Carbon dioxide electroreduction (CO2R) is being actively studied as a promising route to convert carbon emissions to valuable chemicals and fuels. However, the fraction of input CO2 that is productively reduced has typically been very low, <2% for multicarbon products; the balance reacts with hydroxide to form carbonate in both alkaline and neutral reactors. Acidic electrolytes would overcome this limitation, but hydrogen evolution has hitherto dominated under those conditions. We report that concentrating potassium cations in the vicinity of electrochemically active sites accelerates CO2 activation to enable efficient CO2R in acid. We achieve CO2R on copper at pH <1 with a single-pass CO2 utilization of 77%, including a conversion efficiency of 50% toward multicarbon products (ethylene, ethanol, and 1-propanol) at a current density of 1.2 amperes per square centimeter and a full-cell voltage of 4.2 volts.

The electrochemical conversion of CO 2 produces valuable chemicals and fuels. However, operating at high reaction rates produces locally alkaline conditions that convert reactant CO 2 into cell-damaging carbonate salts. These salts precipitate in the porous cathode structure, block CO 2 transport, reduce reaction efficiency, and render CO 2 electrolysis inherently unstable. We propose a self-cleaning CO 2 reduction strategy with short, periodic reductions in applied voltage, which avoids saturation and prevents carbonate salt formation. We demonstrate this approach in a membrane electrode assembly (MEA) with silver and copper catalysts, on carbon and polytetrafluoroethylene (PTFE)-based gas diffusion electrodes, respectively. When operated continuously, the C 2 selectivity of the copper−PTFE system started to decline rapidly after only ∼10 h. With the self-cleaning strategy, the same electrode operated for 157 h (236 h total duration), maintaining 80% C 2 product selectivity and 138 mA cm −2 of C 2 partial current density, at a cost of <1% additional energy input.

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.

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