Zero-Gap Electrochemical CO2 Reduction Cells: Challenges and Operational Strategies for Prevention of Salt Precipitation

Stabilizing *COOH on Ni Single-Atom Sites by Dual-Phase Ni3ZnC0.7 and Ni for Enhanced Electrocatalytic CO2 Reduction

Metal-based nanoparticle-modulated single-atom catalysts have garnered significant attention in the field of electrocatalytic CO2 reduction reaction. However, the scaling relationships between the intermediates and their binding energies lead to unsatisfactory selectivity for specific products. Herein, Ni3ZnC0.7-Ni nanoparticles (NPs)-modulated Ni single-atoms (SAs) supported on N-doped carbon (NiSAs/Ni3ZnC0.7-NiNPs@NC) were constructed using a metal-organic framework as a template. Experiments and theoretical calculations reveal that the charge transfer from Ni3ZnC0.7 and Ni NPs to Ni SAs results in the formation of electron-enriched Ni SAs sites, which is conducive to stabilize the key *COOH intermediate. The catalyst shows a partial current density for CO of -345 mA cm-2 and a Faradaic efficiency for CO (FECO) of 99.3% at -0.8 V versus a reversible hydrogen electrode in a flow cell. Furthermore, the catalyst maintains FECO of above 94% after continuous electrolysis for 18 h, showcasing its remarkable long-term stability.

Reactor operating parameters and their effects on the local reaction environment of CO(2) electroreduction

Low temperature aqueous electrochemical CO(2) reduction (ECR) emerged as a pathway to close the carbon cycle with the integration of renewable energy. However, activity, selectivity, and stability barriers prevent ECR from entering industrial scale operation. While catalyst design has made meaningful progress towards selective and active production of many products including CO, formate, and ethylene, operating conditions during catalyst testing have not been standardized. Operational parameters drastically impact the local reaction environment of the ECR and thus the performance of ECR. Herein, we summarize the prevailing operational variability of ECR and their interconnectedness. We first analyze reactant availability via tuning of cell geometry and CO(2) pressures. Then, optimization towards electrolyzer components including electrolyte, electrodes, and bipolar plates is discussed. We further assess the electrochemical protocols to enhance the performance or accelerate the degradation of ECR and the considerations required to scale up ECR to pilot scale. Finally, we provide perspectives on the current challenges of ECR and their promising solutions.

Carbon Capture and Utilization for Sustainable Supply Chain Design of Intermediate Chemicals: The Formate Factory

Carbon capture and use technologies (CCUt) to valorize industrial flue gases into products is the key to a circular economy. Risks related to technology readiness level (TRL) and supply chain design challenges still lack clarity, however, which might hinder the widespread implementation of CCUt. Industrial decarbonization requires a holistic approach, that includes supply chain design, techno-economic analysis (TEA), and lifecycle assessment (LCA) to drive the transition toward a low-carbon future. Here, formate production with biocatalytic (BR) or electrocatalytic (ER) routes was evaluated as a potential CCU strategy for industrial decarbonization. Electrocatalysis typically had a lower production cost than biocatalysis manufacturing, while the product carbon footprint (PCF) was generally lower for biotechnology. The uncertainty analysis (UA) indicated 58% and 2% probability to reduce emissions below petrochemical emissions with the BR and ER, respectively. Strategies for facilitating the deployment of formate factories, including carbon trading schemes, creating a market for industrial flue gas, and/or producing lower-grade products, were discussed.

Efficient Bicarbonate Electrolysis to Formate Enabled via Ionomer Surface Modification in Cation Exchange Membrane Electrolyzers

Electrochemical CO2 reduction (CO2RR) is a promising method for converting CO2 into valuable chemicals, with formate being a particularly viable product. However, current gas-fed CO2RR systems rely on highly pure CO2 feed gases and are incompatible with point-source CO2 emissions without prior capture and concentration. Bicarbonate electrolysis offers a potential solution by bridging the gap between CO2 emissions and utilization. However, existing electrolyzer configurations, especially those using bipolar membranes (BPM), require high working voltages and suffer from poor energy efficiency. Here, we present a cation exchange membrane (CEM)-based membrane electrode assembly (MEA) incorporating a surface-modified bismuth cathode catalyst. The success of this approach is attributed to two key factors: the use of the positively charged ionomer PiperION for surface modification, which creates a favorable cathode microenvironment; the single CEM that enhances proton flux from the anode to the cathode while reducing ionic impedance. The CEM-based MEA demonstrates a formate faradaic efficiency of up to 80%, with a significant 1.5 V reduction in operating voltage compared to BPM-based MEAs at 300 mA cm-2. Additionally, the CEM-based MEA exhibits excellent tolerance to O2 impurities and maintains high performance even with simulated flue gas, making it suitable for direct CO2 utilization from point sources.

Non-isothermal CO2 electrolysis enables simultaneous enhanced electrochemical and anti-precipitation performance

Electrochemical conversion of CO2 into fuels represents an important pathway for addressing the challenges of climate change and energy storage. However, large-scale applications remain hindered by the instability and inefficiency of CO2 reduction systems, particularly under highly alkaline electrolytes and high current densities. One primary obstacle is the cathodic salt precipitation, which hinders mass transfer and blocks active sites limiting the lifespan of these systems. Here, we present a non-isothermal strategy that leverages a thermal gradient across the membrane electrode assembly to enhance electrochemical performance and suppress salt precipitation. By maintaining a cooler cathode and warmer anode, we exploit the Soret effect to drive cations away from the cathode, mitigating salting-out while boosting anodic activity and cathodic CO2 solubility. The non-isothermal case has demonstrated over 200 h of stable operation at 100 mA cm-2 under highly alkaline conditions, outperforming conventional isothermal systems. Techno-economic analysis reveals reductions in CO2-to-CO production costs, supporting the scalability of this strategy. These findings enable the practical deployment of stable, high-efficiency CO2 electrolysis systems.

Environmentally Friendly and Earth-Abundant Self-Healing Electrocatalyst Systems for Durable and Efficient Acidic Water Splitting

Electrochemical water splitting under acidic conditions is an efficient route for green hydrogen production from renewable electricity. Its implementation on a globally relevant scale is hindered by the lack of abundant and low-cost electrocatalysts for the oxygen evolution reaction that can operate stably and efficiently under highly acidic anodic conditions. Here, we report the design of stable and efficient acidic OER electrocatalysts consisting of a self-healing bismuth (Bi)-based matrix hosting transition metal active sites. Comprehensive structural performance investigation of Co- and Ni-BiOx electrodes provides insights into the role of the electrolyte composition and pH in the self-healing mechanism under anodic conditions. Our best-performing [Co-Bi]Ox and [Ni-Bi]Ox anodes achieve over 200 h of continuous electrolysis at a catalytic current of 10 mA cm-2 with an overpotential of 590 and 670 mV at a pH of 1 in a 0.1 M H2SO4 electrolyte. Notably, while the [Bi]Ox matrix did not contribute to the catalytic activity, it was essential to stabilize the active Co and Ni sites during the acidic OER. Our findings provide a promising strategy for the engineering of earth-abundant materials for efficient acidic water splitting, as an alternative to the use of poorly scalable and expensive noble metal catalysts.

Metal-organic double layer to stabilize selective multi-carbon electrosynthesis

Stable operation of the gas diffusion electrodes is key for industrial-scale electrochemical CO2 reduction (eCO2R). To enhance the electrolytic stability, we shield the Cu-coated gas diffusion electrode with a polycationic sheath via electrospinning and propose a Metal-Organic Double Layer (MODL) scheme to depict the triphasic interface. The as-fabricated electrode exhibits a high multi-carbon Faradaic efficiency of 91.2 ± 3.8%, along with operational stability for over 300 h at 300 mA cm-2 in an alkaline flow cell. In a membrane electrode assembly with pure water as the anolyte, it further achieves an ethylene Faradaic efficiency over 50% at 200 mA cm-2. Mechanistic investigations unveil that replacing hydrated cationic counter ions in the conventional double layer with hydrogen bond-woven polycationic groups in the MODL allows simultaneously tailoring the local electric field and interfacial water structure. This study introduces a molecular-level redesign of the electric double layer in eCO2R systems, achieving precisely tunable electrostatic characteristics and tailored chemical microenvironments while leveraging sustainable electrolysis systems to enable highly efficient and stable multi-carbon production.

Excess Cations Alter *CO Intermediate Configuration and Product Selectivity of Cu in Acidic Electrochemical CO2 Reduction Reaction

Concentrated cations are often employed to promote electrochemical CO2 reduction reaction (CO2RR) selectivity in acidic electrolytes. Here, we investigate the influence of excess cations on the *CO adsorption configuration and the product distribution of the CO2RR. Operando attenuated total reflectance surface-enhanced infrared absorption spectroscopy (ATR-SEIRAS) reveals that increasing the Cs+ concentration shifts the preference of the *CO intermediate on the Cu surface from the atop (*COatop) to the bridge (*CObridge) configuration. This transition leads to a sharp decline in C-C coupling and an increase in the hydrogen evolution reaction at high Cs+ concentrations (0.7 and 1.0 M) under acidic conditions. Time-resolved SEIRAS scans show that *COatop is kinetically dominant and the proportion of *CObridge increases gradually only at high cation concentrations. Density functional theory simulations confirm that Cs+ on the Cu surface can interact electrostatically with *CO and stabilize *CObridge over *COatop on the Cu surface. The evolution of *CObridge is also observed on Ag catalysts, indicating that the effect at high concentrations is not limited to Cu. Furthermore, polymeric binders on the Cu surface mitigate these detrimental effects on the CO2RR and restore C2H4 production by preventing the cation from altering the *CO adsorption sites on the catalyst surface. This study provides new insights into the effects of cations on catalyst performance, with implications for catalyst design and operation.

Electrochemical CO2 Reduction in Acidic Media: A Perspective

The electrochemical CO2 reduction reaction (eCO2RR) is a promising approach for converting CO2 to useful chemicals and, hence, achieving carbon neutrality. Though high selectivity and activity of products have been achieved recently, all are reported in neutral or alkaline electrolytes. Although these electrolyte media give high selectivity and activity, they face the major challenge of low CO2 utilization because of carbonate formation, which lowers the overall efficiency of the process. Conducting the eCO2RR in acidic media can help overcome the issue of carbonate formation and hence can increase the CO2 utilization efficiency. However, there are many challenges associated with acidic eCO2RR. Two major concerns are the highly competitive hydrogen evolution reaction in acidic media and salt precipitation issues. This Perspective focuses on the fundamentals of acidic eCO2RR, recent catalyst development strategies, and relevant problems that need to be addressed in the future. In the end, we provide a future outlook that will give an idea about the problems to focus on in the future in the field of acidic eCO2RR.

Heating dictates the scalability of CO2 electrolyzer types

Electrochemical CO2 reduction offers a promising method of converting renewable electrical energy into valuable hydrocarbon compounds vital to hard-to-abate sectors. Significant progress has been made on the lab scale, but scale-up demonstrations remain limited. Because of the low energy efficiency of CO2 reduction, we suspect that significant thermal gradients may develop in industrially relevant dimensions. We describe here a model prediction for non-isothermal behavior beyond the typical 1D models to illustrate the severity of heating at larger scales. We develop a 2D model for two membrane electrode assembly (MEA) CO2 electrolyzers; a liquid anolyte fed MEA (exchange MEA) and a fully gas fed configuration (full MEA). Our results indicate that full MEA configurations exhibit very poor electrochemical performance at moderately larger scales due to non-isothermal effects. Heating results in severe membrane dehydration, which induces large Ohmic losses in the membrane, resulting in a sharp decline in the current density along the flow direction. In contrast, the anolyte employed in the exchange MEA configuration is effective in preventing large thermal gradients. Membrane dehydration is not a problem for the exchange MEA configuration, leading to a nearly constant current density over the entire length of the modeled domain, and indicating that exchange MEA configurations are well suited for scale-up. Our results additionally indicate that a balance between faster kinetics, higher ionic conductivity, smaller pH gradients and lower CO2 solubility causes an optimum operating temperature between 60 and 70 °C.

Solid-State-Electrolyte Reactor: New Opportunity for Electrifying Manufacture

Electrocatalysis, which leverages renewable electricity, has emerged as a cornerstone technology in the transition toward sustainable energy and chemical production. However, traditional electrocatalytic systems often produce mixed, impure products, necessitating costly purification. Solid-state electrolyte (SSE) reactors represent a transformative advancement by enabling the direct production of high-purity chemicals, significantly reducing purification costs and energy consumption. The versatility of SSE reactors extends to applications such as CO2 capture and tandem reactions, aligning with the green and decentralized production paradigm. This Perspective provides a comprehensive overview of SSE reactors, discussing their principles, design innovations, and applications in producing pure chemicals-such as liquid carbon fuels, hydrogen peroxide, and ammonia-directly from CO2 and other sources. We further explore the potential of SSE reactors in applications such as CO2 capture and tandem reactions, highlighting their compatibility with versatile production systems. Finally, we outline future research directions for SSE reactors, underscoring their role in advancing sustainable chemical manufacturing.

Macro- and Nano-Porous Ag Electrodes Enable Selective and Stable Aqueous CO2 Reduction

Electrochemical carbon dioxide (CO2) reduction from aqueous solutions offers a promising strategy to overcome flooding and salt precipitation in gas diffusion electrodes used in gas-phase CO2 electrolysis. However, liquid-phase CO2 electrolysis often exhibits low CO2 reduction rates because of limited CO2 availability. Here, a macroporous Ag mesh is employed and activated to achieve selective CO2 conversion to CO with high rates from an aqueous bicarbonate solution. It is found that activation of Ag surface using oxidation/reduction cycles produces nanoporous surfaces that favor CO2-to-CO conversion. Notably, it is found that a combination of dissolved CO2 in bicarbonate solution with CO2 generated in situ from bicarbonate ions enables increased CO2 availability and a CO2-to-CO conversion rate over 100 mA cm-2. By optimizing the oxidation/reduction cycles to fine-tune the structure of Ag surface, CO2-to-CO conversion is reported from a bicarbonate solution with CO Faradaic efficiency of over 85% at current density of 100 mA cm-2, high concentration of 24.7% at outlet gas stream and stability of over 100 h with maintaining CO FE over 85% during whole reaction time.

The Role of Surfactant in Electrocatalytic Carbon Dioxide Reduction in the Absence of Metal Cations

Carbon dioxide electroreduction does not occur on Au when metal cations are absent from the electrode surfaces. Here we show that the electroreduction can be enabled without metal cations, albeit with low efficiency, by the presence of cationic surfactants on Au. The findings demonstrate that in addition to possibly stabilizing CO2 reduction intermediates the presence of surfactants plays a role in suppressing the competing reactions. At potentials negative of a critical potential, a cationic surfactant adsorbs onto the electrode surface, displacing interfacial water molecules, hampering the access of proton donors to the electrode surface and inhibiting hydrogen evolution during electrolysis.

Polyelectrolyte Additive-Modulated Interfacial Microenvironment Boosting CO2 Electrolysis in Acid

Acidic CO2 electrolysis offers a promising strategy to achieve high carbon utilization and high energy efficiency. However, challenges still remain in suppressing the competitive hydrogen evolution reaction (HER) and improving product selectivity. Although high concentrations of potassium ions (K+) can suppress HER and accelerate CO2 reduction, they still inevitably suffer from salt precipitation problems. In this study, we demonstrate that the sulfonate-based polyelectrolyte, polystyrene sulfonate (PSS), enables to reconstruct the electrode-electrolyte interface to significantly enhance the acidic CO2 electrolysis. Mechanistic studies reveal that PSS induces high local K+ concentrations through the electrostatic interaction between PSS anions and K+. In situ spectroscopy reveals that PSS reshapes the interfacial hydrogen-bond (H-bond) network, which is attributed to the H-bonds between PSS anions and hydrated proton, as well as the steric hindrance of the additive molecules. This greatly weakens proton transfer kinetics and leads to the suppression of undesirable HER. As a result, a Faradaic efficiency of 93.9 % for CO can be achieved at 250 mA cm-2, simultaneous with a high single-pass carbon efficiency of 72.2 % on commercial Ag catalysts in acid. This study highlights the important role of the electrode-electrolyte interface induced by polyelectrolyte additives in promoting electrocatalytic reactions.

ICP-MS Assisted EDX Tomography: A Robust Method for Studying Electrolyte Penetration Phenomena in Gas Diffusion Electrodes Applied to CO2 Electrolysis

A carbon paper-based gas diffusion electrode (GDE) is used with a bismuth(III) subcarbonate active catalyst phase for the electrochemical reduction of CO2 in a gas/electrolyte flow-by configuration electrolyser at high current density. It is demonstrated that in this configuration, the gas and catholyte phases recombine to form K2CO3/KHCO3 precipitates to an extent that after electrolyses, vast amount of K+ ions is found by EDX mapping in the entire GDE structure. The fact that the entirety of the GDE gets wetted during electrolysis should, however, not be interpreted as a sign of flooding of the catalyst layer, since electrolyte perspiring through the GDE can largely be removed with the outflow gas, and the efficiency of electrolysis (toward the selective production of formate) can thus be maintained high for several hours. For a full spatial scale quantitative monitoring of electrolyte penetration into the GDE, (relying on K+ ions as tracer) the method of inductively coupled plasma-mass spectrometry (ICP-MS) assisted energy dispersive X-ray (EDX) tomography is introduced. This new, cheap and robust tomography of non-uniform aspect ratio has a large planar span that comprises the entire GDE surface area and a submicrometer depth resolution, hence it can provide quantitative information about the amount and distribution of K+ remnants inside the GDE structure, in three dimensions.

Quantitative Analysis and Manipulation of Alkali Metal Cations at the Cathode Surface in Membrane Electrode Assembly Electrolyzers for CO2 Reduction Reactions

The stable operation of the CO2 reduction reaction (CO2RR) in membrane electrode assembly (MEA) electrolyzers is known to be hindered by the accumulation of bicarbonate salt, which are derived from alkali metal cations in anolytes, on the cathode side. In this study, we conducted a quantitative evaluation of the correlation between the CO2RR activity and the transported alkali metal cations in MEA electrolyzers. As a result, although the presence of transported alkali metal cations on the cathode surface significantly contributes to the generation of C2+ compounds, the rate of K+ ion transport did not match the selectivity of C2+, suggesting that a continuous supply of high amount of K+ to the cathode surface is not required for C2+ formation. Based on these findings, we achieved a faradaic efficiency (FE) and a partial current density for C2+ of 77 % and 230 mA cm-2, respectively, even after switching the anode solution from 0.1 M KHCO3 to a dilute K+ solution (<7 mM). These values were almost identical to those when 0.1 M KHCO3 was continuously supplied. Based on this insight, we successfully improved the durability of the system against salt precipitation by intermittently supplying concentrated KHCO3, compared with the continuous supply.

Substituent tuning of Cu coordination polymers enables carbon-efficient CO2 electroreduction to multi-carbon products

CO2 electroreduction is a potential pathway to achieve net-zero emissions in the chemical industry. Yet, CO2 loss, resulting from (bi)carbonate formation, renders the process energy-intensive. Acidic environments can address the issue but at the expense of compromised product Faradaic efficiencies (FEs), particularly for multi-carbon (C2+) products, as rapid diffusion and migration of protons (H+) favors competing H2 and CO production. Here, we present a strategy of tuning the 2-position substituent length on benzimidazole (BIM)-based copper (Cu) coordination polymer (CuCP) precatalyst - to enhance CO2 reduction to C2+ products in acidic environments. Lengthening the substituent from H to nonyl enhances H+ diffusion retardation and decreases Cu-Cu coordination numbers (CNs), favoring further reduction of CO. This leads to a nearly 24× enhancement of selectivity towards CO hydrogenation and C-C coupling at 60 mA cm-2. We report the highest C2+ product FE of more than 70% at 260 mA cm-2 on pentyl-CuCP and demonstrate a CO2-to-C2+ single-pass conversion (SPC) of ~54% at 180 mA cm-2 using pentyl-CuCP in zero-gap electrolyzers.

Exploring the influence of cell configurations on Cu catalyst reconstruction during CO2 electroreduction

Membrane electrode assembly (MEA) cells incorporating Cu catalysts are effective for generating C2+ chemicals via the CO2 reduction reaction (CO2RR). However, the impact of MEA configuration on the inevitable reconstruction of Cu catalysts during CO2RR remains underexplored, despite its considerable potential to affect CO2RR efficacy. Herein, we demonstrate that MEA cells prompt a unique reconstruction of Cu, in contrast to H-type cells, which subsequently influences CO2RR outcomes. Utilizing three Cu-based catalysts, specifically engineered with different nanostructures, we identify contrasting selectivity trends in the production of C2+ chemicals between H-type and MEA cells. Operando X-ray absorption spectroscopy, alongside ex-situ analyses in both cell types, indicates that MEA cells facilitate the reduction of Cu2O, resulting in altered Cu surfaces compared to those in H-type cells. Time-resolved CO2RR studies, supported by Operando analysis, further highlight that significant Cu reconstruction within MEA cells is a primary factor leading to the deactivation of CO2RR into C2+ chemicals.

CO2 Loss into Solution: An Experimental Investigation of CO2 Electrolysis with a Membrane Electrode Assembly Cell

In pursuit of commercial viability for carbon dioxide (CO2) electrolysis, this study investigates the operational challenges associated with membrane electrode assembly (MEA)-type CO2 electrolyzers, with a focus on CO2 loss into the solution phase through bicarbonate (HCO3 -) and carbonate (CO3 2-) ion formation. Utilizing a silver electrode known for selectively facilitating CO2 to CO conversion, the molar production of CO2, CO, and H2 is measured across a range of current densities from 0 to 600 mA/cm2, while maintaining a constant CO2 inlet flow rate of 58 mL/min. The dynamics of CO2 loss are monitored through measurements of pH changes in the electrolyte and carbon elemental balance analysis. Employing the concept of conservation of elemental carbon, a chemical reaction analysis is conducted, identifying the critical role of the hydroxide (OH-) ion. At lower current densities below 125 mA/cm2, where CO2 reduction predominates, it is observed that CO2 loss is proportional to current density, reaching up to 0.18 mmol/min, and directly correlates with the rate of OH- ion production, indicative of HCO3 -/CO3 2- ion formation. Conversely, at higher current densities above 450 mA/cm2, where hydrogen evolution is the dominant process, CO2 loss is shown to decouple from the OH- ion production rate with a constant limit condition of 0.12 mmol/min, regardless of the current density. This suggests that electrolyte-induced cathode flooding restricts CO2 access to cathode sites. Additionally, pH change in the electrolyte during the electrolysis further infers differing ion populations in the CO2 reduction and hydrogen evolution regimes, and their movement across the membrane. Continued monitoring of the pH change after the cessation of electricity offers insights into the accumulation of HCO3 -/CO3 2- ion at the cathode, influencing salt formation.

Local ionic transport enables selective PGM-free bipolar membrane electrode assembly

Bipolar membranes in electrochemical CO2 conversion cells enable different reaction environments in the CO2-reduction and O2-evolution compartments. Under ideal conditions, water-splitting in the bipolar membrane allows for platinum-group-metal-free anode materials and high CO2 utilizations. In practice, however, even minor unwanted ion crossover limits stability to short time periods. Here we report the vital role of managing ionic species to improve CO2 conversion efficiency while preventing acidification of the anodic compartment. Through transport modelling, we identify that an anion-exchange ionomer in the catalyst layer improves local bicarbonate availability and increasing the proton transference number in the bipolar membranes increases CO2 regeneration and limits K+ concentration in the cathode region. Through experiments, we show that a uniform local distribution of bicarbonate ions increases the accessibility of reverted CO2 to the catalyst surface, improving Faradaic efficiency and limiting current densities by twofold. Using these insights, we demonstrate a fully platinum-group-metal-free bipolar membrane electrode assembly CO2 conversion system exhibiting <1% CO2/cation crossover rates and 80-90% CO2-to-CO utilization efficiency over 150 h operation at 100 mA cm-2 without anolyte replenishment.

Trilayer Polymer Electrolytes Enable Carbon-Efficient CO2 to Multicarbon Product Conversion in Alkaline Electrolyzers

The electrochemical CO2 reduction reaction (CO2RR) is an appealing method for carbon utilization. Alkaline CO2 electrolyzers exhibit high CO2RR activity, low full-cell voltages, and cost-effectiveness. However, the issue of CO2 loss caused by (bi)carbonate formation leads to excessive energy consumption, rendering the process economically impractical. In this study, we propose a trilayer polymer electrolyte (TPE) comprising a perforated anion exchange membrane (PAEM) and a bipolar membrane (BPM) to facilitate alkaline CO2RR. This TPE enables the coexistence of high alkalinity near the catalyst surface and the H+ flux at the interface between the PAEM and the cation exchange layer (CEL) of the BPM, conditions favoring both CO2 reduction to multicarbon products and (bi)carbonate removal in KOH-fed membrane electrode assembly (MEA) reactors. As a result, we achieve a Faradaic efficiency (FE) of approximately 46 % for C2H4, corresponding to a C2+ FE of 64 % at 260 mA cm-2, with a CO2-to-C2H4 single-pass conversion (SPC) of approximately 32 % at 140 mA cm-2-nearly 1.3 times the limiting SPC in conventional AEM-MEA electrolyzers. Furthermore, coupling CO2 reduction with formaldehyde oxidation reaction (FOR) in the TPE-MEA electrolyzer reduces the full-cell voltage to 2.3 V at 100 mA cm-2 without compromising the C2H4 FE.

Bifunctional Catalysts for CO2 Reduction and O2 Evolution: A Pivotal for Aqueous Rechargeable Zn-CO2 Batteries

The quest for the advancement of green energy storage technologies and reduction of carbon footprint is determinedly rising toward carbon neutrality. Aqueous rechargeable Zn-CO2 batteries (ARZCBs) hold the great potential to encounter both the targets simultaneously, i.e., green energy storage and CO2 conversion to value-added chemicals/fuels. The major descriptor of ARZCBs efficiency is allied with the reactions occurring at cathode during discharging (CO2 reduction) and charging (O2 evolution) which own different fundamental mechanisms and hence mandate the employment of two different catalysts. This presents an overall complex and expensive battery system which requires a concrete solution, while the development and application of a bifunctional cathode catalyst toward both reactions could reduce the complexity and cost and thus can be a pivotal for ARZCBs. However, despite the increasing research interest and ongoing research, a systematic evaluation of bifunctional catalysts is rarely reported. In this review, the need of bifunctional cathode catalysts for ARZCBs and associated challenges with strategies have been critically assessed. A detailed progress examination and understanding toward designing of bifunctional catalyst for ARZCBs have been provided. This review will enlighten the future research approaching boosted performance of ARZCBs through the development of efficient bifunctional cathode catalysts.

Toward Durable CO2 Electroreduction with Cu-Based Catalysts via Understanding Their Deactivation Modes

The technology of CO2 electrochemical reduction (CO2ER) provides a means to convert CO2, a waste greenhouse gas, into value-added chemicals. Copper is the most studied element that is capable of catalyzing CO2ER to obtain multicarbon products, such as ethylene, ethanol, acetate, etc., at an appreciable rate. Under the operating condition of CO2ER, the catalytic performance of Cu decays because of several factors that alters the surface properties of Cu. In this review, these factors that cause the degradation of Cu-based CO2ER catalysts are categorized into generalized deactivation modes, that are applicable to all electrocatalytic systems. The fundamental principles of each deactivation mode and the associated effects of each on Cu-based catalysts are discussed in detail. Structure- and composition-activity relationship developed from recent in situ/operando characterization studies are presented as evidence of related deactivation modes in operation. With the aim to address these deactivation modes, catalyst design and reaction environment engineering rationales are suggested. Finally, perspectives and remarks built upon the recent advances in CO2ER are provided in attempts to improve the durability of CO2ER catalysts.

Nonconductive Metal Oxide Gas Diffusion Layer for Mitigating Electrowetting during CO2 Electrolysis

Gas diffusion electrodes (GDEs) are extensively used for high current density electrochemical CO2 electrolysis (ECO2R), enabled by significantly reducing mass transfer resistance of CO2 to the catalyst layer. Conventionally, these GDEs are based upon hydrophobic carbon-based gas-diffusion layers (GDLs) that facilitate the gas transport; however, these supports are prone to flood with electrolyte during electrolysis. This potential-induced flooding, known as electrowetting, is related to the inherent conductivity of carbon and limits the activity of ECO2R. To investigate the effect of electrical conductivity more carefully, a GDE is constructed based on a Cu mesh with a nonconductive microporous GDL applied to this substrate, the latter composed of a mixture of metal oxide and polytetrafluoroethylene. With alumina as the metal oxide, a stable operation is obtained at -200 mA cm-2 with 70% selectivity for ECO2R (with over half toward C2+ products) without flooding as observed by in situ microscopy. On the contrary, with a Vulcan carbon-based GDL, the initial activity is rapidly lost as severe flooding ensues. It is reasoned that electrowetting is averted by virtue of the nonconductive nature of alumina, providing a new perspective on alternative GDL compositions and their influence on ECO2R performance.

Aryl ether-free polymer electrolytes for electrochemical and energy devices

Anion exchange polymers (AEPs) play a crucial role in green hydrogen production through anion exchange membrane water electrolysis. The chemical stability of AEPs is paramount for stable system operation in electrolysers and other electrochemical devices. Given the instability of aryl ether-containing AEPs under high pH conditions, recent research has focused on quaternized aryl ether-free variants. The primary goal of this review is to provide a greater depth of knowledge on the synthesis of aryl ether-free AEPs targeted for electrochemical devices. Synthetic pathways that yield polyaromatic AEPs include acid-catalysed polyhydroxyalkylation, metal-promoted coupling reactions, ionene synthesis via nucleophilic substitution, alkylation of polybenzimidazole, and Diels-Alder polymerization. Polyolefinic AEPs are prepared through addition polymerization, ring-opening metathesis, radiation grafting reactions, and anionic polymerization. Discussions cover structure-property-performance relationships of AEPs in fuel cells, redox flow batteries, and water and CO2 electrolysers, along with the current status of scale-up synthesis and commercialization.

Rational Design of Local Reaction Environment for Electrocatalytic Conversion of CO2 into Multicarbon Products

The electrocatalytic conversion of CO2 into multi-carbon (C2+) products provides an attractive route for storing intermittent renewable electricity as fuels and feedstocks with high energy densities. Although substantial progress has been made in selective electrosynthesis of C2+ products via engineering the catalyst, rational design of the local reaction environment in the vicinity of catalyst surface also acts as an effective approach for further enhancing the performance. Here, we discuss recent advances and pertinent challenges in the modulation of local reaction environment, encompassing local pH, the choice of the species and concentrations of cations and anions as well as local reactant/intermediate concentrations, for achieving high C2+ selectivity. In addition, mechanistic understanding in the effects of the local reaction environment is also discussed. Particularly, the important progress extracted from in situ and operando spectroscopy techniques provides insights into how local reaction environment affects C-C coupling and key intermediates formation that lead to reaction pathways toward a desired C2+ product. The possible future direction in understanding and engineering the local reaction environment is also provided.

Pure-Water-Fed Forward-Bias Bipolar Membrane CO2 Electrolyzer

Coupling renewable electricity to reduce carbon dioxide (CO2) electrochemically into carbon feedstocks offers a promising pathway to produce chemical fuels sustainably. While there has been success in developing materials and theory for CO2 reduction, the widespread deployment of CO2 electrolyzers has been hindered by challenges in the reactor design and operational stability due to CO2 crossover and (bi)carbonate salt precipitation. Herein, we design asymmetrical bipolar membranes assembled into a zero-gap CO2 electrolyzer fed with pure water, solving both challenges. By investigating and optimizing the anion-exchange-layer thickness, cathode differential pressure, and cell temperature, the forward-bias bipolar membrane CO2 electrolyzer achieves a CO faradic efficiency over 80% with a partial current density over 200 mA cm-2 at less than 3.0 V with negligible CO2 crossover. In addition, this electrolyzer achieves 0.61 and 2.1 mV h-1 decay rates at 150 and 300 mA cm-2 for 200 and 100 h, respectively. Postmortem analysis indicates that the deterioration of catalyst/polymer-electrolyte interfaces resulted from catalyst structural change, and ionomer degradation at reductive potential shows the decay mechanism. All these results point to the future research direction and show a promising pathway to deploy CO2 electrolyzers at scale for industrial applications.

Electrochemical Characterization of Electrodeposited Copper in Amine CO2 Capture Media

This study explores the stability of electrodeposited copper catalysts utilized in electrochemical CO2 reduction (ECR) across various amine media. The focus is on understanding the influence of different amine types, corrosion ramifications, and the efficacy of pulse ECR methodologies. Employing a suite of electrochemical techniques including potentiodynamic polarization, linear resistance polarization, cyclic voltammetry, and chronopotentiometry, the investigation reveals useful insights. The findings show that among the tested amines, CO2-rich monoethanolamine (MEA) exhibits the highest corrosion rate. However, in most cases, the rates remain within tolerable limits for ECR operations. Primary amines, notably monoethanolamine (MEA), show enhanced compatibility with ECR processes, attributable to their resistance against carbonate salt precipitation and sustained stability over extended durations. Conversely, tertiary amines such as methyldiethanolamine (MDEA) present challenges due to the formation of carbonate salts during ECR, impeding their effective utilization. This study highlights the effectiveness of pulse ECR strategies in stabilizing ECR. A noticeable shift in cathodic potential and reduced deposit formation on the catalyst surface through periodic oxidation underscores the efficacy of such strategies. These findings offer insights for optimizing ECR in amine media, thereby providing promising pathways for advancements in CO2 emission reduction technologies.

Backbone Engineering of Polymeric Catalysts for High-Performance CO2 Reduction in Bipolar Membrane Zero-Gap Electrolyzer

Bipolar membranes (BPMs) have emerged as a promising solution for mitigating CO2 losses, salt precipitation and high maintenance costs associated with the commonly used anion-exchange membrane electrode assembly for CO2 reduction reaction (CO2RR). However, the industrial implementation of BPM-based zero-gap electrolyzer is hampered by the poor CO2RR performance, largely attributed to the local acidic environment. Here, we report a backbone engineering strategy to improve the CO2RR performance of molecular catalysts in BPM-based zero-gap electrolyzers by covalently grafting cobalt tetraaminophthalocyanine onto a positively charged polyfluorene backbone (PF-CoTAPc). PF-CoTAPc shows a high acid tolerance in BPM electrode assembly (BPMEA), achieving a high FE of 82.6 % for CO at 100 mA/cm2 and a high CO2 utilization efficiency of 87.8 %. Notably, the CO2RR selectivity, carbon utilization efficiency and long-term stability of PF-CoTAPc in BPMEA outperform reported BPM systems. We attribute the enhancement to the stable cationic shield in the double layer and suppression of proton migration, ultimately inhibiting the undesired hydrogen evolution and improving the CO2RR selectivity. Techno-economic analysis shows the least energy consumption (957 kJ/mol) for the PF-CoTAPc catalyst in BPMEA. Our findings provide a viable strategy for designing efficient CO2RR catalysts in acidic environments.

Exploring how cation entropy influences electric double layer formation and electrochemical reactivity

Electric double layers are crucial to energy storage and electrocatalytic device performance. While double layer formation originates in electrostatic interactions, electric double layer properties are governed by a balance of both electrostatic and entropic driving forces. Favorable ion-surface electrostatic interactions attract counterions to charged surfaces to compensate, or "screen," potentials, but the confinement of these same ions from a bulk reservoir to the interface incurs an entropic penalty. Here, we use a dicationic imidazolium ionic liquid and its monovalent analogue to explore how cation valence and entropy influence double layer formation and electrochemical reactivity using CO2 electroreduction as a model reaction. We find that divalent and monovalent cations display similar CO2 reduction kinetics but differ vastly in steady-state reactivity due to rapid electrochemically induced precipitation of insulating dicationic (bi)carbonate films. Using in situ surface-enhanced Raman scattering spectroscopy, we find that potential-dependent cation reorientation occurs at similar potentials between the two ionic liquids, but the introduction of a covalent link in the divalent cation imparts a more ordered double layer structure that favors (bi)carbonate precipitation. In mixed monovalent-divalent electrolytes, we find that the divalent cations dominate interfacial properties by preferentially accumulating at surfaces even at very low relative concentrations. Our findings confirm that ion entropy plays a key role in modulating local electrochemical environments. Furthermore, we highlight how double layer properties are sensitive to the properties of counterions that pay the lowest entropic penalty to accumulate at interfaces. Overall, we illustrate that ion entropy provides a new knob to tune reaction microenvironments and unveil how entropy plays a major role in modulating electrochemical reactivity in mixed ion electrolytes.

Oxygen-Resistant CO2 Reduction Enabled by Electrolysis of Liquid Feedstocks

Electrolytic CO2 reduction fails in the presence of O2. This failure occurs because the reduction of O2 is thermodynamically favored over the reduction of CO2. Consequently, O2 must be removed from the CO2 feed prior to entering an electrolyzer, which is expensive. Here, we show that the use of liquid bicarbonate feedstocks (e.g., aqueous 3.0 M KHCO3), rather than gaseous CO2 feedstocks, enables efficient and selective CO2 reduction without additional procedures for removing O2. This effect is made possible because liquid bicarbonate solutions, which serve as a liquid CO2 carrier, deliver high concentrations of captured CO2 to the cathode, while the low solubility of O2 in aqueous media maintains a low O2 concentration at the same cathode surface. Consequently, electrolyzers fed with liquid bicarbonate feedstocks create an environment at the cathode that favors the reduction of CO2 over O2. We validate this claim by electrochemically converting CO2 into CO with reaction selectivities of 65% at 100 mA cm-2 using a 3.0 M KHCO3 solution bubbled with 100% CO2 or 100% O2. Similar experiments performed with a gaseous CO2 feedstock showed that merely 0.5% of O2 in the feedstock reduced CO selectivity by >90% after 1 h of electrolysis. Our findings demonstrate that a liquid bicarbonate feedstock enables efficient CO2 reduction without the need for expensive O2 removal steps.

Advanced Catalyst Design and Reactor Configuration Upgrade in Electrochemical Carbon Dioxide Conversion

Electrochemical carbon dioxide reduction reaction (CO2 RR) driven by renewable energy shows great promise in mitigating and potentially reversing the devastating effects of anthropogenic climate change and environmental degradation. The simultaneous synthesis of energy-dense chemicals can meet global energy demand while decoupling emissions from economic growth. However, the development of CO2 RR technology faces challenges in catalyst discovery and device optimization that hinder their industrial implementation. In this contribution, a comprehensive overview of the current state of CO2 RR research is provided, starting with the background and motivation for this technology, followed by the fundamentals and evaluated metrics. Then the underlying design principles of electrocatalysts are discussed, emphasizing their structure-performance correlations and advanced electrochemical assembly cells that can increase CO2 RR selectivity and throughput. Finally, the review looks to the future and identifies opportunities for innovation in mechanism discovery, material screening strategies, and device assemblies to move toward a carbon-neutral society.

Enrichment Strategies for Efficient CO2 Electroreduction in Acidic Electrolytes

Electrochemical CO2 reduction reaction (CO2 RR) has been recognized as an appealing route to remarkably accelerate the carbon-neutral cycle and reduce carbon emissions. Notwithstanding great catalytic activity that has been acquired in neutral and alkaline conditions, the carbonates generated from the inevitable reaction of the input CO2 with the hydroxide severely lower carbon utilization and energy efficiency. By contrast, CO2 RR in an acidic condition can effectively circumvent the carbonate issues; however, the activity and selectivity of CO2 RR in acidic electrolytes will be decreased significantly due to the competing hydrogen evolution reaction (HER). Enriching the CO2 and the key intermediates around the catalyst surface can promote the reaction rate and enhance the product selectivity, providing a promising way to boost the performance of CO2 RR. In this review, the catalytic mechanism and key technique challenges of CO2 RR are first introduced. Then, the critical progress of enrichment strategies for promoting the CO2 RR in the acidic electrolyte is summarized with three aspects: catalyst design, electrolyte regulation, and electrolyzer optimization. Finally, some insights and perspectives for further development of enrichment strategies in acidic CO2 RR are expounded.

Stability Issues in Electrochemical CO2 Reduction: Recent Advances in Fundamental Understanding and Design Strategies

Electrochemical CO2 reduction reaction (CO2 RR) offers a promising approach to close the anthropogenic carbon cycle and store intermittent renewable energy in fuels or chemicals. On the path to commercializing this technology, achieving the long-term operation stability is a central requirement but still confronts challenges. This motivates to organize the present review to systematically discuss the stability issue of CO2 RR. This review starts from the fundamental understanding on the destabilization mechanisms of CO2 RR, with focus on the degradation of electrocatalyst and change of reaction microenvironment during continuous electrolysis. Subsequently, recent efforts on catalyst design to stabilize the active sites are summarized, where increasing atomic binding strength to resist surface reconstruction is highlighted. Next, the optimization of electrolysis system to enhance the operation stability by maintaining reaction microenvironment especially mitigating flooding and carbonate problems is demonstrated. The manipulation on operation conditions also enables to prolong CO2 RR lifespan through recovering catalytically active sites and mass transport process. This review finally ends up by indicating the challenges and future opportunities.

A Bismuth-Based Zeolitic Organic Framework with Coordination-Linked Metal Cages for Efficient Electrocatalytic CO2 Reduction to HCOOH

Zeolitic metal-organic frameworks (ZMOFs) have emerged as one of the most promsing catalysts for energy conversion, but they suffer from either weak bonding between metal-organic cubes (MOCs) that decrease their stability during catalysis processes or low activity due to inadequate active sites. In this work, through ligand-directing strategy, we successfully obtain an unprecedented bismuth-based ZMOF (Bi-ZMOF) featuring a ACO topological crystal structure with strong coordination bonding between the Bi-based cages. As a result, it enables efficient reduction of CO2 to formic acid (HCOOH) with Faradaic efficiency as high as 91 %. A combination of in situ surface-enhanced infrared absorption spectroscopy and density functional theory calculation reveals that the Bi-N coordination contributes to facilitating charge transfer from N to Bi atoms, which stabilize the intermediate to boost the reduction efficiency of CO2 to HCOOH. This finding highlights the importance of the coordination environment of metal active sites on electrocatalytic CO2 reduction. We believe that this work will offer a new clue to rationally design zeolitic MOFs for catalytic reaction.

Non-invasive current collectors for improved current-density distribution during CO2 electrolysis on super-hydrophobic electrodes

Electrochemical reduction of CO2 presents an attractive way to store renewable energy in chemical bonds in a potentially carbon-neutral way. However, the available electrolyzers suffer from intrinsic problems, like flooding and salt accumulation, that must be overcome to industrialize the technology. To mitigate flooding and salt precipitation issues, researchers have used super-hydrophobic electrodes based on either expanded polytetrafluoroethylene (ePTFE) gas-diffusion layers (GDL's), or carbon-based GDL's with added PTFE. While the PTFE backbone is highly resistant to flooding, the non-conductive nature of PTFE means that without additional current collection the catalyst layer itself is responsible for electron-dispersion, which penalizes system efficiency and stability. In this work, we present operando results that illustrate that the current distribution and electrical potential distribution is far from a uniform distribution in thin catalyst layers (~50 nm) deposited onto ePTFE GDL's. We then compare the effects of thicker catalyst layers (~500 nm) and a newly developed non-invasive current collector (NICC). The NICC can maintain more uniform current distributions with 10-fold thinner catalyst layers while improving stability towards ethylene (≥ 30%) by approximately two-fold.

Developing Catalysts Integrated in Gas-Diffusion Electrodes for CO2 Electrolyzers

ConspectusAs the demand for a carbon-neutral society grows rapidly, research on CO2 electrolysis has become very active. Many catalysts are reported for converting CO2 into value-added products by electrochemical reactions, which have to perform at high Faradaic and energy efficiency to become commercially viable. Various types of CO2 electrolyzers have been used in this effort, such as the H-cell, flow cell, and zero-gap membrane-electrode assembly (MEA) cell. H-cell studies are conducted with electrodes immersed in CO2-saturated electrolyte and have been used to elucidate reaction pathways and kinetic parameters of electrochemical CO2 reduction on many types of catalytic surfaces. From a transport phenomenological perspective, the low solubility and diffusion of CO2 to the electrode surface severely limit the maximum attainable current density, and this metric has been shown to have significant influence on the product spectrum. Flow and MEA cells provide a solution in the form of gas-diffusion electrodes (GDEs) that enable gaseous CO2 to closely reach the catalyst layer and yield record-high current densities. Because GDEs involve a complicated interface consisting of the catalyst surface, gaseous CO2, polymer overlayers, and liquid electrolyte, catalysts with high intrinsic activity might not show high performance in these GDE-based electrolyzers. Catalysts showing low overpotentials at low current densities may suffer from poor electron conductivity and mass transfer limitations at high current densities. Furthermore, the stability of the GDE-based catalysts is often compromised as CO2 electrolysis is pursued with high activity, most notoriously by electrolyte flooding.In this Account, we introduce recent examples where the electrocatalysts were integrated in GDEs, achieving high production rates. The performance of such systems is contingent on both GDE and cell design, and various parameters that affect the cell performance are discussed. Gaseous products, such as carbon monoxide, methane, and ethylene, and liquid products, such as formate and ethanol, have been mainly reported with high partial current density using the flow or MEA cells. Different strategies to this end are described, such as controlling microenvironments by the use of polymers mixed within the catalyst layer or the functionalization of catalyst surfaces with ligands to increase local concentrations of intermediates. Unique CO2 electrolyzer designs are also treated, including the incorporation of light-responsive plasmonic catalysts in the GDE, and combining the electrolyzer with a fermenter utilizing a microbial biocatalyst to synthesize complex multicarbon products. Basic conditions which the catalyst should satisfy to be adapted in the GDEs are listed, and our perspective is provided.

Unintended cation crossover influences CO2 reduction selectivity in Cu-based zero-gap electrolysers

Membrane electrode assemblies enable CO₂ electrolysis at industrially relevant rates, yet their operational stability is often limited by formation of solid precipitates in the cathode pores, triggered by cation crossover from the anolyte due to imperfect ion exclusion by anion exchange membranes. Here we show that anolyte concentration affects the degree of cation movement through the membranes, and this substantially influences the behaviors of copper catalysts in catholyte-free CO₂ electrolysers. Systematic variation of the anolyte (KOH or KHCO₃) ionic strength produced a distinct switch in selectivity between either predominantly CO or C₂₊ products (mainly C₂H₄) which closely correlated with the quantity of alkali metal cation (K⁺) crossover, suggesting cations play a key role in C-C coupling reaction pathways even in cells without discrete liquid catholytes. Operando X-ray absorption and quasi in situ X-ray photoelectron spectroscopy revealed that the Cu surface speciation showed a strong dependence on the anolyte concentration, wherein dilute anolytes resulted in a mixture of Cu⁺ and Cu⁰ surface species, while concentrated anolytes led to exclusively Cu⁰ under similar testing conditions. These results show that even in catholyte-free cells, cation effects (including unintentional ones) significantly influence reaction pathways, important to consider in future development of catalysts and devices.