Scalable Gas Diffusion Electrode Fabrication for Electrochemical CO2 Reduction Using Physical Vapor Deposition Methods.

Electrochemical CO2 reduction (ECR) promises the replacement of fossil fuels as the source of feedstock chemicals and seasonal storage of renewable energy. While much progress has been made in catalyst development and electrochemical reactor design, few studies have addressed the effect of catalyst integration on device performance. Using a microfluidic gas diffusion electrolyzer, we systematically studied the effect of thickness and the morphology of electron beam (EB) and magnetron-sputtered (MS) Cu catalyst coatings on ECR performance. We observed that EB-Cu outperforms MS-Cu in current density, selectivity, and energy efficiency, with 400 nm thick catalyst coatings performing the best. The superior performance of EB-Cu catalysts is assigned to their faceted surface morphology and sharper Cu/gas diffusion layer interface, which increases their hydrophobicity. Tests in a large-scale zero-gap electrolyzer yielded similar product selectivity distributions with an ethylene Faradaic efficiency of 39% at 200 mA/cm2, demonstrating the scalability for industrial ECR applications.

Assessing adsorbent-biomass interactions during expanded bed adsorption onto ion exchangers utilizing surface energetics.

Biomass adhesion onto an adsorbent matrix or "interaction" as well as biological particle co-adhesion or "aggregation" can severely affect the overall performance of many direct-contact methods for downstream processing of bioproducts. Studies to quantitatively describe this biomass-adsorbent interaction were developed utilizing surface energetics. An indirect thermodynamic approach via contact angle and zeta potential measurements was utilized. Intact yeast cells, yeast homogenates, and disrupted bacterial paste were employed as model system. Various surfaces that are relevant to biochemical and environmental applications were characterized. The extended Derjaguin, Landau, Verwey, Overbeek (XDLVO) theory was found to appropriately predict biomass adhesion behaviour. It was observed that cell attachment onto anion-exchange supports is promoted by strong and close interaction within a secondary energy minimum followed by moderate multilayer cell aggregation. On the other hand, cell interaction with cation-exchange materials can take place within a reversible secondary energy minimum and at longer separation distance. The influence of particle charge and size, as well as the influence of the nature of the material under study were summarized in the form of energy vs. distance profiles. These investigations lead to many process-related conclusions: (a) process buffer conductivity windows can be recommended for anion-exchange chromatography (AEX) vs. cation-exchange chromatography (CEX) systems, (b) increased hydrodynamic shear is required to prevent biomass attachment onto AEX as compared to CEX, and (c) aggregation phenomena is a function of contact time and biomass concentration. Understanding biomass-adsorbent interaction at the particle (local) level is opening the pave for optimized operation of expanded bed adsorption methods at the process (macro) scale. A universal methodological approach is presented to guide both process and material design.