Zero-Gap Bipolar Membrane Electrolyzer for Carbon Dioxide Reduction Using Acid-Tolerant Molecular Electrocatalysts

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.

Impact of the Surface Microenvironment on the Redox Properties of a Co-Based Molecular Cathode for Selective Aqueous Electrochemical CO2-to-CO Reduction

Electrode-confined molecular catalysts are promising systems to enable the efficient conversion of CO2 to useful products. Here, we describe the development of an original molecular cathode for CO2 reduction to CO based on the noncovalent integration of a tetraazamacrocyclic Co complex to a carbon nanotube-based matrix. Aqueous electrochemical characterization of the modified electrode allowed for clear observation of a change of redox behavior of the Co center as surface concentration was tuned, highlighting the impact of the catalyst microenvironment on its redox properties. The molecular cathode enabled efficient CO2-to-CO conversion in fully aqueous conditions, giving rise to a turnover number (TONCO) of up to 20 × 103 after 2 h of constant electrolysis at a mild overpotential (η = 450 mV) and with a faradaic efficiency for CO of about 95%. Post operando measurements using electrochemical techniques, inductively coupled plasma, X-ray photoelectron spectroscopy and X-ray absorption spectroscopy characterization of the films demonstrated that the catalysis remained of molecular nature, making this Co-based electrode a new promising alternative for molecular electrocatalytic conversion of CO2-to-CO in fully aqueous media.

Addressing the Carbonate Issue: Electrocatalysts for Acidic CO2 Reduction Reaction

Electrochemical CO2 reduction reaction (CO2RR) powered by renewable energy provides a promising route to CO2 conversion and utilization. However, the widely used neutral/alkaline electrolyte consumes a large amount of CO2 to produce (bi)carbonate byproducts, leading to significant challenges at the device level, thereby impeding the further deployment of this reaction. Conducting CO2RR in acidic electrolytes offers a promising solution to address the "carbonate issue"; however, it presents inherent difficulties due to the competitive hydrogen evolution reaction, necessitating concerted efforts toward advanced catalyst and electrode designs to achieve high selectivity and activity. This review encompasses recent developments of acidic CO2RR, from mechanism elucidation to catalyst design and device engineering. This review begins by discussing the mechanistic understanding of the reaction pathway, laying the foundation for catalyst design in acidic CO2RR. Subsequently, an in-depth analysis of recent advancements in acidic CO2RR catalysts is provided, highlighting heterogeneous catalysts, surface immobilized molecular catalysts, and catalyst surface enhancement. Furthermore, the progress made in device-level applications is summarized, aiming to develop high-performance acidic CO2RR systems. Finally, the existing challenges and future directions in the design of acidic CO2RR catalysts are outlined, emphasizing the need for improved selectivity, activity, stability, and scalability.

Backbone Engineering of Polymeric Catalysts for High-Performance CO2 Reduction in Bipolar Membrane Zero-Gap Electrolyzer

Bipolar membranes (BPMs) have emerged as a promising solution for mitigating CO2 losses, salt precipitation and high maintenance costs associated with the commonly used anion-exchange membrane electrode assembly for CO2 reduction reaction (CO2RR). However, the industrial implementation of BPM-based zero-gap electrolyzer is hampered by the poor CO2RR performance, largely attributed to the local acidic environment. Here, we report a backbone engineering strategy to improve the CO2RR performance of molecular catalysts in BPM-based zero-gap electrolyzers by covalently grafting cobalt tetraaminophthalocyanine onto a positively charged polyfluorene backbone (PF-CoTAPc). PF-CoTAPc shows a high acid tolerance in BPM electrode assembly (BPMEA), achieving a high FE of 82.6 % for CO at 100 mA/cm2 and a high CO2 utilization efficiency of 87.8 %. Notably, the CO2RR selectivity, carbon utilization efficiency and long-term stability of PF-CoTAPc in BPMEA outperform reported BPM systems. We attribute the enhancement to the stable cationic shield in the double layer and suppression of proton migration, ultimately inhibiting the undesired hydrogen evolution and improving the CO2RR selectivity. Techno-economic analysis shows the least energy consumption (957 kJ/mol) for the PF-CoTAPc catalyst in BPMEA. Our findings provide a viable strategy for designing efficient CO2RR catalysts in acidic environments.

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.

Connecting Biological and Synthetic Approaches for Electrocatalytic CO2 Reduction

Electrocatalytic CO2 reduction has developed into a broad field, spanning fundamental studies of enzymatic 'model' catalysts to synthetic molecular catalysts and heterogeneous gas diffusion electrodes producing commercially relevant quantities of product. This diversification has resulted in apparent differences and a disconnect between seemingly related approaches when using different types of catalysts. Enzymes possess discrete and well understood active sites that can perform reactions with high selectivity and activities at their thermodynamic limit. Synthetic small molecule catalysts can be designed with desired active site composition but do not yet display enzyme-like performance. These properties of the biological and small molecule catalysts contrast with heterogeneous materials, which can contain multiple, often poorly understood active sites with distinct reactivity and therefore introducing significant complexity in understanding their activities. As these systems are being better understood and the continuously improving performance of their heterogeneous active sites closes the gap with enzymatic activity, this performance difference between heterogeneous and enzymatic systems begins to close. This convergence removes the barriers between using different types of catalysts and future challenges can be addressed without multiple efforts as a unified picture for the biological-synthetic catalyst spectrum emerges.

Smart Electrode Surfaces by Electrolyte Immobilization for Electrocatalytic CO2 Conversion

The activity and selectivity of molecular catalysts for the electrochemical CO2 reduction reaction (CO2RR) are influenced by the induced electric field at the electrode/electrolyte interface. We present here a novel electrolyte immobilization method to control the electric field at this interface by positively charging the electrode surface with an imidazolium cation organic layer, which significantly favors CO2 conversion to formate, suppresses hydrogen evolution reaction, and diminishes the operating cell voltage. Those results are well supported by our previous DFT calculations studying the mechanistic role of imidazolium cations in solution for CO2 reduction to formate catalyzed by a model molecular catalyst. This smart electrode surface concept based on covalent grafting of imidazolium on a carbon electrode is successfully scaled up for operating at industrially relevant conditions (100 mA cm-2) on an imidazolium-modified carbon-based gas diffusion electrode using a flow cell configuration, where the CO2 conversion to formate process takes place in acidic aqueous solution to avoid carbonate formation and is catalyzed by a model molecular Rh complex in solution. The formate production rate reaches a maximum of 4.6 gHCOO- m-2 min-1 after accumulating a total of 9000 C of charge circulated on the same electrode. Constant formate production and no significant microscopic changes on the imidazolium-modified cathode in consecutive long-term CO2 electrolysis confirmed the high stability of the imidazolium organic layer under operating conditions for CO2RR.

Enrichment Strategies for Efficient CO2 Electroreduction in Acidic Electrolytes

Electrochemical CO2 reduction reaction (CO2 RR) has been recognized as an appealing route to remarkably accelerate the carbon-neutral cycle and reduce carbon emissions. Notwithstanding great catalytic activity that has been acquired in neutral and alkaline conditions, the carbonates generated from the inevitable reaction of the input CO2 with the hydroxide severely lower carbon utilization and energy efficiency. By contrast, CO2 RR in an acidic condition can effectively circumvent the carbonate issues; however, the activity and selectivity of CO2 RR in acidic electrolytes will be decreased significantly due to the competing hydrogen evolution reaction (HER). Enriching the CO2 and the key intermediates around the catalyst surface can promote the reaction rate and enhance the product selectivity, providing a promising way to boost the performance of CO2 RR. In this review, the catalytic mechanism and key technique challenges of CO2 RR are first introduced. Then, the critical progress of enrichment strategies for promoting the CO2 RR in the acidic electrolyte is summarized with three aspects: catalyst design, electrolyte regulation, and electrolyzer optimization. Finally, some insights and perspectives for further development of enrichment strategies in acidic CO2 RR are expounded.

Accurate assessment of electrocatalytic carbon dioxide reduction products at industrial-level current density

During the electrocatalytic CO2 reduction reaction, the faradaic efficiency of products seriously deviates from 100% due to the misjudgment of outlet flow, especially at industrial-level large current density. In this work, several modified equations and internal standard methods are recommended to calibrate the thermal mass flowmeter and establish benchmarks for CO2 reduction performance assessment.

A Bipolar Membrane-Integrated Electrochlorination Process for Highly Efficient Ammonium Removal in Mature Landfill Leachate: The Importance of ClO• Generation

Electrochemical oxidation has been demonstrated to be a useful method for removing biorefractory organic pollutants in mature landfill leachate but suffers from low efficiency in eliminating ammonium because of its resistance to being oxidized by HO• or free chlorine (FC) at decreased pH. Here, we propose a new bipolar membrane-electrochlorination (BPM-EC) process to address this issue. We found that the BPM-EC system was significantly superior to both the undivided and divided reactors with monopolar membranes in terms of elevated rate of ammonium removal, attenuated generation of byproducts (e.g., nitrate and chloramines), increased Faradaic efficiency, and decreased energy consumption. Mechanistic studies revealed that the integration of BPM was helpful in creating alkaline environments in the vicinity of the anode, which facilitated production of surface-bound HO• and FC and eventually promoted in situ generation of ClO•, a crucial reactive species mainly responsible for accelerating ammonium oxidation and selective transformation to nitrogen. The efficacy of BPM-EC in treating landfill leachates with different ammonium concentrations was verified under batch and continuous-flow conditions. A kinetic model that incorporates the key parameters was developed, which can successfully predict the optimal number of BPM-EC reactors (e.g., 2 and 5 for leachates containing 589.4 ± 5.5 and 1258.1 ± 9.6 mg L-1 NH4+-N, respectively) necessary for complete removal of ammonium. These findings reveal that the BPM-EC process shows promise in treating ammonium-containing wastewater, with advantages that include effectiveness, adaptability, and flexibility.

Microenvironment Regulation Strategies Facilitating High-Efficiency CO2 Electrolysis in a Zero-Gap Bipolar Membrane Electrolyzer

In alkaline and neutral zero-gap CO2 electrolyzers, the carbon utilization efficiency of the electrocatalytic CO2 reduction to CO is less than 50% because of inherently homogeneous reactions. Utilization of the bipolar membrane (BPM) electrolyzer can effectively suppress (bi)carbonate formation and parasitic CO2 losses; however, an excessive concentration of H+ in the catalyst layer (CL) significantly hinders the activity and selectivity for CO2 reduction. Here, we report a microenvironment regulation strategy that controls the CL thickness and ionomer content to regulate local CO2 transport and the local pH within the CL. We report 80% faradaic efficiency of CO at a current density of 400 mA/cm2 without the use of a buffering layer, exceeding that of state-of-the-art catalysts with a buffering layer. A carbon utilization efficiency of 63.6% at 400 mA/cm2 is also obtained. This study demonstrates the significance of regulating the microenvironment of the CL in a BPM system.

Enhanced performance of molecular electrocatalysts for CO2 reduction in a flow cell following K+ addition

Electrocatalytic CO2 reduction is a key aspect of artificial photosynthesis systems designed to produce fuels. Although some molecular catalysts have good performance for CO2 reduction, these compounds also suffer from poor durability and energy efficiency. The present work demonstrates the improved CO2 reduction activity exhibited by molecular catalysts in a flow cell. These catalysts were composed of a cobalt-tetrapyridino-porphyrazine complex supported on carbon black together with potassium salt and were both stable and efficient. These systems were found to promote electrocatalytic CO2 reduction with a current density of 100 mA/cm2 and generated CO over at least 1 week with a selectivity of approximately 95%. The optimal catalyst gave a turnover number of 3,800,000 and an energy conversion efficiency of more than 62% even at 200 mA/cm2.

CoNiFe alloy nanoparticles encapsulated into nitrogen-doped carbon nanotubes toward superior electrocatalytic overall water splitting in alkaline freshwater/seawater under large-current density

Developing bifunctional catalysts for overall water splitting with high activity and durability at high current density remains a challenge. In an attempt to overcome this bottleneck, in this work, unique CoNiFe-layered double hydroxide nanoflowers are in situ grown on nickel-iron (NiFe) foam through a corrosive approach and following a chemical vapor deposition process to generate nitrogen-doped carbon nanotubes at the presence of melamine (CoNiFe@NCNTs). The coupling effects between various metal species act a key role in accelerating the reaction kinetics. Moreover, the in situ formed NCNTs also favor promoting electrocatalytic activity and stability. For oxygen evolution reaction it requires low overpotentials of 330 and 341 mV in 1M KOH and 1M KOH + seawater to drive 500 mA cm-2. Moreover, water electrolysis can be operated with CoNiFe@NCNTs as both anode and cathode with small voltages of 1.95 and 1.93 V to achieve 500 mA cm-2 in 1M KOH and 1M KOH + seawater, respectively.

Combined Electrospinning-Electrospraying for High-Performance Bipolar Membranes with Incorporated MCM-41 as Water Dissociation Catalysts

Electrospinning has been demonstrated as a very promising method to create bipolar membranes (BPMs), especially as it allows three-dimensional (3D) junctions of entangled anion exchange and cation exchange nanofibers. These newly developed BPMs are relevant to demanding applications, including acid and base production, fuel cells, flow batteries, ammonia removal, concentration of carbon dioxide, and hydrogen generation. However, these applications require the introduction of catalysts into the BPM to allow accelerated water dissociation, and this remains a challenge. Here, we demonstrate a versatile strategy to produce very efficient BPMs through a combined electrospinning-electrospraying approach. Moreover, this work applies the newly investigated water dissociation catalyst of nanostructured silica MCM-41. Several BPMs were produced by electrospraying MCM-41 nanoparticles into the layers directly adjacent to the main BPM 3D junction. BPMs with various loadings of MCM-41 nanoparticles and BPMs with different catalyst positions relative to the junction were investigated. The membranes were carefully characterized for their structure and performance. Interestingly, the water dissociation performance of BPMs showed a clear optimal MCM-41 loading where the performance outpaced that of a commercial BPM, recording a transmembrane voltage of approximately 1.11 V at 1000 A/m2. Such an excellent performance is very relevant to fuel cell and flow battery applications, but our results also shed light on the exact function of the catalyst in this mode of operation. Overall, we demonstrate clearly that introducing a novel BPM architecture through a novel hybrid electrospinning-electrospraying method allows the uptake of promising new catalysts (i.e., MCM-41) and the production of very relevant BPMs.

Modular Solar-to-Fuel Electrolysis at Low Cell Potentials Enabled by Glycerol Electrooxidation and a Bipolar Membrane Separator

Solar fuel generation through water electrolysis or electrochemical CO2 reduction is thermodynamically limited when it is paired with oxygen evolution reaction (OER). Glycerol electrooxidation reaction (GEOR) is an alternative anodic reaction with lower anodic electrochemical potential that utilizes a renewable coproduct produced during biodiesel synthesis. We show that GEOR on an Au-Pt-Bi ternary metal electrocatalyst in a model alkaline crude glycerol solution can provide significant cell potential reductions even when paired to reduction reactions in seawater and acidic catholytes via a bipolar membrane (BPM). We showed that the combination of GEOR and a BPM separator lowers the total cell potential by 1 V at an electrolysis current of 10.0 mA cm-2 versus an anode performing anode's OER when paired with hydrogen evolution and CO2 reduction cathodes. The observed voltage reduction was steady for periods of up to 80 h, with minimal glycerol crossover observed through the membrane. These results motivate new, high-performance cell designs for photoelectrochemical solar fuel integrated systems based on glycerol electrooxidation.

Acidic CO2 Electrolysis Addressing the "Alkalinity Issue" and Achieving High CO2 Utilization

Electrochemical CO2 reduction reaction (CO2 RR) provides a promising approach for sustainable chemical fuel production of carbon neutrality. Neutral and alkaline electrolytes are predominantly employed in the current electrolysis system, but with striking drawbacks of (bi)carbonate (CO3 2- /HCO3 - ) formation and crossover due to the rapid and thermodynamically favourable reaction between hydroxide (OH- ) with CO2 , resulting in low carbon utilization efficiency and short-lived catalysis. Very recently, CO2 RR in acidic media can effectively address the (bi)carbonate issue; however, the competing hydrogen evolution reaction (HER) is more kinetically favourable in acidic electrolytes, which dramatically reduces CO2 conversion efficiency. Thus, it is a big challenge to effectively suppress HER and accelerate acidic CO2 RR. In this review, we begin by summarizing the recent progress of acidic CO2 electrolysis, discussing the key factors limiting the application of acidic electrolytes. We then systematically discuss addressing strategies for acidic CO2 electrolysis, including electrolyte microenvironment modulation, alkali cations adjusting, surface/interface functionalization, nanoconfinement structural design, and novel electrolyzer exploitation. Finally, the new challenges and perspectives of acidic CO2 electrolysis are suggested. We believe this timely review can arouse researchers' attention to CO2 crossover, inspire new insights to solve the "alkalinity problem" and enable CO2 RR as a more sustainable technology.

Integrated CO2 capture and electrochemical upgradation: the underpinning mechanism and techno-chemical analysis

Coupling post-combustion CO2 capture with electrochemical utilization (CCU) is a quantum leap in renewable energy science since it eliminates the cost and energy involved in the transport and storage of CO2. However, the major challenges involved in industrial scale implementation are selecting an appropriate solvent/electrolyte for CO2 capture, modeling an appropriate infrastructure by coupling an electrolyser with a CO2 point source and a separator to isolate CO2 reduction reaction (CO2RR) products, and finally selection of an appropriate electrocatalyst. In this review, we highlight the major difficulties with detailed mechanistic interpretation in each step, to find out the underpinning mechanism involved in the integration of electrochemical CCU to achieve higher-value products. In the past decades, most of the studies dealt with individual parts of the integration process, i.e., either selecting a solvent for CO2 capture, designing an electrocatalyst, or choosing an ideal electrolyte. In this context, it is important to note that solvents such as monoethanolamine, bicarbonate, and ionic liquids are often used as electrolytes in CO2 capture media. Therefore, it is essential to fabricate a cost-effective electrolyser that should function as a reversible binder with CO2 and an electron pool capable of recovering the solvent to electrolyte reversibly. For example, reversible ionic liquids, which are non-ionic in their normal forms, but produce ionic forms after CO2 capture, can be further reverted back to their original non-ionic forms after CO2 release with almost 100% efficiency through the chemical or thermal modulations. This review also sheds light on a focused techno-economic evolution for converting the electrochemically integrated CCU process from a pilot-scale project to industrial-scale implementation. In brief, this review article will summarize a state-of-the-art argumentation of challenges and outcomes over the different segments involved in electrochemically integrated CCU to stimulate urgent progress in the field.

Continuous ammonia electrosynthesis using physically interlocked bipolar membrane at 1000 mA cm-2

Electrosynthesis of ammonia from nitrate reduction receives extensive attention recently for its relatively mild conditions and clean energy requirements, while most existed electrochemical strategies can only deliver a low yield rate and short duration for the lack of stable ion exchange membranes at high current density. Here, a bipolar membrane nitrate reduction process is proposed to achieve ionic balance, and increasing water dissociation sites is delivered by constructing a three-dimensional physically interlocked interface for the bipolar membrane. This design simultaneously boosts ionic transfer and interfacial stability compared to traditional ones, successfully reducing transmembrane voltage to 1.13 V at up to current density of 1000 mA cm^-2. By combining a Co three-dimensional nanoarray cathode designed for large current and low concentration utilizations, a continuous and high yield bipolar membrane reactor for NH₃ electrosynthesis realized a stable electrolysis at 1000 mA cm^-2 for over 100 h, Faradaic efficiency of 86.2% and maximum yield rate of 68.4 mg h^-1 cm^-2 with merely 2000 ppm NO₃^- alkaline electrolyte. These results show promising potential for artificial nitrogen cycling in the near future.

Neutralization Short-Circuiting with Weak Electrolytes Erodes the Efficiency of Bipolar Membranes

Bipolar membranes (BPMs) are critical components of a variety of electrochemical energy technologies. Many electrochemical applications require the use of buffers to maintain stable, nonextreme pH environments, yet the impact of buffers or weak acids/bases on the electrochemical behavior of BPMs remains poorly understood. Our data for a cell containing weak electrolytes is consistent with internal pH gradients within the anion exchange membrane (AEM) or cation exchange membrane (CEM) component of the BPM that form via ionic short-circuiting processes at open-circuit. Short-circuiting results from the coupling of co-ion crossover and parasitic neutralization and leads to buffering of the bipolar interface. This phenomenon, which we term neutralization short-circuiting, serves to erode BPM efficiency by attenuating the open-circuit membrane voltage and introducing parasitic reverse bias currents associated with weak acid/base dissociation at the interface. These findings establish a mechanistic basis for the operation of BPM cells in the presence of weak acid/base electrolytes.

CO2 Electroreduction in Water with a Heterogenized C-Substituted Nickel Cyclam Catalyst

Molecular catalysis for selective CO₂ electroreduction into CO can be achieved with a variety of metal complexes. Their immobilization on cathodes is required for their practical implementation in electrolytic cells and can benefit from the advantages of a solid material such as easy separation of products and catalysts, efficient electron transfer to the catalyst, and high stability. However, this approach remains insufficiently explored up to now. Here, using an appropriate and original modification of the cyclam ligand, we report a novel [Ni(cyclam)]²⁺ complex which can be immobilized on carbon nanotubes. This material, once deposited on a gas diffusion layer, provides a novel electrode which is remarkably selective for CO₂ electroreduction to CO, not only in organic solvents but also, more remarkably, in water, with faradic efficiencies for CO larger than 90% and current densities of 5-10 mA cm^-2 during controlled potential electrolysis in H-cells.