Continuous electroreduction of CO2 towards formate in gas-phase operation at high current densities with an anion exchange membrane

Ion exchange membranes in environmental applications: Comprehensive review

Ion exchange membranes (IEMs) are transformative materials in environmental and industrial applications, offering selective ion transport capabilities crucial for water desalination, wastewater treatment, energy generation, and resource recovery. Recent advancements have focused on developing nanocomposite and organic-inorganic hybrid membranes, integrating materials like graphene oxide, silica, and carbon nanotubes to enhance mechanical strength, thermal stability, and chemical resistance. These innovations have yielded remarkable results, such as achieving 77.9 % energy conversion efficiency and current densities of 1000 mA/cm2 in seawater electrolysis systems. Additionally, advanced IEMs demonstrate significant improvements in selective ion removal, with lithium recovery efficiencies reaching 93 % and fluoride reduction below WHO guidelines. Despite these successes, challenges like fouling, chemical degradation, high costs, and scalability barriers remain. Future research directions emphasize sustainability, with a focus on biopolymer-based membranes, renewable energy integration, and computational modeling. By addressing these challenges, IEMs can significantly contribute to global environmental sustainability and resource efficiency. IEMs are vital in energy generation, enabling ion transport in fuel cells (PEMFCs, AEMFCs) for clean energy, redox flow batteries (VRFBs) for efficient energy storage, and electrolyzers (PEMELs, AEMELs) for hydrogen production. They also support salinity gradient power in reverse electrodialysis (RED) and pressure-retarded osmosis (PRO) and facilitate CO2 electroreduction (CO2RR) for carbon-neutral fuel production. This review (covering 2020-2024 publication years) explores recent developments in IEM technology, highlighting their applications, challenges, and future prospects in addressing global environmental and industrial challenges.

Multi-metallic Layered Catalysts for Stable Electrochemical CO2 Reduction to Formate and Formic Acid

Electrochemical CO2 reduction (ECR) to value-added products such as formate/formic acid is a promising approach for CO2 mitigation. Practical ECR requires long-term stability at industrially relevant reduction rates, which is challenging due to the rapid degradation of most catalysts at high current densities. Herein, we report the development of a bismuth (Bi) gas diffusion electrode on a polytetrafluoroethylene-based electrically conductive silver (Ag) substrate (Ag@Bi), which exhibits high Faradaic efficiency (FE) for formate of over 90 % in 1 M KOH and 1 M KHCO3 electrolytes. The catalyst also shows high selectivity of formic acid above 85 % in 1 M NaCl catholyte, which has a bulk pH of 2-3 during ECR, at current densities up to 300 mA cm-2. In 1 M KHCO3 condition, Ag@Bi maintains formate FE above 90 % for at least 500 hours at the current density of 100 mA cm-2. We found that the Ag@Bi catalyst degrades over time due to the leaching of Bi in the NaCl catholyte. To overcome this challenge, we deposited a layer of Ag nanoparticles on the surface of Ag@Bi to form a multi-layer Ag@Bi/Ag catalyst. This designed catalyst exhibits 300 hours of stability with FE for formic acid ≥70 % at 100 mA cm-2. Our work establishes a new strategy for achieving the operational longevity of ECR under wide pH conditions, which is critical for practical applications.

Cu-Based Materials for Enhanced C2+ Product Selectivity in Photo-/Electro-Catalytic CO2 Reduction: Challenges and Prospects

Carbon dioxide conversion into valuable products using photocatalysis and electrocatalysis is an effective approach to mitigate global environmental issues and the energy shortages. Among the materials utilized for catalytic reduction of CO2, Cu-based materials are highly advantageous owing to their widespread availability, cost-effectiveness, and environmental sustainability. Furthermore, Cu-based materials demonstrate interesting abilities in the adsorption and activation of carbon dioxide, allowing the formation of C2+ compounds through C-C coupling process. Herein, the basic principles of photocatalytic CO2 reduction reactions (PCO2RR) and electrocatalytic CO2 reduction reaction (ECO2RR) and the pathways for the generation C2+ products are introduced. This review categorizes Cu-based materials into different groups including Cu metal, Cu oxides, Cu alloys, and Cu SACs, Cu heterojunctions based on their catalytic applications. The relationship between the Cu surfaces and their efficiency in both PCO2RR and ECO2RR is emphasized. Through a review of recent studies on PCO2RR and ECO2RR using Cu-based catalysts, the focus is on understanding the underlying reasons for the enhanced selectivity toward C2+ products. Finally, the opportunities and challenges associated with Cu-based materials in the CO2 catalytic reduction applications are presented, along with research directions that can guide for the design of highly active and selective Cu-based materials for CO2 reduction processes in the future.

A Tin Oxide-Coated Copper Foam Hybridized with a Gas Diffusion Electrode for Efficient CO2 Reduction to Formate with a Current Density Exceeding 1 A cm-2

The electrochemical CO₂ reduction reaction (CO₂ RR) is a promising strategy for closing the carbon cycle. Increasing the current density (  J) for CO₂ RR products is a critical requirement for the social implementation of this technology. Herein, nanoscale tin-oxide-modified copper-oxide foam is hybridized with a carbon-based gas-diffusion electrode (GDE). Using the resultant electrode, the J_formate is increased to -1152 mA cm^-2 at -1.2 V versus RHE in 1 m KOH, which is the highest value for CO₂ -to-formate electrolysis. The formate faradaic efficiency (FE_formate ) reaches ≈99% at -0.6 V versus RHE. The achievement of ultra-high-rate formate production is attributable to the following factors: i) homogeneously-modified Sn atoms suppressing H₂ evolution and ii) the hydrophobic carbon nanoparticles on GDEs penetrating the macroporous structure of the foam causing the increase in the thickness of triple-phase interface. Additionally, the FE_formate remains at ≈70% under a high J of -1.0 A cm^-2 for more than 20 h.

Electrochemical Reduction of Gaseous CO2 at Low-Intermediate Temperatures Using a Solid Acid Membrane Cell

In this study, the electrochemical reduction of gaseous carbon dioxide (CO2) at low-intermediate temperatures (~250 °C) using a solid acid membrane cell was demonstrated, for the first time. Compared to solid oxide fuel cells, which operate at higher temperatures (>600 °C), this system can utilize the advantage of gaseous CO2 reduction, while being considerably more simply implemented. A Cu-based electrocatalyst was developed as a cathode side catalyst for electrochemical reduction of gaseous CO2 and specifically demonstrated its efficacy to produce hydrocarbons and liquid fuels. The result is significant in terms of resolving the challenges associated with producing hydrocarbons and liquid fuels from CO2 reduction. The present study introduced the novel system with the solid acid membrane cell and the Cu-based catalyst for electrochemically reducing gaseous CO2. This system showed a new possibility for electrochemical reduction of gaseous CO2, as it operates at lower temperatures, produces hydrocarbons and liquid fuels and has plenty of room for improvement.

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.

Efficient CO2 Electroreduction over Silver Hollow Fiber Electrode

Electrocatalytic reduction of CO2 to fuels and chemicals is one of the most attractive routes for CO2 utilization. However, low efficiency and poor stability restrict the practical application of most conventional electrocatalysts. Here, a silver hollow fiber electrode is presented as a novel self-supported gas diffusion electrode for efficient and stable CO2 electroreduction to CO. A CO faradaic efficiency of over 92% at current densities of above 150 mA∙cm−2 is achieved in 0.5 M KHCO3 for over 100 h, which is comparable to the most outstanding Ag-based electrocatalysts. The electrochemical results suggest the excellent electrocatalytic performance of silver hollow fiber electrode is attributed to the unique pore structures providing abundant active sites and favorable mass transport, which not only suppresses the competitive hydrogen evolution reaction (HER) but also facilitates the CO2 reduction kinetics.