Systematic screening of gas diffusion layers for high performance CO2 electrolysis

Certain industrially relevant performance metrics of CO 2 electrolyzers have already been approached in recent years. The energy efficiency of CO 2 electrolyzers, however, is yet to be improved, and the reasons behind performance fading must be uncovered. The performance of the electrolyzer cells is strongly affected by their components, among which the gas diffusion electrode is one of the most critical elements. To understand which parameters of the gas diffusion layers (GDLs) affect the cell performance the most, we compared commercially available GDLs in the electrochemical reduction of CO 2 to CO, under identical, fully controlled experimental conditions. By systematically screening the most frequently used GDLs and their counterparts differing in only one parameter, we tested the influence of the microporous layer, the polytetrafluoroethylene content, the thickness, and the orientation of the carbon fibers of the GDLs. The electrochemical results were correlated to different physical/chemical parameters of the GDLs, such as their hydrophobicity and surface cracking

Local hydrophobicity allows high-performance electrochemical carbon monoxide reduction to C 2+ products

Tailoring the hydrophobicity of the cathode gas diffusion electrode mitigates flooding in parallel with enhancing the selectivity of the electrochemical carbon monoxide reduction reaction

Local hydrophobicity allows high-performance electrochemical carbon monoxide reduction to C 2+ products

While CO can already be produced at industrially relevant current densities via CO2 electrolysis, the selective formation of C2+ products seems challenging. CO electrolysis, in principle, can overcome this barrier, hence forming valuable chemicals from CO2 in two steps. Here we demonstrate that a mass-produced, commercially available polymeric pore sealer can be used as a catalyst binder, ensuring high rate and selective CO reduction. We achieved above 70% faradaic efficiency for C2+ products formation at j = 500 mA cm−2 current density. As no specific interaction between the polymer and the CO reactant was found, we attribute the stable and selective operation of the electrolyzer cell to the controlled wetting of the catalyst layer due to the homogeneous polymer coating on the catalyst particles’ surface. These results indicate that sophistically designed surface modifiers are not necessarily required for CO electrolysis, but a simpler alternative can in some cases lead to the same reaction rate, selectivity and energy efficiency; hence the capital costs can be significantly decreased