Early Warning for the Electrolyzer: Monitoring CO2 Reduction via In-Line Electrochemical Impedance Spectroscopy.

The electrochemical CO2 reduction reaction (CO2 RR) to fuels and feedstocks presents an opportunity to decarbonize the chemical industry, and current electrolyzer performance levels approach commercial viability. However, stability remains below that required, in part because of the challenge of probing these electrolyzer systems in real time and the challenge of determining the root cause of failure. Failure can result from initial conditions (e. g., the over- or under-compression of the electrolyzer), gradual degradation of components (e. g., cathode or anode catalysts), the accumulation of products or by-products, or immediate changes such as the development of a hole in the membrane or a short circuit. Identifying and mitigating these assembly-related, gradual, and immediate failure modes would increase both electrolyzer lifetime and economic viability of CO2 RR. We demonstrate the continuous monitoring of CO2 RR electrolyzers during operation via non-disruptive, real-time electrochemical impedance spectroscopy (EIS) analysis. Using this technique, we characterise common failure modes - compression, salt formation, and membrane short circuits - and identify electrochemical parameter signatures for each. We further propose a framework to identify, predict, and prevent failures in CO2 RR electrolyzers. This framework allowed for the prediction of anode degradation ~11 hours before other indicators such as selectivity or voltage.

Bipolar membrane electrolyzers enable high single-pass CO2 electroreduction to multicarbon products.

In alkaline and neutral MEA CO2 electrolyzers, CO2 rapidly converts to (bi)carbonate, imposing a significant energy penalty arising from separating CO2 from the anode gas outlets. Here we report a CO2 electrolyzer uses a bipolar membrane (BPM) to convert (bi)carbonate back to CO2, preventing crossover; and that surpasses the single-pass utilization (SPU) limit (25% for multi-carbon products, C2+) suffered by previous neutral-media electrolyzers. We employ a stationary unbuffered catholyte layer between BPM and cathode to promote C2+ products while ensuring that (bi)carbonate is converted back, in situ, to CO2 near the cathode. We develop a model that enables the design of the catholyte layer, finding that limiting the diffusion path length of reverted CO2 to ~10 µm balances the CO2 diffusion flux with the regeneration rate. We report a single-pass CO2 utilization of 78%, which lowers the energy associated with downstream separation of CO2 by 10× compared with past systems.

Concentrated Ethanol Electrosynthesis from CO2 via a Porous Hydrophobic Adlayer.

Electrochemical CO2 reduction can convert waste emissions into dense liquid fuels compatible with existing energy infrastructure. High-rate electrocatalytic conversion of CO2 to ethanol has been achieved in membrane electrode assembly (MEA) electrolyzers; however, ethanol produced at the cathode is transported, via electroosmotic drag and diffusion, to the anode, where it is diluted and may be oxidized. The ethanol concentrations that result on both the cathodic and anodic sides are too low to justify the energetic and financial cost of downstream separation. Here, we present a porous catalyst adlayer that facilitates the evaporation of ethanol into the cathode gas stream and reduces the water transport, leading to a recoverable stream of concentrated ethanol. The adlayer is comprised of ethylcellulose-bonded carbon nanoparticles and forms a porous, electrically conductive network on the surface of the copper catalyst that slows the transport of water to the gas channel. We achieve the direct production of an ethanol stream of 12.4 wt %, competitive with the concentration of current industrial ethanol production processes.

Low coordination number copper catalysts for electrochemical CO2 methanation in a membrane electrode assembly.

The electrochemical conversion of CO2 to methane provides a means to store intermittent renewable electricity in the form of a carbon-neutral hydrocarbon fuel that benefits from an established global distribution network. The stability and selectivity of reported approaches reside below technoeconomic-related requirements. Membrane electrode assembly-based reactors offer a known path to stability; however, highly alkaline conditions on the cathode favour C-C coupling and multi-carbon products. In computational studies herein, we find that copper in a low coordination number favours methane even under highly alkaline conditions. Experimentally, we develop a carbon nanoparticle moderator strategy that confines a copper-complex catalyst when employed in a membrane electrode assembly. In-situ XAS measurements confirm that increased carbon nanoparticle loadings can reduce the metallic copper coordination number. At a copper coordination number of 4.2 we demonstrate a CO2-to-methane selectivity of 62%, a methane partial current density of 136 mA cm-2, and > 110 hours of stable operation.

Enhanced multi-carbon alcohol electroproduction from CO via modulated hydrogen adsorption.

Multi-carbon alcohols such as ethanol are valued as fuels in view of their high energy density and ready transport. Unfortunately, the selectivity toward alcohols in CO2/CO electroreduction is diminished by ethylene production, especially when operating at high current densities (>100 mA cm-2). Here we report a metal doping approach to tune the adsorption of hydrogen at the copper surface and thereby promote alcohol production. Using density functional theory calculations, we screen a suite of transition metal dopants and find that incorporating Pd in Cu moderates hydrogen adsorption and assists the hydrogenation of C2 intermediates, providing a means to favour alcohol production and suppress ethylene. We synthesize a Pd-doped Cu catalyst that achieves a Faradaic efficiency of 40% toward alcohols and a partial current density of 277 mA cm-2 from CO electroreduction. The activity exceeds that of prior reports by a factor of 2.

Efficient Methane Electrosynthesis Enabled by Tuning Local CO2 Availability.

The electroreduction of carbon dioxide (CO2RR) to valuable chemicals is a promising avenue for the storage of intermittent renewable electricity. Renewable methane, obtained via CO2RR using renewable electricity as energy input, has the potential to serve as a carbon-neutral fuel or chemical feedstock, and it is of particular interest in view of the well-established infrastructure for its storage, distribution, and utilization. However, CO2RR to methane still suffers from low selectivity at commercially relevant current densities (>100 mA cm-2). Density functional theory calculations herein reveal that lowering *CO2 coverage on the Cu surface decreases the coverage of the *CO intermediate, and then this favors the protonation of *CO to *CHO, a key intermediate for methane generation, compared to the competing step, C-C coupling. We therefore pursue an experimental strategy wherein we control local CO2 availability on a Cu catalyst by tuning the concentration of CO2 in the gas stream and regulate the reaction rate through the current density. We achieve as a result a methane Faradaic efficiency (FE) of (48 ± 2)% with a partial current density of (108 ± 5) mA cm-2 and a methane cathodic energy efficiency of 20% using a dilute CO2 gas stream. We report stable methane electrosynthesis for 22 h. These findings offer routes to produce methane with high FE and high conversion rate in CO2RR and also make direct use of dilute CO2 feedstocks.

Molecular tuning of CO2-to-ethylene conversion.

The electrocatalytic reduction of carbon dioxide, powered by renewable electricity, to produce valuable fuels and feedstocks provides a sustainable and carbon-neutral approach to the storage of energy produced by intermittent renewable sources1. However, the highly selective generation of economically desirable products such as ethylene from the carbon dioxide reduction reaction (CO2RR) remains a challenge2. Tuning the stabilities of intermediates to favour a desired reaction pathway can improve selectivity3-5, and this has recently been explored for the reaction on copper by controlling morphology6, grain boundaries7, facets8, oxidation state9 and dopants10. Unfortunately, the Faradaic efficiency for ethylene is still low in neutral media (60 per cent at a partial current density of 7 milliamperes per square centimetre in the best catalyst reported so far9), resulting in a low energy efficiency. Here we present a molecular tuning strategy-the functionalization of the surface of electrocatalysts with organic molecules-that stabilizes intermediates for more selective CO2RR to ethylene. Using electrochemical, operando/in situ spectroscopic and computational studies, we investigate the influence of a library of molecules, derived by electro-dimerization of arylpyridiniums11, adsorbed on copper. We find that the adhered molecules improve the stabilization of an 'atop-bound' CO intermediate (that is, an intermediate bound to a single copper atom), thereby favouring further reduction to ethylene. As a result of this strategy, we report the CO2RR to ethylene with a Faradaic efficiency of 72 per cent at a partial current density of 230 milliamperes per square centimetre in a liquid-electrolyte flow cell in a neutral medium. We report stable ethylene electrosynthesis for 190 hours in a system based on a membrane-electrode assembly that provides a full-cell energy efficiency of 20 per cent. We anticipate that this may be generalized to enable molecular strategies to complement heterogeneous catalysts by stabilizing intermediates through local molecular tuning.

Efficient upgrading of CO to C3 fuel using asymmetric C-C coupling active sites.

The electroreduction of C1 feedgas to high-energy-density fuels provides an attractive avenue to the storage of renewable electricity. Much progress has been made to improve selectivity to C1 and C2 products, however, the selectivity to desirable high-energy-density C3 products remains relatively low. We reason that C3 electrosynthesis relies on a higher-order reaction pathway that requires the formation of multiple carbon-carbon (C-C) bonds, and thus pursue a strategy explicitly designed to couple C2 with C1 intermediates. We develop an approach wherein neighboring copper atoms having distinct electronic structures interact with two adsorbates to catalyze an asymmetric reaction. We achieve a record n-propanol Faradaic efficiency (FE) of (33 ± 1)% with a conversion rate of (4.5 ± 0.1) mA cm-2, and a record n-propanol cathodic energy conversion efficiency (EEcathodic half-cell) of 21%. The FE and EEcathodic half-cell represent a 1.3× improvement relative to previously-published CO-to-n-propanol electroreduction reports.

Dopant-tuned stabilization of intermediates promotes electrosynthesis of valuable C3 products.

The upgrading of CO2/CO feedstocks to higher-value chemicals via energy-efficient electrochemical processes enables carbon utilization and renewable energy storage. Substantial progress has been made to improve performance at the cathodic side; whereas less progress has been made on improving anodic electro-oxidation reactions to generate value. Here we report the efficient electroproduction of value-added multi-carbon dimethyl carbonate (DMC) from CO and methanol via oxidative carbonylation. We find that, compared to pure palladium controls, boron-doped palladium (Pd-B) tunes the binding strength of intermediates along this reaction pathway and favors DMC formation. We implement this doping strategy and report the selective electrosynthesis of DMC experimentally. We achieve a DMC Faradaic efficiency of 83 ± 5%, fully a 3x increase in performance compared to the corresponding pure Pd electrocatalyst.

Electrochemical CO2 Reduction into Chemical Feedstocks: From Mechanistic Electrocatalysis Models to System Design.

The electrochemical reduction of CO2 is a promising route to convert intermittent renewable energy to storable fuels and valuable chemical feedstocks. To scale this technology for industrial implementation, a deepened understanding of how the CO2 reduction reaction (CO2 RR) proceeds will help converge on optimal operating parameters. Here, a techno-economic analysis is presented with the goal of identifying maximally profitable products and the performance targets that must be met to ensure economic viability-metrics that include current density, Faradaic efficiency, energy efficiency, and stability. The latest computational understanding of the CO2 RR is discussed along with how this can contribute to the rational design of efficient, selective, and stable electrocatalysts. Catalyst materials are classified according to their selectivity for products of interest and their potential to achieve performance targets is assessed. The recent progress and opportunities in system design for CO2 electroreduction are described. To conclude, the remaining technological challenges are highlighted, suggesting full-cell energy efficiency as a guiding performance metric for industrial impact.

Metal-Organic Frameworks Mediate Cu Coordination for Selective CO2 Electroreduction.

The electrochemical carbon dioxide reduction reaction (CO2RR) produces diverse chemical species. Cu clusters with a judiciously controlled surface coordination number (CN) provide active sites that simultaneously optimize selectivity, activity, and efficiency for CO2RR. Here we report a strategy involving metal-organic framework (MOF)-regulated Cu cluster formation that shifts CO2 electroreduction toward multiple-carbon product generation. Specifically, we promoted undercoordinated sites during the formation of Cu clusters by controlling the structure of the Cu dimer, the precursor for Cu clusters. We distorted the symmetric paddle-wheel Cu dimer secondary building block of HKUST-1 to an asymmetric motif by separating adjacent benzene tricarboxylate moieties using thermal treatment. By varying materials processing conditions, we modulated the asymmetric local atomic structure, oxidation state and bonding strain of Cu dimers. Using electron paramagnetic resonance (EPR) and in situ X-ray absorption spectroscopy (XAS) experiments, we observed the formation of Cu clusters with low CN from distorted Cu dimers in HKUST-1 during CO2 electroreduction. These exhibited 45% C2H4 faradaic efficiency (FE), a record for MOF-derived Cu cluster catalysts. A structure-activity relationship was established wherein the tuning of the Cu-Cu CN in Cu clusters determines the CO2RR selectivity.

CO2 electroreduction to ethylene via hydroxide-mediated copper catalysis at an abrupt interface.

Carbon dioxide (CO2) electroreduction could provide a useful source of ethylene, but low conversion efficiency, low production rates, and low catalyst stability limit current systems. Here we report that a copper electrocatalyst at an abrupt reaction interface in an alkaline electrolyte reduces CO2 to ethylene with 70% faradaic efficiency at a potential of -0.55 volts versus a reversible hydrogen electrode (RHE). Hydroxide ions on or near the copper surface lower the CO2 reduction and carbon monoxide (CO)-CO coupling activation energy barriers; as a result, onset of ethylene evolution at -0.165 volts versus an RHE in 10 molar potassium hydroxide occurs almost simultaneously with CO production. Operational stability was enhanced via the introduction of a polymer-based gas diffusion layer that sandwiches the reaction interface between separate hydrophobic and conductive supports, providing constant ethylene selectivity for an initial 150 operating hours.

Hydronium-Induced Switching between CO2 Electroreduction Pathways.

Over a broad range of operating conditions, many CO2 electroreduction catalysts can maintain selectivity toward certain reduction products, leading to materials and surfaces being categorized according to their products; here we ask, is product selectivity truly a property of the catalyst? Silver is among the best electrocatalysts for CO in aqueous electrolytes, where it reaches near-unity selectivity. We consider the hydrogenations of the oxygen and carbon atoms via the two proton-coupled-electron-transfer processes as chief determinants of product selectivity; and find using density functional theory (DFT) that the hydronium (H3O+) intermediate plays a key role in the first oxygen hydrogenation step and lowers the activation energy barrier for CO formation. When this hydronium influence is removed, the activation energy barrier for oxygen hydrogenation increases significantly, and the barrier for carbon hydrogenation is reduced. These effects make the formate reaction pathway more favorable than CO. Experimentally, we then carry out CO2 reduction in highly concentrated potassium hydroxide (KOH), limiting the hydronium concentration in the aqueous electrolyte. The product selectivity of a silver catalyst switches from entirely CO under neutral conditions to over 50% formate in the alkaline environment. The simulated and experimentally observed selectivity shift provides new insights into the role of hydronium on CO2 electroreduction processes and the ability for electrolyte manipulation to directly influence transition state (TS) kinetics, altering favored CO2 reaction pathways. We argue that selectivity should be considered less of an intrinsic catalyst property, and rather a combined product of the catalyst and reaction environment.

Rapid prototyping of all-solution-processed multi-lengthscale electrodes using polymer-induced thin film wrinkling.

Three-dimensional electrodes that are controllable over multiple lengthscales are very important for use in bioanalytical systems that integrate solid-phase devices with solution-phase samples. Here we present a fabrication method based on all-solution-processing and thin film wrinkling using smart polymers that is ideal for rapid prototyping of tunable three-dimensional electrodes and is extendable to large volume manufacturing. Although all-solution-processing is an attractive alternative to vapor-based techniques for low-cost manufacturing of electrodes, it often results in films suffering from low conductivity and poor substrate adhesion. These limitations are addressed here by using a smart polymer to create a conformal layer of overlapping wrinkles on the substrate to shorten the current path and embed the conductor onto the polymer layer. The structural evolution of these wrinkled electrodes, deposited by electroless deposition onto a nanoparticle seed layer, is studied at varying deposition times to understand its effects on structural parameters such as porosity, wrinkle wavelength and height. Furthermore, the effect of structural parameters on functional properties such as electro-active surface area and surface-enhanced Raman scattering is investigated. It is found that wrinkling of electroless-deposited thin films can be used to reduce sheet resistance, increase surface area, and enhance the surface-enhanced Raman scattering signal.

Programmable Wrinkling of Self-Assembled Nanoparticle Films on Shape Memory Polymers.

Hierarchically structured materials, inspired by sophisticated structures found in nature, are finding increasing applications in a variety of fields. Here, we describe the fabrication of wrinkled gold nanoparticle films, which leverage the structural tunability of gold nanoparticles to program the wavelength and amplitude of gold wrinkles. We have carefully examined the structural evolution and tuning of these wrinkled surfaces through varying nanoparticle parameters (diameter, number of layers, density) and substrate parameters (number of axes constrained during wrinkling) through scanning electron microscopy and cross-sectional transmission electron microscopy. It is found that nanoparticle layers of sufficient density are required to obtain periodical wrinkled structures. It was also found that tuning the nanoparticle diameter and number of layers can be used to program the wrinkle wavelength and amplitude by changing the film thickness and mechanical properties. This dual degree of tunability, not previously seen with continuous films, allows us to develop one of the smallest wrinkles developed to date with tunability in the sub-100 nm regime. The effect of the induced structural tunability on the enhancement of the intensity of the 4-mercaptopyridine Raman spectra is also studied through the application of these devices as substrates for surface-enhanced Raman spectroscopy (SERS), where wrinkling proves to be an effective method for enhancing the SERS signal in cases where there is an inherently low density of gold nanoparticles.

Rapidly prototyped multi-scale electrodes to minimize the voltage requirements for bacterial cell lysis.

Lab-on-a-chip systems used for nucleic acid based detection of bacteria rely on bacterial lysis for the release of cellular material. Although electrical lysis devices can be miniaturized for on-chip integration and reagent-free lysis, they often suffer from high voltage requirements, and rely on the use of off-chip voltage supplies. To overcome this barrier, we developed a rapid prototyping method for creating multi-scale electrodes that are structurally tuned for lowering the voltage needed for electrical bacterial lysis. These three-dimensional multi-scale electrodes ­ with micron scale reaction areas and nanoscale features ­ are fabricated using benchtop methods including craft cutting, polymer-induced wrinkling, and electrodeposition, which enable a lysis device to be designed, fabricated, and optimized in a matter of hours. These tunable electrodes show superior behaviour compared to lithographically-prepared electrodes in terms of lysis efficiency and voltage requirement. Successful extraction of nucleic acids from bacterial samples processed by these electrodes demonstrates the potential for these rapidly prototyped devices to be integrated within practical lab-on-a-chip systems.

Prototyping of wrinkled nano-/microstructured electrodes for electrochemical DNA detection.

Biosensing platforms are ideal for addressing the diagnostic needs of resource-poor areas; however, the translation of such systems from the laboratory to the point-of-need has been a slow process. Rapid prototyping methods that enable an application-specific biosensor to be created in a matter of hours from design to fabrication would expedite the clinical and field testing of such systems. Here, we demonstrate a benchtop method based on craft cutting and polymer-induced wrinkling for creating multiplexed electrochemical DNA biosensors. This fabrication method allows multiscale wrinkled electrodes with features in the millimeter to nanometer length scales to be created in a matter of hours. These wrinkled electrodes display an enhanced surface area compared to planar electrodes and are shown to be structurally tunable by changing the film thickness. We demonstrate that structural tunability of these electrodes is translatable to functional tunability as the density of surface-immobilized probe molecules can be manipulated using wrinkled electrodes of different thicknesses. Furthermore, a simple proof-of-concept electrocatalytic DNA biosensor is demonstrated for distinguishing between complementary and noncomplementary oligonucleotides.

An algorithm to discover gene signatures with predictive potential.

BACKGROUND: The advent of global gene expression profiling has generated unprecedented insight into our molecular understanding of cancer, including breast cancer. For example, human breast cancer patients display significant diversity in terms of their survival, recurrence, metastasis as well as response to treatment. These patient outcomes can be predicted by the transcriptional programs of their individual breast tumors. Predictive gene signatures allow us to correctly classify human breast tumors into various risk groups as well as to more accurately target therapy to ensure more durable cancer treatment. RESULTS: Here we present a novel algorithm to generate gene signatures with predictive potential. The method first classifies the expression intensity for each gene as determined by global gene expression profiling as low, average or high. The matrix containing the classified data for each gene is then used to score the expression of each gene based its individual ability to predict the patient characteristic of interest. Finally, all examined genes are ranked based on their predictive ability and the most highly ranked genes are included in the master gene signature, which is then ready for use as a predictor. This method was used to accurately predict the survival outcomes in a cohort of human breast cancer patients. CONCLUSIONS: We confirmed the capacity of our algorithm to generate gene signatures with bona fide predictive ability. The simplicity of our algorithm will enable biological researchers to quickly generate valuable gene signatures without specialized software or extensive bioinformatics training.