Gortex-Based Gas Diffusion Electrodes with Unprecedented Resistance to Flooding and Leaking

Scale-Up of PTFE-Based Gas Diffusion Electrodes Using an Electrolyte-Integrated Polymer-Coated Current Collector Approach

Nonconductive porous polymer substrates, such as PTFE, have been pivotal in the fabrication of stable and high-performing gas diffusion electrodes (GDEs) for the reduction of CO2/CO in small scale electrolyzers; however, the scale-up of polymer-based GDEs without performance penalties to technologically more relevant electrode sizes has remained elusive. This work reports on a new current collector concept that enables the scale-up of PTFE-based GDEs from 5 to 100 cm2 and beyond. The present approach builds on a multifunctional current collector concept that enables multipoint front-contacting of thin catalyst coatings, which mitigates performance losses even for high resistivity cathodes. Our improved current collector design concomitantly incorporates a flow-field functionality in a monopolar plate configuration, keeping electrolyte gaps small for increased performance. Experiments with 100 cm2 cathodes were conducted in a one-gap alkaline AEM and acid CEM system. Our design represents an important step forward in the development of larger-size CO2 electrolyzers.

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).

Electrocatalytic Oxygen Reduction to Produce Hydrogen Peroxide: Rational Design from Single-Atom Catalysts to Devices

Electrocatalytic production of hydrogen peroxide (H2O2) via the 2e- transfer route of the oxygen reduction reaction (ORR) offers a promising alternative to the energy-intensive anthraquinone process, which dominates current industrial-scale production of H2O2. The availability of cost-effective electrocatalysts exhibiting high activity, selectivity, and stability is imperative for the practical deployment of this process. Single-atom catalysts (SACs) featuring the characteristics of both homogeneous and heterogeneous catalysts are particularly well suited for H2O2 synthesis and thus, have been intensively investigated in the last few years. Herein, we present an in-depth review of the current trends for designing SACs for H2O2 production via the 2e- ORR route. We start from the electronic and geometric structures of SACs. Then, strategies for regulating these isolated metal sites and their coordination environments are presented in detail, since these fundamentally determine electrocatalytic performance. Subsequently, correlations between electronic structures and electrocatalytic performance of the materials are discussed. Furthermore, the factors that potentially impact the performance of SACs in H2O2 production are summarized. Finally, the challenges and opportunities for rational design of more targeted H2O2-producing SACs are highlighted. We hope this review will present the latest developments in this area and shed light on the design of advanced materials for electrochemical energy conversion.

Graphical abstract

Effects of the Catalyst Dynamic Changes and Influence of the Reaction Environment on the Performance of Electrochemical CO2 Reduction

Electrochemical reduction of carbon dioxide (CO₂ ) is substantially researched due to its potential for storing intermittent renewable electricity and simultaneously helping mitigating the pressing CO₂ emission concerns. The major challenge of electrochemical CO₂ reduction lies on having good controls of this reaction due to its complicated reaction networks and its unusual sensitivity to the dynamic changes of the catalyst structure (chemical states, compositions, facets and morphology, etc.), and to the non-catalyst components at the electrode/electrolyte interface, in another word the reaction environments. To date, a comprehensive analysis on the interplays between the above catalyst-dynamic-changes/reaction environments and the CO₂ reduction performance is rare, if not none. In this review, the catalyst dynamic changes observed during the catalysis are discussed based on the recent reports of electrochemical CO₂ reduction. Then, the above dynamic changes are correlated to their effects on the catalytic performance. The influences of the reaction environments on the performance of CO₂ reduction are also discussed. Finally, some perspectives on future investigations are offered with the aim of understanding the origins of the effects from the catalyst dynamic changes and the reaction environments, which will allow one to better control the CO₂ reduction toward the desired products.

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.