Electrochemical CO2 reduction has the potential
to use
excess renewable electricity to produce hydrocarbon chemicals and
fuels. Gas diffusion electrodes (GDEs) allow overcoming the limitations
of CO2 mass transfer but are sensitive to flooding from
(hydrostatic) pressure differences, which inhibits upscaling. We investigate
the effect of the flooding behavior on the CO2 reduction
performance. Our study includes six commercial gas diffusion layer
materials with different microstructures (carbon cloth and carbon
paper) and thicknesses coated with a Ag catalyst and exposed to differential
pressures corresponding to different flow regimes (gas breakthrough,
flow-by, and liquid breakthrough). We show that physical electrowetting
further limits the flow-by regime at commercially relevant current
densities (≥200 mA cm–2), which reduces the
Faradaic efficiency for CO (FECO) for most carbon papers.
However, the carbon cloth GDE maintains its high CO2 reduction
performance despite being flooded with the electrolyte due to its
bimodal pore structure. Exposed to pressure differences equivalent
to 100 cm height, the carbon cloth is able to sustain an average FECO of 69% at 200 mA cm–2 even when the liquid
continuously breaks through. CO2 electrolyzers with carbon
cloth GDEs are therefore promising for scale-up because they enable
high CO2 reduction efficiency while tolerating a broad
range of flow regimes.