Sn nanoparticles on gas diffusion electrodes: Synthesis, characterization and use for continuous CO 2 electroreduction to formate

Spherical Bi2O3/ATO catalyst with N2 pre-reduction electrocatalytic reduction of CO2 to formic acid

Bi2O3 catalyst with Bi-O bond crystal structure has more active sites, which shows better CO2 catalytic performance than pure Bi catalysts in many catalytic reactions. How to strengthen the Bi-O bond in Bi2O3 to obtain higher selectivity and catalytic activity is a problem worthy of consideration. Here, we develop a N2 pre-reduced spherical Bi2O3/ATO catalyst that has a high formate Faradaic efficiency of 92.7%, which is superior to the existing tin oxide catalyst. Detailed electrocatalytic analysis shows that N2 pre-reduction and spherical structure are helpful for Sn to stabilize the oxidation state of Bi, thus retaining part of the Bi-O structure. The existence of the Bi-O structure can reduce the energy barrier of the CO2 production *OCHO reaction and promote the reaction rate of the CO2-*OCHO-HCOOH path, thus promoting the formation of formate.

Coverage enhancement accelerates acidic CO2 electrolysis at ampere-level current with high energy and carbon efficiencies

Acidic CO2 electroreduction (CO2R) using renewable electricity holds promise for high-efficiency generation of storable liquid chemicals with up to 100% CO2 utilization. However, the strong parasitic hydrogen evolution reaction (HER) limits its selectivity and energy efficiency (EE), especially at ampere-level current densities. Here we present that enhancing CO2R intermediate coverage on catalysts promotes CO2R and concurrently suppresses HER. We identified and engineered robust Cu6Sn5 catalysts with strong *OCHO affinity and weak *H binding, achieving 91% Faradaic efficiency (FE) for formic acid (FA) production at 1.2 A cm-2 and pH 1. Notably, the single-pass carbon efficiency reaches a new benchmark of 77.4% at 0.5 A cm-2 over 300 hours. In situ electrochemical Fourier-transform infrared spectroscopy revealed Cu6Sn5 enhances *OCHO coverage ~2.8× compared to Sn at pH 1. Using a cation-free, solid-state-electrolyte-based membrane-electrode-assembly, we produce 0.36 M pure FA at 88% FE over 130 hours with a marked full-cell EE of 37%.

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.

A scalable membrane electrode assembly architecture for efficient electrochemical conversion of CO2 to formic acid

The electrochemical reduction of carbon dioxide to formic acid is a promising pathway to improve CO2 utilization and has potential applications as a hydrogen storage medium. In this work, a zero-gap membrane electrode assembly architecture is developed for the direct electrochemical synthesis of formic acid from carbon dioxide. The key technological advancement is a perforated cation exchange membrane, which, when utilized in a forward bias bipolar membrane configuration, allows formic acid generated at the membrane interface to exit through the anode flow field at concentrations up to 0.25 M. Having no additional interlayer components between the anode and cathode this concept is positioned to leverage currently available materials and stack designs ubiquitous in fuel cell and H2 electrolysis, enabling a more rapid transition to scale and commercialization. The perforated cation exchange membrane configuration can achieve >75% Faradaic efficiency to formic acid at <2 V and 300 mA/cm2 in a 25 cm2 cell. More critically, a 55-hour stability test at 200 mA/cm2 shows stable Faradaic efficiency and cell voltage. Technoeconomic analysis is utilized to illustrate a path towards achieving cost parity with current formic acid production methods.

Effects of Iron Species on Low Temperature CO2 Electrolyzers

Electrochemical energy conversion devices are considered key in reducing CO2 emissions and significant efforts are being applied to accelerate device development. Unlike other technologies, low temperature electrolyzers have the ability to directly convert CO2 into a range of value-added chemicals. To make them commercially viable, however, device efficiency and durability must be increased. Although their design is similar to more mature water electrolyzers and fuel cells, new cell concepts and components are needed. Due to the complexity of the system, singular component optimization is common. As a result, the component interplay is often overlooked. The influence of Fe-species clearly shows that the cell must be considered holistically during optimization, to avoid future issues due to component interference or cross-contamination. Fe-impurities are ubiquitous, and their influence on single components is well-researched. The activity of non-noble anodes has been increased through the deliberate addition of iron. At the same time, however, Fe-species accelerate cathode and membrane degradation. Here, we interpret literature on single components to gain an understanding of how Fe-species influence low temperature CO2 electrolyzers holistically. The role of Fe-species serves to highlight the need for considerations regarding component interplay in general.

Production of Gas Diffusion Layers with Tunable Characteristics

Gas diffusion electrodes (GDEs) allow electrochemical reactions to occur at higher rates by enhancing the mass transport of gaseous reactants to the catalyst. These electrodes are made of two layers: the catalyst layer and the gas diffusion layer (GDL). The catalyst layer is frequently studied for gas diffusion electrodes, and the GDL is rarely a focus. Consequently, no studies investigate interaction effects that may be present between these two layers. To study such interactions, it must be possible to obtain GDLs with various characteristics. This study uses a design of experiments to understand how multiple factors in the production method for GDLs can be adjusted to tune the characteristics of the GDL. These GDLs are particularly intended for the electrochemical reduction of CO₂. The conductance through the GDL, surface conductivity, thickness, elasticity, hydrophobicity, and porosity are measured for the 26 synthesized electrodes, and the top influential production factors are identified for each characteristic.

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.

Electro-Conversion of Carbon Dioxide to Valuable Chemicals in a Membrane Electrode Assembly

Electro-conversion of carbon dioxide (CO2) into valuable chemicals is an efficient method to deal with excessive CO2 in the atmosphere. However, undesirable CO2 reaction kinetics in the bulk solution strongly limit current density, and thus it is incompetent in market promotion. Flow cell technology provides an insight into uplifting current density. As an efficient flow cell configuration, membrane electrode assembly (MEA) has been proposed and proven as a viable technology for scalable CO2 electro-conversion, promoting current density to several hundred mA/cm2. In this review, we systematically reviewed recent perspectives and methods to put forward the utilization of state-of-the-art MEA to convert CO2 into valuable chemicals. Configuration design, catalysts nature, and flow media were discussed. At the end of this review, we also presented the current challenges and the potential directions for potent MEA design. We hope this review could offer some clear, timely, and valuable insights on the development of MEA for using wastewater-produced CO2.

Anode Catalysts in CO2 Electrolysis: Challenges and Untapped Opportunities

The field of electrochemical carbon dioxide reduction has developed rapidly during recent years. At the same time, the role of the anodic half-reaction has received considerably less attention. In this Perspective, we scrutinize the reports on the best-performing CO2 electrolyzer cells from the past 5 years, to shed light on the role of the anodic oxygen evolution catalyst. We analyze how different cell architectures provide different local chemical environments at the anode surface, which in turn determines the pool of applicable anode catalysts. We uncover the factors that led to either a strikingly high current density operation or an exceptionally long lifetime. On the basis of our analysis, we provide a set of criteria that have to be fulfilled by an anode catalyst to achieve high performance. Finally, we provide an outlook on using alternative anode reactions (alcohol oxidation is discussed as an example), resulting in high-value products and higher energy efficiency for the overall process.

The inchoate horizon of electrolyzer designs, membranes and catalysts towards highly efficient electrochemical reduction of CO2 to formic acid

This review explores the recent advances in CO2 reactor configurations, components, membranes and electrocatalysts for HCOOH generation and draw readers attention to construct the economic, scalable and energy efficient CO2R electrolyzers.

Immobilization of formate dehydrogenase in metal organic frameworks for enhanced conversion of carbon dioxide to formate

Hydrogenation of carbon dioxide (CO₂) to formic acid by the enzyme formate dehydrogenase (FDH) is a promising technology for reducing CO₂ concentrations in an environmentally friendly manner. However, the easy separation of FDH with enhanced stability and reusability is essential to the practical and economical implementation of the process. To achieve this, the enzyme must be used in an immobilized form. However, conventional immobilization by physical adsorption is prone to leaching, resulting in low stability. Although other immobilization methods (such as chemical adsorption) enhance stability, they generally result in low activity. In addition, mass transfer limitations are a major problem with most conventional immobilized enzymes. In this review paper, the effectiveness of metal organic frameworks (MOFs) is assessed as a promising alternative support for FDH immobilization. Kinetic mechanisms and stability of wild FDH from various sources were assessed and compared to those of cloned and genetically modified FDH. Various techniques for the synthesis of MOFs and different immobilization strategies are presented, with special emphasis on in situ and post synthetic immobilization of FDH in MOFs for CO₂ hydrogenation.

Unveiling the effects of dimensionality of tin oxide-derived catalysts on CO2 reduction by using gas-diffusion electrodes

Catalyst dimensionality is essential for the reactivity and selectivity of gas-diffusion electrodes for CO₂ electrochemical reduction to produce formate.

Electrochemical conversion of pressurized CO2 at simple silver-based cathodes in undivided cells: study of the effect of pressure and other operative parameters

Abstract

Electrochemical reduction of pressurized CO2 is proposed as an interesting approach to overcome the main hurdle of the CO2 electrochemical conversion in aqueous solution, its low solubility (ca. 0.033 M), and to achieve good faradaic efficiency in CO using simple sheet silver cathodes and undivided cells, thus lowering the overall costs of the process. The effect on the process of CO2 pressure (1–30 bar), current density, nature of the supporting electrolyte and other operative conditions, such as the surface of the cathode or the mixing rate, was studied to enhance the production of CO. It was shown that pressurized conditions allow to improve drastically the current efficiency of CO (CECO). Furthermore, at relatively high pressure (20 bars), the utilization of simple sheet silver cathodes and silver electrodes with high surfaces gave similar CECO. The stability of the system was monitored for 10 h; it was shown that at a relatively high pressure (15 bar) in aqueous electrolyte of KOH using a simple plate silver cathode a constant current efficiency of CO close to 70% was obtained.

Graphic abstract

Continuous Electrochemical Reduction of CO2 to Formate: Comparative Study of the Influence of the Electrode Configuration with Sn and Bi-Based Electrocatalysts

Climate change has become one of the most important challenges in the 21st century, and the electroreduction of CO2 to value-added products has gained increasing importance in recent years. In this context, formic acid or formate are interesting products because they could be used as raw materials in several industries as well as promising fuels in fuel cells. Despite the great number of studies published in the field of the electrocatalytic reduction of CO2 to formic acid/formate working with electrocatalysts of different nature and electrode configurations, few of them are focused on the comparison of different electrocatalyst materials and electrode configurations. Therefore, this work aims at presenting a rigorous and comprehensive comparative assessment of different experimental data previously published after many years of research in different working electrode configurations and electrocatalysts in a continuous mode with a single pass of the inputs through the reactor. Thus, the behavior of the CO2 electroreduction to formate is compared operating with Sn and Bi-based materials under Gas Diffusion Electrodes (GDEs) and Catalyst Coated Membrane Electrodes (CCMEs) configurations. Considering the same electrocatalyst, the use of CCMEs improves the performance in terms of formate concentration and energy consumption. Nevertheless, higher formate rates can be achieved with GDEs because they allow operation at higher current densities of up to 300 mA·cm-2. Bi-based-GDEs outperformed Sn-GDEs in all the figures of merit considered. The comparison also highlights that in CCME configuration, the employ of Bi-based-electrodes enhanced the behavior of the process, increasing the formate concentration by 35% and the Faradaic efficiency by 11%.

Recent Advances in the Catalyst Design and Mass Transport Control for the Electrochemical Reduction of Carbon Dioxide to Formate

Closing the carbon cycle by the electrochemical reduction of CO2 to formic acid and other high-value chemicals is a promising strategy to mitigate rapid climate change. The main barriers to commercializing a CO2 reduction reaction (CO2RR) system for formate production are the chemical inertness, low aqueous solubility, and slow mass transport characteristics of CO2, along with the low selectivity and high overpotential observed in formate production via CO2 reduction. To address those problems, we first explain the possible reaction mechanisms of CO2RRs to formate, and then we present and discuss several strategies to overcome the barriers to commercialization. The electronic structure of the catalyst can be tuned to favor a specific intermediate by adjusting the catalyst composition and tailoring the facets, edges, and corners of the catalyst to better expose the active sites, which has primarily led to increased catalytic activity and selectivity. Controlling the local pH, employing a high-pressure reactor, and using systems with three-phase boundaries can tune the mass transport properties of reactants at the catalyst surface. The reported electrocatalytic performances are summarized afterward to provide insight into which strategies have critical effects on the production of formate.

Fundamentals of Gas Diffusion Electrodes and Electrolysers for Carbon Dioxide Utilisation: Challenges and Opportunities

Electrocatalysis plays a prominent role in the development of carbon dioxide utilisation technologies. Many new and improved CO2 conversion catalysts have been developed in recent years, progressively achieving better performance. However, within this flourishing field, a disconnect in catalyst performance evaluation has emerged as the Achilles heel of CO2 electrolysis. Too often, catalysts are assessed in electrochemical settings that are far removed from industrially relevant operational conditions, where CO2 mass transport limitations should be minimised. To overcome this issue, gas diffusion electrodes and gas-fed electrolysers need to be developed and applied, presenting new challenges and opportunities to the CO2 electrolysis community. In this review, we introduce the reader to the fundamentals of gas diffusion electrodes and gas-fed electrolysers, highlighting their advantages and disadvantages. We discuss in detail the design of gas diffusion electrodes and their operation within gas-fed electrolysers in both flow-through and flow-by configurations. Then, we correlate the structure and composition of gas diffusion electrodes to the operational performance of electrolysers, indicating options and prospects for improvement. Overall, this study will equip the reader with the fundamental understanding required to enhance and optimise CO2 catalysis beyond the laboratory scale.

Tuning the Product Selectivity of the Cu Hollow Fiber Gas Diffusion Electrode for Efficient CO2 Reduction to Formate by Controlled Surface Sn Electrodeposition

The efficient CO₂ electrochemical reduction reaction (CO₂RR) relies not only on the development of selective/active catalysts but also on the advanced electrode configuration to solve the critical issue of poor CO₂ mass transport and derived sluggish cathodic reaction kinetics. In this work, to achieve a favorable reaction rate and product selectivity, we designed and synthesized an asymmetric porous Cu hollow fiber gas diffusion electrode (HFGDE) with controlled Sn surface electrodeposition. The HFGDE derived from the optimal Sn electrodeposition condition exhibited a formate Faradaic efficiency (FE) of 78% and a current density of 88 mA cm^-2 at -1.2 V versus reversible hydrogen electrode, which are more than 2 times higher than those from the pristine Cu HFGDE. The achieved performance outperformed most of the other Sn-based GDEs, indicating the creation of sufficient contact among CO₂, electrolyte, and electrode catalyst through the design of the hollow fiber pore structure and catalytic active sites. The enhancement of formate production selectivity and the suppression of the hydrogen by-product were attributed to the optimized ratio of SnO_x species on the electrode surface. The best performance was seen in the HFGDE with the highest Sn²⁺/Sn⁴⁺ (120 s deposition), likely due to the modulating effect of the Cu substrate via electron donation with Sn species. The selectivity control strategy developed in the asymmetric HFGDE provides an efficient and facile method to stimulate selective electrochemical reactions in which the gas-phase reactant with low solubility is involved.

In-situ DRIFT investigation of photocatalytic reduction and oxidation properties of SiO2@α-Fe2O3 core-shell decorated RGO nanocomposite

In this work, SiO₂@α-Fe₂O₃ core-shell decorated RGO nanocomposites were prepared via a simple sol-gel method. The nanocomposites were prepared with different weight percentages (10, 30, and 50 wt %) of the SiO₂@α-Fe₂O₃ core-shell on RGO, and the effects on the structural and optical properties were identified. The photocatalytic reduction and oxidation properties of the nanocomposites in the gas phase were assessed through the reduction of CO₂ and oxidation of ethanol using in-situ diffuse-reflectance infrared fourier transform spectroscopy (DRIFT). The prepared nanocomposite with (30 wt %) of SiO₂@α-Fe₂O₃ showed superior photocatalytic activity for the gas phase reduction of CO₂ and oxidation of ethanol. Enhancement in the activity was also perceived when the light irradiation was coupled with thermal treatment. The DRIFT results for the nanocomposites indicate the active chemical conversion kinetics of the redox catalytic effect in the reduction of CO₂ and oxidation of ethanol. Further, the evaluation of photoelectrochemical CO₂ reduction performance of nanocomposites was acquired by linear sweep voltammetry (LSV), and the results showed a significant improvement in the onset-potential (–0.58 V) for the RGO (30 wt %)-SiO₂@α-Fe₂O₃ nanocomposite.