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.

Geometric Catalyst Utilization in Zero-Gap CO2 Electrolyzers.

The electrochemical reduction of CO2 (CO2RR) on silver catalysts has been demonstrated under elevated current density, longer reaction times, and intermittent operation. Maintaining performance requires that CO2 can access the entire geometric catalyst area, thus maximizing catalyst utilization. Here we probe the time-dependent factors impacting geometric catalyst utilization for CO2RR in a zero-gap membrane electrode assembly. We use three flow fields (serpentine, parallel, and interdigitated) as tools to disambiguate cell behavior. Cathode pressure drop is found to play the most critical role in maintaining catalyst utilization at all time scales by encouraging in-plane CO2 transport throughout the gas-diffusion layer (GDL) and around salt and water blockages. The serpentine flow channel with the highest pressure drop is then the most failure-resistant, achieving a CO partial current density of 205 mA/cm2 at 2.76 V. These findings are confirmed through selectivity measurements over time, double-layer capacitance measurements to estimate GDL flooding, and transport modeling of the spatial CO2 concentration.

Energy comparison of sequential and integrated CO2 capture and electrochemical conversion.

Integrating carbon dioxide (CO2) electrolysis with CO2 capture provides exciting new opportunities for energy reductions by simultaneously removing the energy-demanding regeneration step in CO2 capture and avoiding critical issues faced by CO2 gas-fed electrolysers. However, understanding the potential energy advantages of an integrated process is not straightforward due to the interconnected processes which require knowledge of both capture and electrochemical conversion processes. Here, we identify the upper limits of the integrated process from an energy perspective by comparing the working principles and performance of integrated and sequential approaches. Our high-level energy analyses unveil that an integrated electrolyser must show similar performance to the gas-fed electrolyser to ensure an energy benefit of up to 44% versus the sequential route. However, such energy benefits diminish if future gas-fed electrolysers resolve the CO2 utilisation issue and if an integrated electrolyser shows lower conversion efficiencies than the gas-fed system.

CO2 Electrolysis via Surface-Engineering Electrografted Pyridines on Silver Catalysts.

The electrochemical reduction of carbon dioxide (CO2) to value-added materials has received considerable attention. Both bulk transition-metal catalysts and molecular catalysts affixed to conductive noncatalytic solid supports represent a promising approach toward the electroreduction of CO2. Here, we report a combined silver (Ag) and pyridine catalyst through a one-pot and irreversible electrografting process, which demonstrates the enhanced CO2 conversion versus individual counterparts. We find that by tailoring the pyridine carbon chain length, a 200 mV shift in the onset potential is obtainable compared to the bare silver electrode. A 10-fold activity enhancement at -0.7 V vs reversible hydrogen electrode (RHE) is then observed with demonstratable higher partial current densities for CO, indicating that a cocatalytic effect is attainable through the integration of the two different catalytic structures. We extended the performance to a flow cell operating at 150 mA/cm2, demonstrating the approach's potential for substantial adaptation with various transition metals as supports and electrografted molecular cocatalysts.

Electrochemical removal of sulfide on porous carbon-based flow-through electrodes.

Electrochemical oxidation of hydrogen sulfide and its separation from the waste stream in the form of sulfur was studied at low-cost carbon-based porous materials, activated carbon felt (ACF) and graphite felt (GF). Both materials were capable of selective HS- oxidation to elemental sulfur in low-conductivity solutions (i.e., <1 mS cm-1), as well as in raw sewage. The HS- removal rate was ten times faster at ACF compared with GF electrode due to the higher surface area and chemisorption of HS-. To address the electrode passivation with the electrodeposited sulfur, different electrochemical recovery strategies were tested. GF could be only partially regenerated (i.e., 30% efficiency) using cathodic polarization. Also, both anodic and cathodic polarization improved the sulfide removal in the subsequent working cycle due to the introduction of new redox-active oxygen containing functional groups. Sulfur deposited at the ACF electrode could not be recovered by any of the investigated strategies. Thus, sulfur was incorporated into the carbon matrix and strongly bonded with the carbon functional groups at both GF and ACF electrodes. Although carbon-based electrodes have been widely investigated for electrochemical sulfide removal, this study demonstrates that their application is limited by low regeneration efficiency of the electrodeposited sulfur.

Mn3O4@CoMn2O4-CoxOy Nanoparticles: Partial Cation Exchange Synthesis and Electrocatalytic Properties toward the Oxygen Reduction and Evolution Reactions.

Mn3O4@CoMn2O4 nanoparticles (NPs) were produced at low temperature and ambient atmosphere using a one-pot two-step synthesis protocol involving the cation exchange of Mn by Co in preformed Mn3O4 NPs. Selecting the proper cobalt precursor, the nucleation of CoxOy crystallites at the Mn3O4@CoMn2O4 surface could be simultaneously promoted to form Mn3O4@CoMn2O4-CoxOy NPs. Such heterostructured NPs were investigated for oxygen reduction and evolution reactions (ORR, OER) in alkaline solution. Mn3O4@CoMn2O4-CoxOy NPs with [Co]/[Mn] = 1 showed low overpotentials of 0.31 V at -3 mA·cm(-2) and a small Tafel slope of 52 mV·dec(-1) for ORR, and overpotentials of 0.31 V at 10 mA·cm(-2) and a Tafel slope of 81 mV·dec(-1) for OER, thus outperforming commercial Pt-, IrO2-based and previously reported transition metal oxides. This cation-exchange-based synthesis protocol opens up a new approach to design novel heterostructured NPs as efficient nonprecious metal bifunctional oxygen catalysts.