The effect of flue gas contaminants on the CO2 electroreduction to formic acid

Reaction Environment Regulation for Electrocatalytic CO2 Reduction in Acids

The electrocatalytic CO2 reduction reaction (CO2RR) is a sustainable route for converting CO2 into value-added fuels and feedstocks, advancing a carbon-neutral economy. The electrolyte critically influences CO2 utilization, reaction rate and product selectivity. While typically conducted in neutral/alkaline aqueous electrolytes, the CO2RR faces challenges due to (bi)carbonate formation and its crossover to the anolyte, reducing efficiency and stability. Acidic media offer promise by suppressing these processes, but the low Faradaic efficiency, especially for multicarbon (C2+) products, and poor electrocatalyst stability persist. The effective regulation of the reaction environment at the cathode is essential to favor the CO2RR over the competitive hydrogen evolution reaction (HER) and improve long-term stability. This review examines progress in the acidic CO2RR, focusing on reaction environment regulation strategies such as electrocatalyst design, electrode modification and electrolyte engineering to promote the CO2RR. Insights into the reaction mechanisms via in situ/operando techniques and theoretical calculations are discussed, along with critical challenges and future directions in acidic CO2RR technology, offering guidance for developing practical systems for the carbon-neutral community.

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.

Oxygen-Resistant CO2 Reduction Enabled by Electrolysis of Liquid Feedstocks

Electrolytic CO2 reduction fails in the presence of O2. This failure occurs because the reduction of O2 is thermodynamically favored over the reduction of CO2. Consequently, O2 must be removed from the CO2 feed prior to entering an electrolyzer, which is expensive. Here, we show that the use of liquid bicarbonate feedstocks (e.g., aqueous 3.0 M KHCO3), rather than gaseous CO2 feedstocks, enables efficient and selective CO2 reduction without additional procedures for removing O2. This effect is made possible because liquid bicarbonate solutions, which serve as a liquid CO2 carrier, deliver high concentrations of captured CO2 to the cathode, while the low solubility of O2 in aqueous media maintains a low O2 concentration at the same cathode surface. Consequently, electrolyzers fed with liquid bicarbonate feedstocks create an environment at the cathode that favors the reduction of CO2 over O2. We validate this claim by electrochemically converting CO2 into CO with reaction selectivities of 65% at 100 mA cm-2 using a 3.0 M KHCO3 solution bubbled with 100% CO2 or 100% O2. Similar experiments performed with a gaseous CO2 feedstock showed that merely 0.5% of O2 in the feedstock reduced CO selectivity by >90% after 1 h of electrolysis. Our findings demonstrate that a liquid bicarbonate feedstock enables efficient CO2 reduction without the need for expensive O2 removal steps.

Investigation of the Mechanisms of CO2/O2 Adsorption Selectivity on Carbon Materials Enhanced by Oxygen Functional Groups

Power plant flue gas and industrial waste gas are produced in large quantities. Using these as feedstocks for CO2 electroreduction has important practical significance for the treatment of excessive CO2 emissions. However, O2 in such sources strongly inhibits the electrochemical conversion of CO2. The inhibitory effect of O2 can be mitigated by constructing CO2-enriched regions on the surface of the cathode. In this study, the reaction zone was controlled by the selective adsorption of CO2 on oxygen-functionalized carbon materials. The results of quantum chemical simulations showed that CO2 adsorption was mainly influenced by electrostatic interactions, whereas O2 adsorption was completely regulated by dispersion interactions. This distinction indicated that introducing polar oxygen functional groups at the edge of the carbon plane can significantly enhance the selectivity for CO2/O2 adsorption. The difference in the adsorption energy between CO2 and O2 increased most noticeably after the carboxyl groups were introduced. The results of the adsorption experiments showed that oxygen-functionalization increased the CO2/O2 selectivity of the carbon material under an atmosphere of multicomponent gases by more than 4.9 times. The carboxyl groups played a dominant role. Our findings might act as a reference for the selective adsorption of polar molecules over nonpolar molecules.

Recent Progress on Electrode Design for Efficient Electrochemical Valorisation of CO2 , O2 , and N2

CO2 reduction, two-electron O2 reduction, and N2 reduction are sustainable technologies to valorise common molecules. Their further development requires working electrode design to promote the multistep electrochemical processes from gas reactants to value-added products at the device level. This review proposes critical features of a desirable electrode based on the fundamental electrochemical processes and the development of scalable devices. A detailed discussion is made to approach such a desirable electrode, addressing the recent progress on critical electrode components, assembly strategies, and reaction interface engineering. Further, we highlight the electrode design tailored to reaction properties (e.g., its thermodynamics and kinetics) for performance optimisation. Finally, the opportunities and remaining challenges are presented, providing a framework for rational electrode design to push these gas reduction reactions towards an improved technology readiness level (TRL).

An Efficient Strategy for Electroreduction Reactor Outlet Fractioning into Valuable Products

In this work, two industrial dual-step pressure swing adsorption (PSA) processes were designed and simulated to obtain high-purity methane, CO₂, and syngas from a gas effluent of a CO₂ electroreduction reactor using different design configurations. Among the set of zeolites that was investigated using Monte Carlo and molecular dynamics simulations, NaX and MFI were the ones selected. The dual-PSA process for case study 1 is only capable of achieving a 90.5% methane purity with a 95.2% recovery. As for case study 2, methane is obtained with a 97.5% purity and 95.3% recovery. Both case studies can produce CO₂ with high purity and recovery (>97 and 95%, respectively) and syngas with a H₂/CO ratio above 4. Although case study 2 allows methane to be used as domestic gas, a much higher value for its energy consumption is observed compared to case study 1 (64.9 vs 29.8 W h mol_CH4^-1).

Electrochemical CO2 Reduction in the Presence of Impurities: Influences and Mitigation Strategies

The electrochemical conversion of waste CO₂ into useful fuels and chemical products is a promising approach to reduce CO₂ emissions; however, several challenges still remain to be addressed. Thus far, most CO₂ reduction studies use pure CO₂ as the gas reactant, but CO₂ emissions typically contain a number of gas impurities, such as nitrogen oxides, oxygen gas, and sulfur oxides. Gas impurities in CO₂ can pose a significant obstacle for efficient CO₂ electrolysis because they can influence the reaction and catalyst. This Minireview highlights early examples of CO₂ reduction studies using mixed-gas feeds, explores strategies to sustain CO₂ reduction in the presence of gas impurities, and discusses their implications for future progress in this emerging field.