provide an alternative approach to traditional catalytic processes, and these concepts can be further extended to other chemical reactions and products, thereby opening new opportunities for innovative CO₂ utilization technologies.

Correlating CO Coverage and CO Electroreduction on Cu via High-Pressure in Situ Spectroscopic and Reactivity Investigations

The absolute coverage of CO has been a missing piece in the mechanistic puzzle of the CO reduction reaction (CORR) on Cu. For the first time, we revealed the upper bound of the CO coverage under electrocatalytic conditions to be 0.05 monolayer at atmospheric pressure and the saturation CO coverage to be ∼0.25 monolayer by conducting surface enhanced infrared spectroscopy at CO pressures up to 60 barg in a custom-designed spectroelectrochemical cell. CORR activities on Cu were also determined in the same pressure range. Calculated reaction orders of C₂₊ products with respect to adsorbed CO are substantially less than unity, clearly indicating that the coupling of adsorbed CO is not the rate-determining step leading to multicarbon products. The increase in CO coverage can reduce the C affinity on the Cu surface and favor the selectivity towards oxygenates, especially acetate, over ethylene. Uncommon products, including ethane, glycolaldehyde, and ethylene glycol, were detected in appreciable amounts, likely due to a new C-C coupling mechanism taking place at elevated CO pressures.

A hybrid inorganic-biological artificial photosynthesis system for energy-efficient food production

Artificial photosynthesis systems are proposed as an efficient alternative route to capture CO₂ to produce additional food for growing global demand. Here a two-step CO₂ electrolyser system was developed to produce a highly concentrated acetate stream with a 57% carbon selectivity (CO₂ to acetate), allowing its direct use for the heterotrophic cultivation of yeast, mushroom-producing fungus and a photosynthetic green alga, in the dark without inputs from biological photosynthesis. An evaluation of nine crop plants found that carbon from exogenously supplied acetate incorporates into biomass through major metabolic pathways. Coupling this approach to existing photovoltaic systems could increase solar-to-food energy conversion efficiency by about fourfold over biological photosynthesis, reducing the solar footprint required. This technology allows for a reimagination of how food can be produced in controlled environments.

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

For the efficient electrochemical conversion of CO2 into valuable chemical feedstocks, a well-coordinated interaction of all electrolyzer compartments is required. In addition to the catalyst, whose role is described in detail in the part "Electrochemical CO2 Reduction toward Multicarbon Alcohols - The Microscopic World of Catalysts & Process Conditions" of this divided review, the general cell setups, design and manufacture of the electrodes, membranes used, and process parameters must be optimally matched. The authors' goal is to provide a comprehensive review of the current literature on how these aspects affect the overall performance of CO2 electrolysis. To be economically competitive as an overall process, the framework conditions, i.e., CO2 supply and reaction product treatment must also be considered. If the key indicators for current density, selectivity, cell voltage, and lifetime of a CO2 electrolyzer mentioned in the techno-economic consideration of this review are met, electrochemical CO2 reduction can make a valuable contribution to the creation of closed carbon cycles and to a sustainable energy economy.

Electrochemical Approaches for CO2 Conversion to Chemicals: A Journey toward Practical Applications

Carbon capture, utilization, and sequestration play an essential role to address CO₂ emissions. Among all carbon utilization technologies, CO₂ electroreduction has gained immense interest due to its potential for directly converting CO₂ to a variety of valuable commodity chemicals using clean, renewable electricity as the sole energy source. The research community has witnessed rapid advances in CO₂ electrolysis technology in recent years, including highly selective catalysts, larger-scale reactors, specific process modeling, as well as a mechanistic understanding of the CO₂ reduction reaction. The rapid advances in the field brings promise to the commercial application of the technology and the rapid rollout of the CO₂ electroreduction for chemical manufacturing.This Account focuses on our contributions in both fundamental and applied research in the field of electrocatalytic CO₂ and CO reduction reactions. We first discuss (1) the development of novel electrocatalysts for CO₂/CO electroreduction to enhance the product selectivity and lower the energy consumption. Specifically, we synthesized nanoporous Ag and homogeneously mixed Cu-based bimetallic catalysts for the enhanced production of CO from CO₂ and multicarbon products from CO, respectively. Then, we review our efforts in (2) the field of reactor engineering, including a dissolved CO₂ H-type cell, vapor-fed CO₂ three-compartment flow cell, and vapor-fed CO₂ membrane electrode assembly, for enhancing reaction rates and scalability. Next, we describe (3) the investigation of reaction mechanisms using in situ and operando techniques, such as surface-enhanced vibrational spectroscopies and electrochemical mass spectroscopy. We revealed the participation of bicarbonate in CO₂ electroreduction on Au using attenuated total-reflectance surface-enhanced infrared absorption spectroscopy, the presence of an "oxygenated" surface of Cu under CO electroreduction conditions using surface-enhanced Raman spectroscopy, and the origin of oxygen in acetaldehyde and other CO electroreduction products on Cu using flow electrolyzer mass spectrometry. Lastly, we examine (4) the commercial potential of the CO₂ electrolysis technology, such as understanding pollutant effects in CO₂ electroreduction and developing techno-economic analysis. Specifically, we discuss the effects of SO₂ and NO_x in CO₂ electroreduction using Cu, Ag, and Sn catalysts. We also identify technical barriers that need to be overcome and offer our perspective on accelerating the commercial deployment of the CO₂ electrolysis technology.

Transient Effects Caused by Gas Depletion during Carbon Dioxide Electroreduction

The novel use of carbon dioxide (CO₂) electroreduction to generate carbon-based products which do not contribute to the greenhouse effect has promoted the vision of carbon dioxide as a renewable feedstock for future clean fuel production. Depending on the material choice for the electrocatalysis, a certain variety of products is expected from the carbon dioxide reduction reaction (CO2RR). However, as the CO₂ concentration in areas close to the working electrode (relative to the diffusive boundary layer) decreases as it is being consumed and transformed into other products, the generation of H₂ is favored to the detriment of CO₂ electroreduction. Therefore, the extent to which H₂ is produced can be used as a metric to evaluate the efficiency of CO2RR. This article proposes a model that accounts for the modes in which aqueous gas depletion evolves over time and affects the long-term CO₂ electroreduction and the corresponding pH evolution near the electrode's surface. For the latter, two main contributions are distinguished: gas depletion due to CO₂ consumption and ion generation in areas close to the electrocatalyst surface. pH is then suggested as an accurate and indirect means to measure CO₂ concentration in a liquid electrolyte. We conclude that CO₂ depletion causes a strong decay in the electrochemical reaction efficiency. In the end, we discuss several methods which may delay the onset of the adverse effects caused by gas depletion, such as the utilization of pulsed electroreduction, cycling the applied current to electrodes on and off periodically.

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.

Recent Development of Electrocatalytic CO2 Reduction Application to Energy Conversion

Carbon dioxide (CO₂ ) emission has caused greenhouse gas pollution worldwide. Hence, strengthening CO₂ recycling is necessary. CO₂ electroreduction reaction (CRR) is recognized as a promising approach to utilize waste CO₂ . Electrocatalysts in the CRR process play a critical role in determining the selectivity and activity of CRR. Different types of electrocatalysts are introduced in this review: noble metals and their derived compounds, transition metals and their derived compounds, organic polymer, and carbon-based materials, as well as their major products, Faradaic efficiency, current density, and onset potential. Furthermore, this paper overviews the recent progress of the following two major applications of CRR according to the different energy conversion methods: electricity generation and formation of valuable carbonaceous products. Considering electricity generation devices, the electrochemical properties of metal-CO₂ batteries, including Li-CO₂ , Na-CO₂ , Al-CO₂ , and Zn-CO₂ batteries, are mainly summarized. Finally, different pathways of CO₂ electroreduction to carbon-based fuels is presented, and their reaction mechanisms are illustrated. This review provides a clear and innovative insight into the entire reaction process of CRR, guiding the new electrocatalysts design, state-of-the-art analysis technique application, and reaction system innovation.

Direct electrosynthesis of 52% concentrated CO on silver's twin boundary

The gaseous product concentration in direct electrochemical CO₂ reduction is usually hurdled by the electrode's Faradaic efficiency, current density, and inevitable mixing with the unreacted CO₂. A concentrated gaseous product with high purity will greatly lower the barrier for large-scale CO₂ fixation and follow-up industrial usage. Here, we developed a pneumatic trough setup to collect the CO₂ reduction product from a precisely engineered nanotwinned electrocatalyst, without using ion-exchange membrane. The silver catalyst's twin boundary density can be tuned from 0.3 to 1.5 × 10⁴ cm^-1. With the lengthy and winding twin boundaries, this catalyst exhibits a Faradaic efficiency up to 92% at -1.0 V and a turnover frequency of 127 s^-1 in converting CO₂ to CO. Through a tandem electrochemical-CVD system, we successfully produced CO with a volume percentage of up to 52%, and further transformed it into single layer graphene film.

An industrial perspective on catalysts for low-temperature CO2 electrolysis

Electrochemical conversion of CO₂ to useful products at temperatures below 100 °C is nearing the commercial scale. Pilot units for CO₂ conversion to CO are already being tested. Units to convert CO₂ to formic acid are projected to reach pilot scale in the next year. Further, several investigators are starting to observe industrially relevant rates of the electrochemical conversion of CO₂ to ethanol and ethylene, with the hydrogen needed coming from water. In each case, Faradaic efficiencies of 80% or more and current densities above 200 mA cm^-2 can be reproducibly achieved. Here we describe the key advances in nanocatalysts that lead to the impressive performance, indicate where additional work is needed and provide benchmarks that others can use to compare their results.

Electrochemical reduction of CO2 towards multi-carbon products via a two-step process

The two-step electroreduction of CO₂ to multi-carbon products with a high selectivity and production rate of industrial relevance provides an alternative route for converting CO₂ to fuels and chemicals.