CO2 electroreduction to formate: Continuous single-pass operation in a filter-press reactor at high current densities using Bi gas diffusion electrodes

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.

Simultaneous Anodic and Cathodic Formate Production in a Paired Electrolyzer by CO2 Reduction and Glycerol Oxidation

Electrochemical CO₂ conversion is a key technology to promote the production of carbon-containing molecules, alongside reducing CO₂ emissions leading to a closed carbon cycle economy. Over the past decade, the interest to develop selective and active electrochemical devices for electrochemical CO₂ reduction emerged. However, most reports employ oxygen evolution reaction as an anodic half-cell reaction causing the system to suffer from sluggish kinetics with no production of value-added chemicals. Therefore, this study reports a conceptualized paired electrolyzer for simultaneous anodic and cathodic formate production at high currents. To achieve this, CO₂ reduction was coupled with glycerol oxidation: a BiOBr-modified gas-diffusion cathode and a Ni_x B on Ni foam anode keep their selectivity for formate in the paired electrolyzer compared to the half-cell measurements. The paired reactor here reaches a combined Faradaic efficiency for formate of 141 % (45 % anode and 96 % cathode) at a current density of 200 mA cm^-2 .

Effective perspiration is essential to uphold the stability of zero-gap MEA-based cathodes used in CO2 electrolysers

The application of gas diffusion electrodes (GDEs) for the electrochemical reduction of CO2 to value-added products creates the possibility of achieving current densities of a few hundred mA cm-2. To achieve stable operation at such high reaction rates remains, however, a challenging task, due to the flooding of the GDE. In order to mitigate flooding in a zero-gap membrane-electrode assembly (MEA) configuration, paths for effective electrolyte perspiration inside the GDE structure have to be kept open during the electrolysis process. Here we demonstrate that apart from the operational parameters of the electrolysis and the structural properties of the supporting gas diffusion layers, also the chemical composition of the applied catalyst inks can play a decisive role in the electrolyte management of GDEs used for CO2 electroreduction. In particular, the presence of excess amounts of polymeric capping agents (used to stabilize the catalyst nanoparticles) can lead to a blockage of micropores, which hinders perspiration and initiates the flooding of the microporous layer. Here we use a novel ICP-MS analysis-based approach to quantitatively monitor the amount of perspired electrolyte that exits a GDE-based CO2 electrolyser, and we show a direct correlation between the break-down of effective perspiration and the appearance of flooding-the latter ultimately leading to a loss of electrolyser stability. We recommend the use of an ultracentrifugation-based approach by which catalyst inks containing no excess amount of polymeric capping agents can be formulated. Using these inks, the stability of electrolyses can be ensured for much longer times.

Use of Chitosan as Copper Binder in the Continuous Electrochemical Reduction of CO2 to Ethylene in Alkaline Medium

This work explores the potential of novel renewable materials in electrode fabrication for the electrochemical conversion of carbon dioxide (CO₂) to ethylene in alkaline media. In this regard, the use of the renewable chitosan (CS) biopolymer as ion-exchange binder of the copper (Cu) electrocatalyst nanoparticles (NPs) is compared with commercial anion-exchange binders Sustainion and Fumion on the fabrication of gas diffusion electrodes (GDEs) for the electrochemical reduction of carbon dioxide (CO₂R) in an alkaline medium. They were tested in membrane electrode assemblies (MEAs), where selectivity to ethylene (C₂H₄) increased when using the Cu:CS GDE compared to the Cu:Sustainion and Cu:Fumion GDEs, respectively, with a Faradaic efficiency (FE) of 93.7% at 10 mA cm^-2 and a cell potential of -1.9 V, with a C₂H₄ production rate of 420 µmol m^-2 s^-1 for the Cu:CS GDE. Upon increasing current density to 90 mA cm^-2, however, the production rate of the Cu:CS GDE rose to 509 µmol/m²s but the FE dropped to 69% due to increasing hydrogen evolution reaction (HER) competition. The control of mass transport limitations by tuning up the membrane overlayer properties in membrane coated electrodes (MCE) prepared by coating a CS-based membrane over the Cu:CS GDE enhanced its selectivity to C₂H₄ to a FE of 98% at 10 mA cm^-2 with negligible competing HER. The concentration of carbon monoxide was below the experimental detection limit irrespective of the current density, with no CO₂ crossover to the anodic compartment. This study suggests there may be potential in sustainable alernatives to fossil-based or perfluorinated materials in ion-exchange membrane and electrode fabrication, which constitute a step forward towards decarbonization in the circular economy perspective.

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.

Electroreduction of CO2 toward High Current Density

Carbon dioxide (CO2) electroreduction offers an attractive pathway for converting CO2 to valuable fuels and chemicals. Despite the existence of some excellent electrocatalysts with superior selectivity for specific products, these reactions are conducted at low current densities ranging from several mA cm−2 to tens of mA cm−2, which are far from commercially desirable values. To extend the applications of CO2 electroreduction technology to an industrial scale, long-term operations under high current densities (over 200 mA cm−2) are desirable. In this paper, we review recent major advances toward higher current density in CO2 reduction, including: (1) innovations in electrocatalysts (engineering the morphology, modulating the electronic structure, increasing the active sites, etc.); (2) the design of electrolyzers (membrane electrode assemblies, flow cells, microchannel reactors, high-pressure cells, etc.); and (3) the influence of electrolytes (concentration, pH, anion and cation effects). Finally, we discuss the current challenges and perspectives for future development toward high current densities.

Empower C1: Combination of Electrochemistry and Biology to Convert C1 Compounds

The idea to somehow combine electrical current and biological systems is not new. It was subject of research as well as of science fiction literature for decades. Nowadays, in times of limited resources and the need to capture greenhouse gases like CO₂, this combination gains increasing interest, since it might allow to use C1 compounds and highly oxidized compounds as substrate for microbial production by "activating" them with additional electrons. In this chapter, different possibilities to combine electrochemistry and biology to convert C1 compounds into useful products will be discussed. The chapter first shows electrochemical conversion of C1 compounds, allowing the use of the product as substrate for a subsequent biosynthesis in uncoupled systems, further leads to coupled systems of biology and electrochemical conversion, and finally reaches the discipline of bioelectrosynthesis, where electrical current and C1 compounds are directly converted by microorganisms or enzymes. This overview will give an idea about the potentials and challenges of combining electrochemistry and biology to convert C1 molecules.

Biochar-Supported BiOx for Effective Electrosynthesis of Formic Acid from Carbon Dioxide Reduction

The electrochemical reduction of carbon dioxide (CO2) to value-added chemicals and fuels has attracted worldwide interest for its potential to address various contemporary global issues such as CO2-related climate change, the earth’s carbon deficit and the energy crisis. In the development of this technology, many efforts have been focused on the design of inexpensive, eco-friendly and effective catalysts. In this work, a bismuth (Bi)-based material was simply synthesized via a scalable method and fully characterized by physical, chemical and electrochemical techniques. The catalyst material consisted of Bi/Bi2O3 nanoparticles and a biochar prevenient from the pyrolysis of brewed coffee waste. It was observed that the surface of the biochar was thoroughly decorated with nanoparticles. Due to its uniform surface, the biochar–BiOx electrode demonstrated good selectivity for CO2 reduction, showing a faradaic efficiency of more than 90% for CO and HCOOH formation in a wide potential range. Particularly, the selectivity for HCOOH reached more than 80% from −0.9 V to −1.3 V vs the reversible hydrogen electrode and peaks at 87%. Besides the selectivity, the production rate of HCOOH also achieved significant values with a maximum of 59.6 mg cm−2 h−1, implying a good application potential for biochar–BiOx material in the conversion of CO2 to HCOOH.

Rational design of Cu3PdN nanocrystals for selective electroreduction of carbon dioxide to formic acid

The selective electrochemical reduction of CO₂ yields value-added products that are important renewable energy resources for carbon recycling. In this study, Cu₃PdN nanocrystals (NCs) exhibited higher electrocatalytic activity for carbon dioxide (CO₂) reduction to formic acid (HCOOH) than as-prepared Cu₃N and Cu₃Pd NCs. In addition, the reaction yielded small amounts of CO (<5%), H₂, and HCOOH as the main products, and the electrocatalytic activity of the Cu NCs was significantly enhanced by modification with N and Pd. This work demonstrates a simple and effective strategy for improving the electrochemical reduction of CO₂.

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%.

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.