Reactive Carbon Capture Enables CO2 Electrolysis with Liquid Feedstocks.

ConspectusThe electrochemical reduction of carbon dioxide (CO2RR) is a promising strategy for mitigating global CO2 emissions while simultaneously yielding valuable chemicals and fuels, such as CO, HCOO-, and C2H4. This approach becomes especially appealing when integrated with surplus renewable electricity, as the ensuing production of fuels could facilitate the closure of the carbon cycle. Despite these advantages, the realization of industrial-scale electrolyzers fed with CO2 will be challenged by the substantial energy inputs required to isolate, pressurize, and purify CO2 prior to electrolysis.To address these challenges, we devised an electrolyzer capable of directly converting reactive carbon solutions (e.g., a bicarbonate-rich eluent that exits a carbon capture unit) into higher value products. This "reactive carbon electrolyzer" operates by reacting (bi)carbonate with acid generated within the electrolyzer to produce CO2 in situ, thereby facilitating CO2RR at the cathode. This approach eliminates the need for expensive CO2 recovery and compression steps, as the electrolyzer can then then coupled directly to the CO2 capture unit.This Account outlines our endeavors in developing this type of electrolyzer, focusing on the design and implementation of materials for electrocatalytic (bi)carbonate conversion. We highlight the necessity for a permeable cathode that allows the efficient transport of (bi)carbonate ions while maintaining a sufficiently high catalytic surface area. We address the importance of the supporting electrolyte, detailing how (bi)carbonate concentration, counter cations, and ionic impurities impact selectivity for products formed in the electrolyzer. We also catalog state-of-the-art performance metrics for reactive carbon electrolyzers (i.e., Faradaic efficiency, full cell voltage, CO2 utilization efficiency) and outline strategies to bridge the gap between these values and those required for commercial operation Collectively, these findings contribute to the ongoing efforts to realize industrial-scale electrochemical reactors for CO2 conversion, bringing us closer to a sustainable and closed-loop carbon cycle.

Visualization of CO2 electrolysis using optical coherence tomography.

Electrolysers offer an appealing technology for conversion of CO2 into high-value chemicals. However, there are few tools available to track the reactions that occur within electrolysers. Here we report an electrolysis optical coherence tomography platform to visualize the chemical reactions occurring in a CO2 electrolyser. This platform was designed to capture three-dimensional images and videos at high spatial and temporal resolutions. We recorded 12 h of footage of an electrolyser containing a porous electrode separated by a membrane, converting a continuous feed of liquid KHCO3 to reduce CO2 into CO at applied current densities of 50-800 mA cm-2. This platform visualized reactants, intermediates and products, and captured the strikingly dynamic movement of the cathode and membrane components during electrolysis. It also linked CO production to regions of the electrolyser in which CO2 was in direct contact with both membrane and catalyst layers. These results highlight how this platform can be used to track reactions in continuous flow electrochemical reactors.

Indirect H2O2 synthesis without H2.

Industrial hydrogen peroxide (H2O2) is synthesized using carbon-intensive H2 gas production and purification, anthraquinone hydrogenation, and anthrahydroquinone oxidation. Electrochemical hydrogenation (ECH) of anthraquinones offers a carbon-neutral alternative for generating H2O2 using renewable electricity and water instead of H2 gas. However, the H2O2 formation rates associated with ECH are too low for commercialization. We report here that a membrane reactor enabled us to electrochemically hydrogenate anthraquinone (0.25 molar) with a current efficiency of 70% at current densities of 100 milliamperes per square centimeter. We also demonstrate continuous H2O2 synthesis from the hydrogenated anthraquinones over the course of 48 h. This study presents a fast rate of electrochemically-driven anthraquinone hydrogenation (1.32 ± 0.14 millimoles per hour normalized per centimeter squared of geometric surface of electrode), and provides a pathway toward carbon-neutral H2O2 synthesis.

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.

Endergonic Hydrogenation at Ambient Conditions Using an Electrochemical Membrane Reactor.

Here, we determine how the hydrogen loading (x) of an electrochemical palladium membrane reactor (ePMR) varies with electrochemical conditions (e.g., applied current density, electrolyte concentration). We detail how x influences the thermodynamic driving force of an ePMR. These studies are accomplished by measuring the fugacity (P) of hydrogen desorbing from the palladium-hydrogen membrane and subsequently relating P to pressure-composition isotherms to determine x. We find that x increases with both applied current density and electrolyte concentration, but plateaus at a loading of x ≅ 0.92 in 1.0 M H2SO4 at -200 mA·cm-2. The validity of the fugacity measurements is supported experimentally and computationally by: (a) electrochemical hydrogen permeation studies; and (b) a palladium-hydrogen porous flow finite element analysis (FEA) model. Both (a) and (b) agree with the fugacity measurements on the following x-dependent properties of the palladium-hydrogen system during electrolysis: (i) the onset for spontaneous hydrogen desorption; (ii) the point of steady-state hydrogen loading; and (iii) the function describing hydrogen desorption between (i) and (ii). We proceed to detail how x defines the free energy of palladium-hydrogen alloy formation (ΔG(x)PdH), which is a descriptor for the thermodynamic driving force of hydrogenation at the PdHx surface of an ePMR. A maximum value ΔGPdH of 11 kJ·mol-1 is observed, suggesting that an ePMR is capable of driving endergonic hydrogenation reactions. We empirically demonstrate this capability by reducing carbon dioxide to formate (ΔGCO2/HCO2H = 3.4 kJ·mol-1) at ambient conditions and neutral pH.

Hydrogen Production and Utilization in a Membrane Reactor.

Industrial hydrogenation consumes ~11 Mt of fossil-derived H2 gas yearly. Our group invented a membrane reactor to bypass the need to use H2 gas for hydrogenation chemistry. The membrane reactor sources hydrogen from water and drives reactions using renewable electricity. In this reactor, a thin piece of Pd separates an electrochemical hydrogen production compartment from a chemical hydrogenation compartment. The Pd in the membrane reactor acts as (i) a hydrogen-selective membrane, (ii) a cathode, and (iii) a catalyst for hydrogenation. Herein, we report the use of atmospheric mass spectrometry (atm-MS) and gas chromatography mass spectrometry (GC-MS) to demonstrate that an applied electrochemical bias across a Pd membrane enables efficient hydrogenation without direct H2 input in a membrane reactor. With atm-MS, we measured a hydrogen permeation of 73%, which enabled the hydrogenation of propiophenone to propylbenzene with 100% selectivity, as measured by GC-MS. In contrast to conventional electrochemical hydrogenation, which is limited to low concentrations of starting material dissolved in a protic electrolyte, the physical separation of hydrogen production from utilization in the membrane reactor enables hydrogenation in any solvent or at any concentration. The use of high concentrations and a wide range of solvents is particularly important for reactor scalability and future commercialization.

Bioelectrocatalysis with a palladium membrane reactor.

Enzyme catalysis is used to generate approximately 50,000 tons of value-added chemical products per year. Nearly a quarter of this production requires a stoichiometric cofactor such as NAD+/NADH. Given that NADH is expensive, it would be beneficial to regenerate it in a way that does not interfere with the enzymatic reaction. Water electrolysis could provide the proton and electron equivalent necessary to electrocatalytically convert NAD+ to NADH. However, this form of electrocatalytic NADH regeneration is challenged by the formation of inactive NAD2 dimers, the use of high overpotentials or mediators, and the long-term electrochemical instability of the enzyme during electrolysis. Here, we show a means of overcoming these challenges by using a bioelectrocatalytic palladium membrane reactor for electrochemical NADH regeneration from NAD+. This achievement is possible because the membrane reactor regenerates NADH through reaction of hydride with NAD+ in a compartment separated from the electrolysis compartment by a hydrogen-permselective Pd membrane. This separation of the enzymatic and electrolytic processes bypasses radical-induced NAD+ degradation and enables the operator to optimize conditions for the enzymatic reaction independent of the water electrolysis. This architecture, which mechanistic studies reveal utilizes hydride sourced from water, provides an opportunity for enzyme catalysis to be driven by clean electricity where the major waste product is oxygen gas.

Catalyst Aggregation Matters for Immobilized Molecular CO2RR Electrocatalysts.

Here, we detail how the catalytic behavior of immobilized molecular electrocatalysts for the CO2 reduction reaction (CO2RR) can be impacted by catalyst aggregation. Operando Raman spectroscopy was used to study the CO2RR mediated by a layer of cobalt phthalocyanine (CoPc) immobilized on the cathode of an electrochemical flow reactor. We demonstrate that during electrolysis, the oxidation state of CoPc in the catalyst layer is dependent upon the degree of catalyst aggregation. Our data indicate that immobilized molecular catalysts must be dispersed on conductive supports to mitigate the formation of aggregates and produce meaningful performance data. We leveraged insights from this mechanistic study to engineer an improved CO-forming immobilized molecular catalyst─cobalt octaethoxyphthalocyanine (EtO8-CoPc)─that exhibited high selectivity (FECO ≥ 95%), high partial current density (JCO ≥ 300 mA/cm2), and high durability (ΔFECO < 0.1%/h at 150 mA/cm2) in a flow cell. This work demonstrates how to accurately identify CO2RR active species of molecular catalysts using operando Raman spectroscopy and how to use this information to implement improved molecular electrocatalysts into flow cells. This work also shows that the active site of CoPc during CO2RR catalysis in a flow cell is the metal center.

High-Efficiency Perovskite Solar Cells with Sputtered Metal Contacts.

Sputter deposition produces dense, uniform, adhesive, and scalable metal contacts for perovskite solar cells (PSCs). However, sputter deposition damages the other layers of the PSC. We here report that the damage caused by sputtering metal contacts can be reversed by aerial oxidation. We support this claim by making PSCs sputtered with Au contacts that exhibit higher efficiencies (18.7%) and stabilities than those made with thermally evaporated Au contacts (18.4%). We performed a series of experiments that show that the post-sputtering oxidation step reconstructs the molecular order of the hole transport layer (HTL) and reverses Au atom diffusion into the HTL. This potential restoration was previously neglected in PSC fabrication recipes because metal contact deposition is generally performed after the HTL oxidation. This result is important for scaling PSCs because sputtering is a superior method for manufacturing optimal-quality coatings or large-area devices.

Direct H2O2 Synthesis, without H2 Gas.

We report here the direct hydrogenation of O2 gas to form hydrogen peroxide (H2O2) using a membrane reactor without H2 gas. Hydrogen is sourced from water, and the reactor is driven by electricity. Hydrogenation chemistry is achieved using a hydrogen-permeable Pd foil that separates an electrolysis chamber that generates reactive H atoms, from a hydrogenation chamber where H atoms react with O2 to form H2O2. Our results show that the concentration of H2O2 can be increased ∼8 times (from 56.5 to 443 mg/L) by optimizing the ratio of methanol-to-water in the chemical chamber, and through catalyst design. We demonstrate that the concentration of H2O2 is acutely sensitive to the H2O2 decomposition rate. This decomposition rate can be minimized by using AuPd alloy catalysts instead of pure Pd. This study presents a new pathway to directly synthesize H2O2 using water electrolysis without ever using H2 gas.

Conversion of Reactive Carbon Solutions into CO at Low Voltage and High Carbon Efficiency.

Electrolyzers are now capable of reducing carbon dioxide (CO2) into products at high reaction rates but are often characterized by low energy efficiencies and low CO2 utilization efficiencies. We report here an electrolyzer that reduces 3.0 M KHCO3(aq) into CO(g) at a high rate (partial current density for CO of 220 mA cm-2) and a CO2 utilization efficiency of 40%, at a voltage of merely 2.3 V. These results were made possible by using: (i) a reactive carbon solution enriched in KHCO3 as the feedstock instead of gaseous CO2; (ii) a cation exchange membrane instead of an anion exchange membrane, which is common to the field; and (iii) the hydrogen oxidation reaction (HOR) at the anode instead of the oxygen evolution reaction (OER). The voltage reported here is the lowest reported for any CO2 to CO electrolyzer that operates at high current densities (i.e., a partial current density for CO greater than 200 mA cm-2) with a CO2 utilization efficiency of greater than 20%. This study highlights how the choice of feedstock, membrane, and anode chemistries affects the rate and efficiency at which CO2 is converted into products.

Ring walking as a regioselectivity control element in Pd-catalyzed C-N cross-coupling.

Ring walking is an important mechanistic phenomenon leveraged in many catalytic C-C bond forming reactions. However, ring walking has been scarcely studied under Buchwald-Hartwig amination conditions despite the importance of such transformations. An in-depth mechanistic study of the Buchwald-Hartwig amination is presented focussing on ligand effects on ring walking behavior. The ability of palladium catalysts to promote or inhibit ring walking is strongly influenced by the chelating nature of the ligand. In stark contrast, the resting state of the catalyst had no impact on ring walking behavior. Furthermore, the complexity of the targeted system enabled the differentiation between catalysts which undergo ring walking versus diffusion-controlled coupling. The insights gained in this study were leveraged to achieve desymmetrization of a tetrabrominated precursor. A small library of asymmetric 2,2',7,7'-tetrakis[N,N-di(4-methoxyphenyl)amino]-9,9'spirobifluorene (SpiroOMeTAD) derivatives were successfully synthesized using this strategy highlighting the ease with which libraries of these compounds can be accessed for screening.

Electrocatalysts Derived from Copper Complexes Transform CO into C2+ Products Effectively in a Flow Cell.

Electrochemical reactors that electrolytically convert CO2 into higher-value chemicals and fuels often pass a concentrated hydroxide electrolyte across the cathode. This strongly alkaline medium converts the majority of CO2 into unreactive HCO3 - and CO3 2- byproducts rather than into CO2 reduction reaction (CO2RR) products. The electrolysis of CO (instead of CO2 ) does not suffer from this undesirable reaction chemistry because CO does not react with OH- . Moreover, CO can be more readily reduced into products containing two or more carbon atoms (i. e., C2+ products) compared to CO2 . We demonstrate here that an electrocatalyst layer derived from copper phthalocyanine (CuPc) mediates this conversion effectively in a flow cell. This catalyst achieved a 25 % higher selectivity for acetate formation at 200 mA/cm2 than a known state-of-art oxide-derived Cu catalyst tested in the same flow cell. A gas diffusion electrode coated with CuPc electrolyzed CO into C2+ products at high rates of product formation (i. e., current densities ≥200 mA/cm2 ), and at high faradaic efficiencies for C2+ production (FEC2+ ; >70 % at 200 mA/cm2 ). While operando Raman spectroscopy did not reveal evidence of structural changes to the copper molecular complex, X-ray photoelectron spectroscopy suggests that the catalyst undergoes conversion to a metallic copper species during catalysis. Notwithstanding, the ligand environment about the metal still impacts catalysis, which we demonstrated through the study of a homologous CuPc bearing ethoxy substituents. These findings reveal new strategies for using metal complexes for the formation of carbon-neutral chemicals and fuels at industrially relevant conditions.

Electrolytic conversion of carbon capture solutions containing carbonic anhydrase.

The electrolysis of carbon capture solutions bypasses energy-intensive CO2 recovery steps that are often required to convert CO2 into value-added products. We report herein an electrochemical flow reactor that converts carbon capture solutions containing carbonic anhydrase enzymes into carbon-based products. Carbonic anhydrase enzymes benefit CO2 capture by increasing the rate of reaction between CO2 and weakly alkaline solutions by 20-fold. In this study, we reduced CO2-enriched bicarbonate solutions containing carbonic anhydrase ("enzymatic CO2 capture solutions") into CO at current densities of 100 mA cm-2. This result demonstrated how to electrolyse enzymatic CO2 capture solutions, but the selectivity for CO production was two-thirds less than bicarbonate solutions without carbonic anhydrase. This reduction in performance occurred because carbonic anhydrase deactivated the catalyst surface. A carbon microporous layer was found to suppress this deactivation.

A self-driving laboratory advances the Pareto front for material properties.

Useful materials must satisfy multiple objectives, where the optimization of one objective is often at the expense of another. The Pareto front reports the optimal trade-offs between these conflicting objectives. Here we use a self-driving laboratory, Ada, to define the Pareto front of conductivities and processing temperatures for palladium films formed by combustion synthesis. Ada discovers new synthesis conditions that yield metallic films at lower processing temperatures (below 200 °C) relative to the prior art for this technique (250 °C). This temperature difference makes possible the coating of different commodity plastic materials (e.g., Nafion, polyethersulfone). These combustion synthesis conditions enable us to to spray coat uniform palladium films with moderate conductivity (1.1 × 105 S m-1) at 191 °C. Spray coating at 226 °C yields films with conductivities (2.0 × 106 S m-1) comparable to those of sputtered films (2.0 to 5.8 × 106 S m-1). This work shows how a self-driving laboratoy can discover materials that provide optimal trade-offs between conflicting objectives.

Quantification of the Effect of an External Magnetic Field on Water Oxidation with Cobalt Oxide Anodes.

Here, we quantify the effect of an external magnetic field (ß) on the oxygen evolution reaction (OER) for a cobalt oxide|fluorine-doped tin oxide coated glass (CoOx|FTO) anode. A bespoke apparatus enables us to precisely determine the relationship between magnetic flux density (ß) and OER activity at the surface of a CoOx|FTO anode. The apparatus includes a strong NdFeB magnet (ßmax = 450 ± 1 mT) capable of producing a magnetic field of 371 ± 1 mT at the surface of the anode. The distance between the magnet and the anode surface is controlled by a linear actuator, enabling submillimeter distance positioning of the magnet relative to the anode surface. We couple this apparatus with a finite element analysis magnetic model that was validated by Hall probe measurements to determine the value of ß at the anode surface. At the largest tested magnetic field strength of ß = 371 ± 1 mT, a 4.7% increase in current at 1.5 V vs the normal hydrogen electrode (NHE) and a change in the Tafel slope of 14.5 mV/dec were observed. We demonstrate through a series of OER measurements at sequential values of ß that the enhancement consists of two distinct regions. The possible use of this effect to improve the energy efficiency of commercial water electrolyzers is discussed, and major challenges pertaining to the accurate measurement of the phenomenon are demonstrated.

Electrolysis Can Be Used to Resolve Hydrogenation Pathways at Palladium Surfaces in a Membrane Reactor.

For common hydrogenation chemistries that occur at high temperatures (where H2 is adsorbed and activated at the same surface which the substrate must also adsorb for reaction), there is often little consensus on how the reactions (e.g., hydro(deoxy)genation) actually occur. We demonstrate here that an electrocatalytic palladium membrane reactor (ePMR) can be used to study hydrogenation reaction mechanisms at ambient temperatures, where the catalyst does not necessarily undergo structural reorganization. The ePMR uses electrolysis and a hydrogen-selective palladium membrane to deliver reactive hydrogen to a catalyst surface in an adjacent compartment for reaction with an organic substrate. This process forms the requisite metal-hydride surface for hydrogenation chemistry, but at ambient temperature and pressure, and without a H2 source. We demonstrate the utility of this analytical tool by studying the hydrogenation of benzaldehyde at palladium nanocubes with dimensions of 13-24 nm. This experimental design enabled us to resolve that the alcohol product forms at the facial sites, whereas the hydrodeoxygenation step occurs at edge sites. These observations enabled us to develop the first site-specific definition of how a carbonyl species undergoes hydro(deoxy)genation.

Physical Separation of H2 Activation from Hydrogenation Chemistry Reveals the Specific Role of Secondary Metal Catalysts.

An electrocatalytic palladium membrane reactor (ePMR) uses electricity and water to drive hydrogenation without H2 gas. The device contains a palladium membrane to physically separate the formation of reactive hydrogen atoms from hydrogenation of the unsaturated organic substrate. This separation provides an opportunity to independently measure the hydrogenation reaction at a surface without any competing H2 activation or proton reduction chemistry. We took advantage of this feature to test how different metal catalysts coated on the palladium membrane affect the rates of hydrogenation of C=O and C=C bonds. Hydrogenation occurs at the secondary metal catalyst and not the underlying palladium membrane. These secondary catalysts also serve to accelerate the reaction and draw a higher flux of hydrogen through the membrane. These results reveal insights into hydrogenation chemistry that would be challenging using thermal or electrochemical hydrogenation experiments.

An industrial perspective on catalysts for low-temperature CO2 electrolysis.

Electrochemical conversion of CO2 to useful products at temperatures below 100 °C is nearing the commercial scale. Pilot units for CO2 conversion to CO are already being tested. Units to convert CO2 to formic acid are projected to reach pilot scale in the next year. Further, several investigators are starting to observe industrially relevant rates of the electrochemical conversion of CO2 to ethanol and ethylene, with the hydrogen needed coming from water. In each case, Faradaic efficiencies of 80% or more and current densities above 200 mA cm-2 can be reproducibly achieved. Here we describe the key advances in nanocatalysts that lead to the impressive performance, indicate where additional work is needed and provide benchmarks that others can use to compare their results.