Towards the Large-Scale Electrochemical Reduction of Carbon Dioxide

Catalyst Design and Engineering for CO2-to-Formic Acid Electrosynthesis for a Low-Carbon Economy

Formic acid (FA) has emerged as a promising candidate for hydrogen energy storage due to its favorable properties such as low toxicity, low flammability, and high volumetric hydrogen storage capacity under ambient conditions. Recent analyses have suggested that FA produced by electrochemical carbon dioxide (CO2) reduction reaction (eCO2RR) using low-carbon electricity exhibits lower fugitive hydrogen (H2) emissions and global warming potential (GWP) during the H2 carrier production, storage and transportation processes compared to those of other alternatives like methanol, methylcyclohexane, and ammonia. eCO2RR to FA can enable industrially relevant current densities without the need for high pressures, high temperatures, or auxiliary hydrogen sources. However, the widespread implementation of eCO2RR to FA is hindered by the requirement for highly stable and selective catalysts. Herein, the aim is to explore and evaluate the potential of catalyst engineering in designing stable and selective nanostructured catalysts that can facilitate economically viable production of FA.

Carbon black supported Ag nanoparticles in zero-gap CO2 electrolysis to CO enabling high mass activity

In this study Ag nanoparticles supported on carbon black (Ag/C) were studied as catalysts for the electrochemical reduction of CO₂ to CO. The nanoparticles were synthesized on three carbon supports, namely Super P, Vulcan and Ketjenblack with surface areas from 50 to 800 m² g^-1 using cysteamine as a linker as proposed by Kim et al., J. Am. Chem. Soc., 2015, 137, 13844. Gas diffusion electrodes were fabricated with all three Ag/Cs and then characterized in a zero-gap electrolyzer. All three supported catalysts achieve high voltage efficiencies, mass activities, and faradaic efficiencies above 80% up to 200 mA cm^-2 with Ag loadings of ∼0.07 mg cm^-2. Using an IrO₂ anode, a partial CO current density of 196 mA cm^-2 at 2.95 V and a mass activity of 3920 mA mg^-1 at a cell voltage of 3.2 V was achieved. When changing the electrolyte from 0.1 M KOH to 0.1 M CsOH, it is possible to achieve 90% FE_CO at 300 mA cm^-2. This results in a mass activity up to 5400 mA mg^-1. Moreover, long-term tests at 300 mA cm^-2 with 0.1 M CsOH resulted in FE_CO remaining above 80% over 11 h. The electrochemical performance did not show a dependence on the carbon support, indicating that mass transport is limiting the cathode, rather than catalyst kinetics. It is worth noting that this may only apply to electrodes with PTFE binders as used in this study, and electrodes with ionomer binders may show a dependence on the catalyst support.

Counter Electrode Reactions-Important Stumbling Blocks on the Way to a Working Electro-organic Synthesis

Over the past two decades, electro-organic synthesis has gained significant interest, both in technical and academic research as well as in terms of applications. The omission of stoichiometric oxidizers or reducing agents enables a more sustainable route for redox reactions in organic chemistry. Even if it is well-known that every electrochemical oxidation is only viable with an associated reduction reaction and vice versa, the relevance of the counter reaction is often less addressed. In this Review, the importance of the corresponding counter reaction in electro-organic synthesis is highlighted and how it can affect the performance and selectivity of the electrolytic conversion. A selection of common strategies and unique concepts to tackle this issue are surveyed to provide a guide to select appropriate counter reactions for electro-organic synthesis.

Recent Advances in Heterogeneous Electroreduction of CO2 on Copper-Based Catalysts

Facing greenhouse effects and the rapid exhaustion of fossil fuel, CO2 electrochemical reduction presents a promising method of environmental protection and energy transformation. Low onset potential, large current density, high faradaic efficiency (FE), and long-time stability are required for industrial production, due to economic costs and energy consumption. This minireview showcases the recent progress in catalyst design and engineering technology in CO2 reduction reaction (CO2RR) on copper based-catalysts. We focus on strategies optimizing the performance of copper-based catalysts, such as single-atom catalysts, doping, surface modification, crystal facet engineering, etc., and reactor design including gas diffusion layer, membrane electrode assembly, etc., in enhancing target electroreduction products including methane, methanol, ethylene, and C2+ oxygenates. The determination of the correlation and the developed technology might be helpful for future applications in the industry.

Scale up of reactors for carbon dioxide reduction

In recent times there has been a great deal of interest in the conversion of carbon dioxide into more useful chemical compounds. On the other hand, the translation of these developments in electrochemical reduction of carbon dioxide from the laboratory bench to practical scale remains an underexplored topic. Here we examine some of the major challenges, demonstrating some promising strategies towards such scale-up, including increased electrode area and stacking of electrode pairs in different configurations. We observed that increasing the electrode area from 1 to 10 cm2 led to only a 4% drop in current density, with similarly small penalties realised when stacking sub-cells together.

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

Continued advancements in the electrochemical reduction of CO₂ (CO₂RR) have emphasized that reactivity, selectivity, and stability are not explicit material properties but combined effects of the catalyst, double-layer, reaction environment, and system configuration. These realizations have steadily built upon the foundational work performed for a broad array of transition metals performed at 5 mA cm^-2, which historically guided the research field. To encompass the changing advancements and mindset within the research field, an updated baseline at elevated current densities could then be of value. Here we seek to re-characterize the activity, selectivity, and stability of the five most utilized transition metal catalysts for CO₂RR (Ag, Au, Pd, Sn, and Cu) at elevated reaction rates through electrochemical operation, physical characterization, and varied operating parameters to provide a renewed resource and point of comparison. As a basis, we have employed a common cell architecture, highly controlled catalyst layer morphologies and thicknesses, and fixed current densities. Through a dataset of 88 separate experiments, we provide comparisons between CO-producing catalysts (Ag, Au, and Pd), highlighting CO-limiting current densities on Au and Pd at 72 and 50 mA cm^-2, respectively. We further show the instability of Sn in highly alkaline environments, and the convergence of product selectivity at elevated current densities for a Cu catalyst in neutral and alkaline media. Lastly, we reflect upon the use and limits of reaction rates as a baseline metric by comparing catalytic selectivity at 10 versus 200 mA cm^-2. We hope the collective work provides a resource for researchers setting up CO₂RR experiments for the first time.

N-Graphene Sheet Stacks/Cu Electrocatalyst for CO2 Reduction to Ethylene

Renewable energy resources (wind, solar) are unpredictable, so it is wise to store the electricity they generate in an energy carrier X. Various PtX (power to useful energy-intensive raw material such as hydrogen, synthetic natural gas, fuel) applications have been proposed. At the heart of our work is widely used idea to convert residual CO2 from biogas plant into higher hydrocarbons using electricity from renewables (e.g., sun, wind, hydro). The specific goal is to produce ethylene-highly demanded hydrocarbon in plastics industry. The process itself is realised on electrocatalytic carbon/copper cathode which must be selective to reaction: 2CO2 + 12e− + 12H+→C2H4 + 4H2O. We propose a bottom-up approach to build catalyst from the smallest particles-graphene sheet stacks (GSS) coated with metallic copper nanocrystals. Composite GSS-Cu structure functions as a CO2 and proton absorber, facilitating hydrogenation and carbon–carbon coupling reactions on Cu-nanocluster/GSS for the formation of C2H4. In our design electrocatalytic electrode is made from nitrogen-doped graphene sheet stacks coated with copper nanostructures. The N-GSSitself can be drop-casted or electrophoretically incorporated onto the carbon paper and gas diffusion electrode. Electrochemical deposition method was recognized as successful and most promising to grow Cu nanocrystals on N-GSS incorporated in conducting carbon substrate. Gaseous products from CO2 electro-catalytic reformation on the cathode were investigated by mass-spectrometer but the electrode surface was analysed by SEM/EDS and XRD methods.

The Prospects of Clay Minerals from the Baltic States for Industrial-Scale Carbon Capture: A Review

Carbon capture is among the most sustainable strategies to limit carbon dioxide emissions, which account for a large share of human impact on climate change and ecosystem destruction. This growing threat calls for novel solutions to reduce emissions on an industrial level. Carbon capture by amorphous solids is among the most reasonable options as it requires less energy when compared to other techniques and has comparatively lower development and maintenance costs. In this respect, the method of carbon dioxide adsorption by solids can be used in the long-term and on an industrial scale. Furthermore, certain sorbents are reusable, which makes their use for carbon capture economically justified and acquisition of natural resources full and sustainable. Clay minerals, which are a universally available and versatile material, are amidst such sorbents. These materials are capable of interlayer and surface adsorption of carbon dioxide. In addition, their modification allows to improve carbon dioxide adsorption capabilities even more. The aim of the review is to discuss the prospective of the most widely available clay minerals in the Baltic States for large-scale carbon dioxide emission reduction and to suggest suitable approaches for clay modification to improve carbon dioxide adsorption capacity.

Application of Porous Materials for CO2 Reutilization: A Review

CO2 reutilization processes contribute to the mitigation of CO2 as a potent greenhouse gas (GHG) through reusing and converting it into economically valuable chemical products including methanol, dimethyl ether, and methane. Solar thermochemical conversion and photochemical and electrochemical CO2 reduction processes are emerging technologies in which solar energy is utilized to provide the energy required for the endothermic dissociation of CO2. Owing to the surface-dependent nature of these technologies, their performance is significantly reliant on the solid reactant/catalyst accessible surface area. Solid porous structures either entirely made from the catalyst or used as a support for coating the catalyst/solid reactants can increase the number of active reaction sites and, thus, the kinetics of CO2 reutilization reactions. This paper reviews the principles and application of porous materials for CO2 reutilization pathways in solar thermochemical, photochemical, and electrochemical reduction technologies. Then, the state of the development of each technology is critically reviewed and evaluated with the focus on the use of porous materials. Finally, the research needs and challenges are presented to further advance the implementation of porous materials in the CO2 reutilization processes and the commercialization of the aforementioned technologies.

Gas evolution in electrochemical flow cell reactors induces resistance gradients with consequences for the positioning of the reference electrode

With the transfer of the electrochemical CO₂-reduction from academic labs towards industrial application, one major factor is the increase in current density. This can be achieved via the usage of a gas diffusion electrode. It allows for electrochemical reactions at the three-phase boundary between gaseous CO₂, liquid electrolyte and electrocatalyst. Thus, current densities in commercially relevant magnitudes of 200 mA cm⁻² and beyond can be reached. However, when increasing the current density one faces a new set of challenges, unknown from low current experiments. Here, we address the issue of gas evolution causing a local increase in resistance and the impact on the operation of flow cells with gas diffusion electrodes. We set up a simple simulation model and compared the results with experiments on a real setup. As a result, the gas evolution's strong impact on current-, potential- and resistance-distributions along the flow axis can be described. Main consequence is that the positioning of the reference electrode has a significant effect on the locally measured IR-drop and thus on the measured or applied potential. Therefore, data from different setups must be compared with great care, especially with respect to the potentials, on which the cell is operated.

The gas evolution during electrolysis in flow cells results in inhomogeneous distributions of resistance, current and voltage along the flow axis.