RESUMO
CO2 electrolyzers require gaseous CO2 or saturated CO2 solutions to achieve high energy efficiency (EE) in flow reactors. However, CO2 capture and delivery to electrolyzers are in most cases responsible for the inefficiency of the technology. Recently, bicarbonate zero-gap flow electrolyzers have proven to convert CO2 directly from bicarbonate solutions, thus mimicking a CO2 capture medium, obtaining high Faradaic efficiency (FE) and partial current density (CD) toward carbon products. However, since bicarbonate electrolyzers use a bipolar membrane (BPM) as a separator, the cell voltage (VCell) is high, and the system becomes less efficient compared to analogous CO2 electrolyzers. Due to the role of the bicarbonate both as a carbon donor and proton donor (in contrast to gas-fed CO2 electrolyzers), optimization by using know-how from conventional gas-fed CO2 electrolyzers is not valid. In this study, we have investigated how different engineering aspects, widely studied for upscaling gas-fed CO2 electrolyzers, influence the performance of bicarbonate zero-gap flow electrolyzers when converting CO2 to formate. The temperature, flow rate, and concentration of the electrolyte are evaluated in terms of FE, productivity, VCell, and EE in a broad range of current densities (10-400 mA cm-2). A CD of 50 mA cm-2, room temperature, high flow rate (5 mL cm-2) of the electrolyte, and high carbon load (KHCO3 3 M) are proposed as potentially optimal parameters to benchmark a design to achieve the highest EE (27% is obtained this way), one of the most important criteria when upscaling and evaluating carbon capture and conversion technologies. On the other hand, at high CD (>300 mA cm-2), low flow rate (0.5 mL cm-2) has the highest interest for downstream processing (>40 g L-1 formate is obtained this way) at the cost of a low EE (<10%).
RESUMO
Direct electrochemical reduction of CO2 to C2 products such as ethylene is more efficient in alkaline media, but it suffers from parasitic loss of reactants due to (bi)carbonate formation. A two-step process where the CO2 is first electrochemically reduced to CO and subsequently converted to desired C2 products has the potential to overcome the limitations posed by direct CO2 electroreduction. In this study, we investigated the technical and economic feasibility of the direct and indirect CO2 conversion routes to C2 products. For the indirect route, CO2 to CO conversion in a high temperature solid oxide electrolysis cell (SOEC) or a low temperature electrolyzer has been considered. The product distribution, conversion, selectivities, current densities, and cell potentials are different for both CO2 conversion routes, which affects the downstream processing and the economics. A detailed process design and techno-economic analysis of both CO2 conversion pathways are presented, which includes CO2 capture, CO2 (and CO) conversion, CO2 (and CO) recycling, and product separation. Our economic analysis shows that both conversion routes are not profitable under the base case scenario, but the economics can be improved significantly by reducing the cell voltage, the capital cost of the electrolyzers, and the electricity price. For both routes, a cell voltage of 2.5 V, a capital cost of $10,000/m2, and an electricity price of <$20/MWh will yield a positive net present value and payback times of less than 15 years. Overall, the high temperature (SOEC-based) two-step conversion process has a greater potential for scale-up than the direct electrochemical conversion route. Strategies for integrating the electrochemical CO2/CO conversion process into the existing gas and oil infrastructure are outlined. Current barriers for industrialization of CO2 electrolyzers and possible solutions are discussed as well.