This paper reports an investigation into the electro-reduction of CO 2 in a laboratory bench-scale continuous reactor with co-current flow of reactant gas and catholyte liquid through a flow-by 3D cathode of 30 # mesh tinned-copper. Factorial and parametric experiments were carried out in this apparatus with the variables: current (1-8 A), gas phase CO 2 concentration (16-100 vol%) and operating time (10-180 min), using a cathode feed of [CO 2 + N 2 ] gas and 0.45 M KHCO 3 (aq) with an anolyte feed of 1 M KOH(aq), in operation near ambient conditions (ca. 115 kPa(abs), 300 K). The primary and secondary reactions here were respectively the reduction of CO 2 to formate (HCOO ) ) and of water to hydrogen, while up to ca. 5% of the current went to production of CO, CH 4 and C 2 H 4 . The current efficiency for formate depended on the current density and CO 2 pressure, coupled with the hydrogen over-potential plus mass transfer capacity of the cathode, and decreased with operating time, as tin was lost from the cathode surface. For superficial current densities ranging from 0.22 to 1.78 kA m )2 , the measured values of the performance indicators are: current efficiency for HCOO ) = 86-13%, reactor voltage = 3-6 Volt, specific energy for HCOO ) = 300-1300 kWh kmol )1 , space-time yield of HCOO ) = 2 · 10 )4 -6 · 10 )4 kmol m )3 s )1 , conversion of CO 2 = 20-80% and yield of organic products from CO 2 = 6-17%. Nomenclature a specific surface area of cathode, m )1 a k Tafel constant for reaction k, V a 2Cu Tafel constant for reaction 2 on copper, V a 2Sn Tafel constant for reaction 2 on tin, V CD current density, kA m )2 CE k current efficiency for reaction k, -D diffusion coefficient of CO 2 (aq), m 2 s )1 d wire diameter in cathode mesh, m d b bubble diameter, m E electrode potential, V(SHE) E cell full-cell operating voltage (absolute value), V E r,k reversible electrode potential of reaction k, V(SHE) E o k standard electrode potential of reaction k, V(SHE) DE voltage window in operation of 3D flow-by electrode, V F Faraday's number, kC kmol )1 G gas load in 3D flow-by electrode, kg m )2 s )1 h liquid hold-up in 3D flow-by electrode, -I current, kA i superficial current density, kA m )2i iL mass transfer limited superficial current density for reaction 1, kA m )2 j k partial real current density of reaction k, kA m )2 j 1L mass transfer limited real current density for reaction 1, kA m )2 K¢, K 0 , K 1 reaction equilibrium constants, -, M kPa )1 , M k F mass transfer coefficient due to forced convection, m s )1 k G mass transfer coefficient due to gas (H 2 ) generation, m s )1 k M combined mass transfer coefficient, m s )1 L liquid load in 3D flow-by electrode, kg m )2 s )1 P total pressure, kPa(abs) p CO 2 partial pressure of CO 2 , kPa(abs) p H 2 partial pressure of H 2 , kPa(abs) R gas constant, kJ kmol )1 K )1 Re bReynolds' number for bubble generation at electrode, -Re g Reynolds' number for gas flow = v g d q g / l g , -Re l Reynolds' number for liquid flow = v l d q l / l l , -SE specific energy for formate p...