Characterizing CO2 Reduction Catalysts on Gas Diffusion Electrodes: Comparing Activity, Selectivity, and Stability of Transition Metal Catalysts

Interrogation of Oxidative Pulsed Methods for the Stabilization of Copper Electrodes for CO2 Electrolysis

Using copper (Cu) as an electrocatalyst uniquely produces multicarbon products (C2+-products) during the CO2 reduction reaction (CO2RR). However, the CO2RR stability of Cu is presently 3 orders of magnitude shorter than required for commercial operation. One means of substantially increasing Cu catalyst lifetimes is through periodic oxidative processes, such as cathodic-anodic pulsing. Despite 100-fold improvements, these oxidative methods only delay, but do not circumvent, degradation. Here, we provide an interrogation of chemical and electrochemical Cu oxidative processes to identify the mechanistic processes leading to stable CO2RR through electrochemical and in situ Raman spectroscopy measurements. We first examine chemical oxidation using an open-circuit potential (OCP), identifying that copper oxidation is regulated by the transient behavior of the OCP curve and limited by the rate of the oxygen reduction reaction (ORR). Increasing O2 flux to the cathode subsequently increased ORR rates, both extending lifetimes and reducing "off" times by 3-fold. In a separate approach, the formation of Cu2O is achieved through electrochemical oxidation. Here, we establish the minimum electrode potentials required for fast Cu oxidation (-0.28 V vs Ag/AgCl, 1 M KHCO3) by accounting for transient local pH changes and tracking oxidation charge transfer. Lastly, we performed a stability test resulting in a 20-fold increase in stable ethylene production versus the continuous case, finding that spatial copper migration is slowed but not mitigated by oxidative pulsing approaches alone.

Scanning Bubble Electrochemical Microscopy: Mapping of Electrocatalytic Activity with Low-Solubility Reactants

Determining electrocatalytic activity for reactions that involve reactants with limited solubility presents a significant challenge due to the reduced mass-transport to the electrocatalyst surface. This limitation is seen in important reactions such as the oxygen reduction reaction, nitrogen reduction reaction, and carbon dioxide reduction reaction. We introduce a new approach, which we call scanning bubble electrochemical microscopy, to enable the detection and high-resolution mapping of electrocatalytic activity with low-solubility reactants at high mass-transport rates. Using a scanning probe approach, a dual-barreled nanopipette is used to precisely deliver the gas-phase reactant within micrometers of an electrocatalyst surface, which results in high mass-transport rates at the electrocatalyst surface directly under the probe. We demonstrate the scanning bubble electrochemical microscopy approach by mapping the oxygen reduction reaction on model platinum microelectrode surfaces. We anticipate that scanning bubble electrochemical microscopy will provide an effective tool for measuring the electrocatalytic activity of reactants that have limited solubility.

Nonconductive Metal Oxide Gas Diffusion Layer for Mitigating Electrowetting during CO2 Electrolysis

Gas diffusion electrodes (GDEs) are extensively used for high current density electrochemical CO2 electrolysis (ECO2R), enabled by significantly reducing mass transfer resistance of CO2 to the catalyst layer. Conventionally, these GDEs are based upon hydrophobic carbon-based gas-diffusion layers (GDLs) that facilitate the gas transport; however, these supports are prone to flood with electrolyte during electrolysis. This potential-induced flooding, known as electrowetting, is related to the inherent conductivity of carbon and limits the activity of ECO2R. To investigate the effect of electrical conductivity more carefully, a GDE is constructed based on a Cu mesh with a nonconductive microporous GDL applied to this substrate, the latter composed of a mixture of metal oxide and polytetrafluoroethylene. With alumina as the metal oxide, a stable operation is obtained at -200 mA cm-2 with 70% selectivity for ECO2R (with over half toward C2+ products) without flooding as observed by in situ microscopy. On the contrary, with a Vulcan carbon-based GDL, the initial activity is rapidly lost as severe flooding ensues. It is reasoned that electrowetting is averted by virtue of the nonconductive nature of alumina, providing a new perspective on alternative GDL compositions and their influence on ECO2R performance.

Low cost 3D printable flow reactors for electrochemistry

Transition to carbon neutrality requires the development of more sustainable pathways to synthesize the next generation of chemical building blocks. Electrochemistry is a promising pathway to achieve this goal, as it allows for the use of renewable energy to drive chemical transformations. While the electroreduction of carbon dioxide (CO2) and hydrogen evolution are attracting significant research interest, fundamental challenges exist in moving the research focus toward performing these reactions on scales relevant to industrial applications. To bridge this gap, we aim to facilitate researchers' access to flow reactors, which allow the characterization of electrochemical transformations under conditions closer to those deployed in the industry. Here, we provide a 3D-printable flow cell design (manufacturing cost < $5), which consists of several plates, offering a customizable alternative to commercially available flow reactors (cost > $6,000). The proposed design and detailed build instructions allow the performance of a wide variety of chemical reactions in flow, including gas and liquid phase electroreduction, electro(less)plating, and photoelectrochemical reactions, providing researchers with more flexibility and control over their experiments. By offering an accessible, low-cost reactor alternative, we reduce the barriers to performing research on sustainable electrochemistry, supporting the global efforts necessary to realize the paradigm shift in chemical manufacturing.

Stabilizing *CO2 Intermediates at the Acidic Interface using Molecularly Dispersed Cobalt Phthalocyanine as Catalysts for CO2 Reduction

CO2 electroreduction (CO2 R) operating in acidic media circumvents the problems of carbonate formation and CO2 crossover in neutral/alkaline electrolyzers. Alkali cations have been universally recognized as indispensable components for acidic CO2 R, while they cause the inevitable issue of salt precipitation. It is therefore desirable to realize alkali-cation-free CO2 R in pure acid. However, without alkali cations, stabilizing *CO2 intermediates by catalyst itself at the acidic interface poses as a challenge. Herein, we first demonstrate that a carbon nanotube-supported molecularly dispersed cobalt phthalocyanine (CoPc@CNT) catalyst provides the Co single-atom active site with energetically localized d states to strengthen the adsorbate-surface interactions, which stabilizes *CO2 intermediates at the acidic interface (pH=1). As a result, we realize CO2 conversion to CO in pure acid with a faradaic efficiency of 60 % at pH=2 in flow cell. Furthermore, CO2 is successfully converted in cation exchanged membrane-based electrode assembly with a faradaic efficiency of 73 %. For CoPc@CNT, acidic conditions also promote the intrinsic activity of CO2 R compared to alkaline conditions, since the potential-limiting step, *CO2 to *COOH, is pH-dependent. This work provides a new understanding for the stabilization of reaction intermediates and facilitates the designs of catalysts and devices for acidic CO2 R.

Synergistic effect of Ag decorated in-liquid plasma treated titanium dioxide catalyst for efficient electrocatalytic CO2 reduction application

Recently, the conversion of carbon dioxide (CO2) into a useful resource and its byproducts by electrocatalytic reduction has been studied. It is well known that CO2 can be selectively reduced by gold, lead, etc. supported on conductive carbon. However, the high pH in the vicinity of the electrode raises concerns about the catalyst and catalyst support degradation. Therefore, we considered that using chemically stable TiO2 (titanium dioxide) powder as an alternative to carbon. Surface treatment using in-liquid plasma was used to improve the electrochemical properties of TiO2. TiO2 maintained its particle shape and crystalline structure after in-liquid plasma treatment. Electrochemical properties were evaluated and the disappearance of Ti4+ and Ti3+ redox peaks derived from TiO2 and a decrease in hydrogen overvoltage were observed. The hydrogen overvoltage relationship suggested that tungsten coating or doping on a portion of the reduced TiO2 surface. Electrocatalytic CO2 reduction using the silver nanoparticle-supported in-liquid plasma treated TiO2 showed increased hydrogen production. In electrocatalytic CO2 reduction, the ratio of hydrogen to carbon monoxide gas is important. Therefore, in-liquid plasma treated TiO2 is useful for the electrocatalytic CO2 reduction application.

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.

Developing Catalysts Integrated in Gas-Diffusion Electrodes for CO2 Electrolyzers

ConspectusAs the demand for a carbon-neutral society grows rapidly, research on CO2 electrolysis has become very active. Many catalysts are reported for converting CO2 into value-added products by electrochemical reactions, which have to perform at high Faradaic and energy efficiency to become commercially viable. Various types of CO2 electrolyzers have been used in this effort, such as the H-cell, flow cell, and zero-gap membrane-electrode assembly (MEA) cell. H-cell studies are conducted with electrodes immersed in CO2-saturated electrolyte and have been used to elucidate reaction pathways and kinetic parameters of electrochemical CO2 reduction on many types of catalytic surfaces. From a transport phenomenological perspective, the low solubility and diffusion of CO2 to the electrode surface severely limit the maximum attainable current density, and this metric has been shown to have significant influence on the product spectrum. Flow and MEA cells provide a solution in the form of gas-diffusion electrodes (GDEs) that enable gaseous CO2 to closely reach the catalyst layer and yield record-high current densities. Because GDEs involve a complicated interface consisting of the catalyst surface, gaseous CO2, polymer overlayers, and liquid electrolyte, catalysts with high intrinsic activity might not show high performance in these GDE-based electrolyzers. Catalysts showing low overpotentials at low current densities may suffer from poor electron conductivity and mass transfer limitations at high current densities. Furthermore, the stability of the GDE-based catalysts is often compromised as CO2 electrolysis is pursued with high activity, most notoriously by electrolyte flooding.In this Account, we introduce recent examples where the electrocatalysts were integrated in GDEs, achieving high production rates. The performance of such systems is contingent on both GDE and cell design, and various parameters that affect the cell performance are discussed. Gaseous products, such as carbon monoxide, methane, and ethylene, and liquid products, such as formate and ethanol, have been mainly reported with high partial current density using the flow or MEA cells. Different strategies to this end are described, such as controlling microenvironments by the use of polymers mixed within the catalyst layer or the functionalization of catalyst surfaces with ligands to increase local concentrations of intermediates. Unique CO2 electrolyzer designs are also treated, including the incorporation of light-responsive plasmonic catalysts in the GDE, and combining the electrolyzer with a fermenter utilizing a microbial biocatalyst to synthesize complex multicarbon products. Basic conditions which the catalyst should satisfy to be adapted in the GDEs are listed, and our perspective is provided.

Advancing integrated CO2 electrochemical conversion with amine-based CO2 capture: a review

Carbon dioxide (CO₂) electrolysis is a promising route to utilise captured CO₂ as a building block to produce valuable feedstocks and fuels such as carbon monoxide and ethylene. Very recently, CO₂ electrolysis has been proposed as an alternative process to replace the amine recovery unit of the commercially available amine-based CO₂ capture process. This process would replace the most energy-intensive unit operation in amine scrubbing while providing a route for CO₂ conversion. The key enabler for such process integration is to develop an efficient integrated electrolyser that can convert CO₂ and recover the amine simultaneously. Herein, this review provides an overview of the fundamentals and recent progress in advancing integrated CO₂ conversion in amine-based capture media. This review first discusses the mechanisms for both CO₂ absorption in the capture medium and electrochemical conversion of the absorbed CO₂. We then summarise recent advances in improving the efficiency of integrated electrolysis via innovating electrodes, tailoring the local reaction environment, optimising operation conditions (e.g., temperatures and pressures), and modifying cell configurations. This review is concluded with future research directions for understanding and developing integrated CO₂ electrolysers.