Concentrated Ethanol Electrosynthesis from CO2 via a Porous Hydrophobic Adlayer

Scaled CO Electroreduction to Alcohols

Electrocatalysis offers a promising route to convert CO2 into alcohols, which is most efficient in a two-step cascade reaction with CO2-to-CO followed by CO-to-alcohol. However, current alcohol-producing CO2/CO electrolyzers suffer from low selectivity or alcohol crossover, resulting in alcohol concentrations of less than 1%, which are further diluted in downstream cold-traps. As a result, electrocatalytic alcohol production has yet to be scaled beyond the lab (1-10 cm2). Here, we reverse the electroosmotic drag of water using a cation exchange membrane assembly, enabling the recovery of over 85% of alcohol products at a concentration of 6 wt.%. We develop a multi-step condenser strategy to separate the produced alcohols from the effluent gas stream without dilution. Scaling up this approach to an 800 cm2 cell resulted in an output of 200 mL alcohol/day.

Microenvironment Tailoring for Electrocatalytic CO2 Reduction: Effects of Interfacial Structure on Controlling Activity and Selectivity

The performance of the electrocatalytic CO2 reduction reaction (CO2RR) is highly dependent on the microenvironment around the cathode. Despite efforts to optimize the microenvironment by modifying nanostructured catalysts or microporous gas diffusion electrodes, their inherent disorder presents a significant challenge to understanding how interfacial structure arrangement within the electrode governs the microenvironment for CO2RR. This knowledge gap limits fundamental understanding of CO2RR while also hindering efforts to enhance CO2RR selectivity and activity. In this work, we investigate this knowledge gap using a tunable system featuring superhydrophobic hierarchical Cu nanowire arrays with microgrooves (NAMs). Adjusting the NAM structure tunes multiple synergistic effects in the microenvironment, which include stabilization of the microwetting state, confinement of CO*, improvement to local CO2 concentration, and modulation of the local pH. Notably, using mass transport modeling, we quantify the role of the gas-liquid-solid interface in boosting local CO2 concentrations within several microns of the interface itself. Leveraging these effects, we elucidate how CO* and H* competitively occupy active sites, influencing reaction pathways toward multicarbon products based on tuning the microenvironment. Consequently, we provide new insights into why the optimized configuration significantly increased CO2RR activity by 690% (as normalized by electrochemical active surface area), C2+ product selectivity by 72%, and Faradaic efficiency by 36%, compared to CO2RR with hydrophobic Cu foil. Based on these insights, our findings unlock new opportunities to engineer the CO2RR microenvironment through the rational organization of hierarchical interface materials in gas diffusion electrodes toward improved CO2RR selectivity and activity.

Concentrated C2+ Alcohol Production Enabled by Post-Intermediate Modulation and Augmented CO Adsorption in CO Electrolysis

The electrocatalytic synthesis of multicarbon products from CO2/CO feedstock represents a sustainable method for chemical production with a reduced carbon footprint. Traditional copper catalysts predominantly produce alkenes, but generating valuable and versatile C2+ alcohols, especially high-energy-density C3 alcohols, has been challenging due to issues with selectivity, activity, and stability. Here, we present the construction of Ru-doped Cu nanowires that enhance the selectivity of n-PrOH and C2+ alcohols. In situ Raman spectroscopy shows that our approach promotes both *CO binding and availability, particularly facilitating the formation of high-frequency-bound *CO (*COHFB) and maintaining multiple *CO adsorption modes on Ru-modified and bare low-coordinated Cu nanowires. Density-functional theory (DFT) simulations illustrate that introducing Ru species onto a low-coordinated Cu step surface simultaneously stabilizes CO and alcohol-related intermediates, shifting the dominant reaction pathway toward alcohols and facilitating CO-C2 coupling at the expense of ethylene selectivity. In an alkaline gas-diffusion electrolyzer, we attained a maximum Faradaic efficiency (FE) of 35.9% for n-PrOH and 62.4% for the total C2+ alcohols. Optimizing parameters in the membrane electrode assembly (MEA) system enabled the one-pot generation and separation of C2+ alcohols, achieving a record concentration of 18.8 wt % (4.2 wt % n-PrOH and 14.6 wt % EtOH) with nearly 100% purity at 200 mA/cm2 over 100 h. This work not only provides new insights and guidance for the development of future catalysts from the perspectives of surface science and mechanisms but also highlights the importance of coupling material engineering with reactor engineering to optimize the production process of high-value alcohol products.

CO2 Electrolyzers

CO2 electrolyzers have progressed rapidly in energy efficiency and catalyst selectivity toward valuable chemical feedstocks and fuels, such as syngas, ethylene, ethanol, and methane. However, each component within these complex systems influences the overall performance, and the further advances needed to realize commercialization will require an approach that considers the whole process, with the electrochemical cell at the center. Beyond the cell boundaries, the electrolyzer must integrate with upstream CO2 feeds and downstream separation processes in a way that minimizes overall product energy intensity and presents viable use cases. Here we begin by describing upstream CO2 sources, their energy intensities, and impurities. We then focus on the cell, the most common CO2 electrolyzer system architectures, and each component within these systems. We evaluate the energy savings and the feasibility of alternative approaches including integration with CO2 capture, direct conversion of flue gas and two-step conversion via carbon monoxide. We evaluate pathways that minimize downstream separations and produce concentrated streams compatible with existing sectors. Applying this comprehensive upstream-to-downstream approach, we highlight the most promising routes, and outlook, for electrochemical CO2 reduction.

Cascade Electrocatalytic and Thermocatalytic Reduction of CO2 to Propionaldehyde

Electrochemical CO2 reduction can convert CO2 to value-added chemicals, but its selectivity toward C3+ products are very limited. One possible solution is to run the reactions in hybrid processes by coupling electrocatalysis with other catalytic routes. In this contribution, we report the cascade electrocatalytic and thermocatalytic reduction of CO2 to propionaldehyde. Using Cu(OH)2 nanowires as the precatalyst, CO2 /H2 O is reduced to concentrated C2 H4 , CO, and H2 gases in a zero-gap membrane electrode assembly (MEA) reactor. The thermochemical hydroformylation reaction is separately investigated with a series of rhodium-phosphine complexes. The best candidate is identified to be the one with the 1,4-bis(diphenylphosphino)butane diphosphine ligand, which exhibits a propionaldehyde turnover number of 1148 under a mild temperature and close-to-atmospheric pressure. By coupling and optimizing the upstream CO2 electroreduction and downstream hydroformylation reaction, we achieve a propionaldehyde selectivity of ~38 % and a total C3 oxygenate selectivity of 44 % based on reduced CO2 . These values represent a more than seven times improvement over the best prior electrochemical system alone or over two times improvement over other hybrid systems.

Enhanced CO2 reduction with hydrophobic cationic-ionomer layer-modified zero-gap MEA in acidic electrolyte

A hydrophobic cationic-ionomer layer of quaternary ammonium poly(N-methyl-piperidine-co-p-terphenyl) and PTFE is presented to enhance the CO2 electroreduction in a zero-gap membrane electrode assembly (MEA) electrolyzer under acidic and low alkali ion concentration conditions. The modified MEA achieved a maximum CO faradaic efficiency of 95.6% at 100 mA cm-2.

Weak CO binding sites induced by Cu-Ag interfaces promote CO electroreduction to multi-carbon liquid products

Electrochemical reduction of carbon monoxide to high-value multi-carbon (C₂₊) products offers an appealing route to store sustainable energy and make use of the chief greenhouse gas leading to climate change, i.e., CO₂. Among potential products, C₂₊ liquid products such as ethanol are of particular interest owing to their high energy density and industrial relevance. In this work, we demonstrate that Ag-modified oxide-derive Cu catalysts prepared via high-energy ball milling exhibit near 80% Faradaic efficiencies for C₂₊ liquid products at commercially relevant current densities (>100 mA cm^-2) in the CO electroreduction in a microfluidic flow cell. Such performance is retained in an over 100-hour electrolysis in a 100 cm² membrane electrode assembly (MEA) electrolyzer. A method based on surface-enhanced infrared absorption spectroscopy is developed to characterize the CO binding strength on the catalyst surface. The lower C and O affinities of the Cu-Ag interfacial sites in the prepared catalysts are proposed to be responsible for the enhanced selectivity for C₂₊ oxygenates, which is the experimental verification of recent computational predictions.

A Pair-Electrosynthesis for Formate at Ultra-Low Voltage Via Coupling of CO2 Reduction and Formaldehyde Oxidation

Formate can be synthesized electrochemically by CO₂ reduction reaction (CO₂RR) or formaldehyde oxidation reaction (FOR). The CO₂RR approach suffers from kinetic-sluggish oxygen evolution reaction at the anode. To this end, an electrochemical system combining cathodic CO₂RR with anodic FOR was developed, which enables the formate electrosynthesis at ultra-low voltage. Cathodic CO₂RR employing the BiOCl electrode in H-cell exhibited formate Faradaic efficiency (FE) higher than 90% within a wide potential range from - 0.48 to - 1.32 V_RHE. In flow cell, the current density of 100 mA cm^-2 was achieved at - 0.67 V_RHE. The anodic FOR using the Cu₂O electrode displayed a low onset potential of - 0.13 V_RHE and nearly 100% formate and H₂ selectivity from 0.05 to 0.35 V_RHE. The CO₂RR and FOR were constructed in a flow cell through membrane electrode assembly for the electrosynthesis of formate, where the CO₂RR//FOR delivered an enhanced current density of 100 mA cm^-2 at 0.86 V. This work provides a promising pair-electrosynthesis of value-added chemicals with high FE and low energy consumption.