Simulation‐based guidance for improving CO2 reduction on silver gas diffusion electrodes

Quantifying mass transport limitations in a microfluidic CO2 electrolyzer with a gas diffusion cathode

A gas diffusion electrode (GDE) based CO2 electrolyzer shows enhanced CO2 transport to the catalyst surface, significantly increasing current density compared to traditional planar immersed electrodes. A two-dimensional model for the cathode side of a microfluidic CO2 to CO electrolysis device with a GDE is developed. The model, validated against experimental data, examines key operational parameters and electrode materials. It predicts an initial rise in CO partial current density (PCD), peaking at 75 mA cm-2 at -1.3 V vs RHE for a fully flooded catalyst layer, then declining due to continuous decrease in CO2 availability near the catalyst surface. Factors like electrolyte flow rate and CO2 gas mass flow rate influence PCD, with a trade-off between high CO PCD and CO2 conversion efficiency observed with increased CO2 gas flow. We observe that a significant portion of the catalyst layer remains underutilized, and suggest improvements like varying electrode porosity and anisotropic layers to enhance mass transport and CO PCD. This research offers insights into optimizing CO2 electrolysis device performance.

Solar fuels design: Porous cathodes modeling for electrochemical carbon dioxide reduction in aqueous electrolytes

The reduction of carbon dioxide emissions is crucial to reduce the atmospheric greenhouse effect, fighting climate change and global warming. Electrochemical CO2 reduction is one of the most promising carbon capture and utilization technologies, that can be powered by solar energy and used to make added-value chemicals and green fuels, providing grid-stability, energy security, and environmental benefits. A two-dimensional finite-elements model for porous electrodes was developed and validated against experimental data, allowing the design and performance improvement of a porous zinc cathode morphology and its operational conditions for an electrolyzer producing syngas via the co-electrolysis of CO2 and water. Porosity, pore length, fiber geometric shape, inlet pressure, system temperature, and catholyte flow rate were explored, and these parameters were thoroughly tuned by using the smart-search Nelder-Mead's multi-parameter optimization algorithm to achieve pronouncedly higher, industrial-relevant current density values than those previously reported, up to 263.6 mA/cm2 at an applied potential of -1.1 V vs. RHE.

Techno-economic Assessment of CO2 Electrolysis: How Interdependencies between Model Variables Propagate Across Different Modeling Scales

The production of base chemicals by electrochemical conversion of captured CO₂ has the potential to close the carbon cycle, thereby contributing to a future energy transition. With the feasibility of low-temperature electrochemical CO₂ conversion demonstrated at lab scale, research is shifting toward optimizing electrolyser design and operation for industrial applications, with target values based on techno-economic analysis. However, current techno-economic analyses often neglect experimentally reported interdependencies of key performance variables such as the current density, the faradaic efficiency, and the conversion. Aiming to understand the impact of these interdependencies on the economic outlook, we develop a model capturing mass transfer effects over the channel length for an alkaline, membrane electrolyser. Coupling the channel scale with the higher level process scale and embedding this multiscale model in an economic framework allows us to analyze the economic trade-off between the performance variables. Our analysis shows that the derived target values for the performance variables strongly depend on the interdependencies described in the channel scale model. Our analysis also suggests that economically optimal current densities can be as low as half of the previously reported benchmarks. More generally, our work highlights the need to move toward multiscale models, especially in the field of CO₂ electrolysis, to effectively elucidate current bottlenecks in the quest toward economically compelling system designs.

Nanoscale Hydrophobicity and Electrochemical Mapping Provides Insights into Facet Dependent Silver Nanoparticle Dissolution

Metal or metallic nanoparticle dissolution influences particle stability, reactivity, potential fate, and transport. This work investigated the dissolution behavior of silver nanoparticles (Ag NPs) in three different shapes (nanocube, nanorod, and octahedron). The hydrophobicity and electrochemical activity at the local surfaces of Ag NPs were both examined using atomic force microscopy (AFM) coupled with scanning electrochemical microscopy (AFM-SECM). The surface electrochemical activity of Ag NPs more significantly affected the dissolution than the local surface hydrophobicity did. Octahedron Ag NPs with dominant surface exposed facets of {111} dissolved faster than the other two kinds of Ag NPs. Density functional theory (DFT) calculation revealed that the {100} facet elicited greater affinities toward H₂O than the {111} facet. Thus, poly(vinylpyrrolidone) or PVP coating on the {100} facet is critical for stabilizing and prevent the {100} facet from dissolution. Finally, COMSOL simulations demonstrated consistent shape dependent dissolution as we observed experimentally.

Micromodel of a Gas Diffusion Electrode Tracks In-Operando Pore-Scale Wetting Phenomena

Utilizing carbon dioxide (CO₂ ) as a resource for carbon monoxide (CO) production using renewable energy requires electrochemical reactors with gas diffusion electrodes that maintain a stable and highly reactive gas/liquid/solid interface. Very little is known about the reasons why gas diffusion electrodes suffer from unstable long-term operation. Often, this is associated with flooding of the gas diffusion electrode (GDE) within a few hours of operation. A better understanding of parameters influencing the phase behavior at the electrolyte/electrode/gas interface is necessary to increase the durability of GDEs. In this work, a microfluidic structure with multi-scale porosity featuring heterogeneous surface wettability to realistically represent the behavior of conventional GDEs is presented. A gas/liquid/solid phase boundary was established within a conductive, highly porous structure comprising a silver catalyst and Nafion binder. Inoperando visualization of wetting phenomena was performed using confocal laser scanning microscopy (CLSM). Non-reversible wetting, wetting of hierarchically porous structures and electrowetting were observed and analyzed. Fluorescence lifetime imaging microscopy (FLIM) enabled the observation of reactions on the model electrode surface. The presented methodology enables the systematic evaluation of spatio-temporally evolving wetting phenomena as well as species characterization for novel catalyst materials under realistic GDE configurations and process parameters.