Conspectus
Carbon dioxide emissions from consumption of
fossil fuels have
caused serious climate issues. Rapid deployment of new energies makes
renewable energy driven CO2 electroreduction to chemical
feedstocks and carbon-neutral fuels a feasible and cost-effective
pathway for achieving net-zero emission. With the urgency of the net-zero
goal, we initiated our research on CO2 electrolysis with
emphasis on industrial relevance.
The CO2 molecules
are thermodynamically stable due to
high activation energy of the two CO bonds, and efficient
electrocatalysts are required to overcome the sluggish dynamics and
competitive hydrogen evolution reaction. The CO2 electrocatalysts
that we have explored include molecular catalysts and nanostructured
catalysts. Molecular catalysts are centered on earth abundant elements
such as Fe and Co for catalyzing CO2 reduction, and using
Fe catalysts, we proposed an amidation strategy for reduction of CO2 to methanol, bypassing the inactive formate pathway. For
nanostructured catalysts, we developed a carbon enrichment strategy
using nitrogen-rich nanomaterials for selective CO2 reduction.
Direct CO2 electroreduction from the flue gas stream
represents the “holy grail” in the field, because typical
CO2 concentration in flue gas is only 6–15%, posing
a significant challenge for CO2 electrolysis. On the other
hand, direct electroreduction of CO2 in the flue gas eliminates
the carbon capture process and simplifies the overall carbon capture
and utilization (CCU) scheme. However, direct flue gas reduction is
frustrated by the reactive oxygen (5–8%), low CO2 concentration (6–15%), and potentially toxic impurities.
Surface CO2 enrichment catalysts with high O2 tolerance could be viable for achieving direct CO2 electroreduction
for decarbonization of flue gas.
In addition to the electrocatalysts,
the incorporation of catalysts
into the electrolyzer and development of a suitable process was also
investigated to meet industrial demands. A membrane electrode assembly
(MEA) is a zero-gap configuration with cathode and anode catalysts
coated on either side of an ion exchange membrane. We adopted the
MEA configuration due to the structural simplicity, low ohmic resistance,
and high efficiency. The electrode factors (for example, membrane
type, catalyst layer porosity, and MEA fabrication method) and the
electrolyzer factors (for example, flow channels, gas diffusion layer)
are critical to highly efficient operation. We separately developed
an anion-exchange membrane-based system for CO production and cation-exchange
membrane-based system for formate production. The optimized electrolyzer
configuration can generate uniform current and voltage distribution
in a large-area electrolyzer and operate using an industrial CO2 stream. The optimized process was developed with the targets
of long-term continuous operation and no electrolyte consumption.