Nature has been in balance for tens of thousands of years, but since the Industrial Revolution mankind has been disturbing this balance by utilizing fossil fuels for technological advancement and for societal prosperity (Chapter 1). Fossil fuels like coal, oil and gas were able to power newly found inventions like the steam and combustion engines. Through oxidation their stored energy could be released and as waste greenhouse gasses, predominantly carbon dioxide (CO2), were produced and ejected into the atmosphere. While initially the impact of our activities was unnoticeable, the continuously increasing world population and its energy demand has led to such a severe amount of emissions that the accumulation of CO2 in the atmosphere started to impact natures balance. International agreements, such as CO2 neutrality by 2050, have been made to phase out fossil fuels and implementing renewable energy technologies as substitutes. However, the phasing out of fossil fuels takes a long time to be realized due to both technological and economic reason. Furthermore, some essential chemical industries rely on carbon-based reagents to produce commodity products and need to find an attractive, non-fossil based process to continue in a sustainable manner. In order to still achieve the climate goals that have been set, alternative technologies to mitigate emissions are being researched, and this is where this doctoral thesis enters the stage...@en

Electrochemical reduction of CO₂ presents an attractive way to store renewable energy in chemical bonds in a potentially carbon-neutral way. However, the available electrolyzers suffer from intrinsic problems, like flooding and salt accumulation, that must be overcome to industrialize the technology. To mitigate flooding and salt precipitation issues, researchers have used super-hydrophobic electrodes based on either expanded polytetrafluoroethylene (ePTFE) gas-diffusion layers (GDL’s), or carbon-based GDL’s with added PTFE. While the PTFE backbone is highly resistant to flooding, the non-conductive nature of PTFE means that without additional current collection the catalyst layer itself is responsible for electron-dispersion, which penalizes system efficiency and stability. In this work, we present operando results that illustrate that the current distribution and electrical potential distribution is far from a uniform distribution in thin catalyst layers (~50 nm) deposited onto ePTFE GDL’s. We then compare the effects of thicker catalyst layers (~500 nm) and a newly developed non-invasive current collector (NICC). The NICC can maintain more uniform current distributions with 10-fold thinner catalyst layers while improving stability towards ethylene (≥ 30%) by approximately two-fold.

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Continued advancements in the electrochemical reduction of CO 2 (CO 2RR) have emphasized that reactivity,selectivity, and stability are not explicit material properties butcombined effects of the catalyst, double-layer, reaction environ-
ment, and system configuration. These realizations have steadily built upon the foundational work performed for a broad array of transition metals performed at 5 mA cm−2, which historically guided the research field. To encompass the changing advancements and mindset within the research field, an updated baseline at elevated current densities could then be of value. Here we seek to
re-characterize the activity, selectivity, and stability of the five most utilized transition metal catalysts for CO2 RR (Ag, Au, Pd, Sn, and Cu) at elevated reaction rates through electrochemical operation, physical characterization, and varied operating parameters to provide a renewed resource and point of comparison. As a basis, we have employed a common cell architecture, highly controlled catalyst layer morphologies and thicknesses, and fixed current densities. Through a dataset of 88 separate experiments, we provide comparisons between CO-producing catalysts (Ag, Au, and Pd), highlighting CO-limiting current densities on Au and Pd at 72 and 50 mA cm−2, respectively. We further show the instability of Sn in highly alkaline environments, and the convergence of product selectivity at elevated current densities for a Cu catalyst in neutral andalkaline media. Lastly, we reflect upon the use and limits of reaction rates as a baseline metric by comparing catalytic selectivity at 10
versus 200 mA cm−2. We hope the collective work provides a resource for researchers setting up CO 2RR experiments for the first time.@en

The electrochemical reduction of carbon dioxide (CO₂) to value-added materials has received considerable attention. Both bulk transition-metal catalysts and molecular catalysts affixed to conductive noncatalytic solid supports represent a promising approach toward the electroreduction of CO₂. Here, we report a combined silver (Ag) and pyridine catalyst through a one-pot and irreversible electrografting process, which demonstrates the enhanced CO₂conversion versus individual counterparts. We find that by tailoring the pyridine carbon chain length, a 200 mV shift in the onset potential is obtainable compared to the bare silver electrode. A 10-fold activity enhancement at -0.7 V vs reversible hydrogen electrode (RHE) is then observed with demonstratable higher partial current densities for CO, indicating that a cocatalytic effect is attainable through the integration of the two different catalytic structures. We extended the performance to a flow cell operating at 150 mA/cm², demonstrating the approach's potential for substantial adaptation with various transition metals as supports and electrografted molecular cocatalysts.

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The electrochemical reduction of CO2 (CO2RR) on silver catalysts has been demonstrated under elevated current density, longer reaction times, and intermittent operation. Maintaining performance requires that CO2 can access the entire geometric catalyst area, thus maximizing catalyst utilization. Here we probe the time-dependent factors impacting geometric catalyst utilization for CO2RR in a zero-gap membrane electrode assembly. We use three flow fields (serpentine, parallel, and interdigitated) as tools to disambiguate cell behavior. Cathode pressure drop is found to play the most critical role in maintaining catalyst utilization at all time scales by encouraging in-plane CO2 transport throughout the gas-diffusion layer (GDL) and around salt and water blockages. The serpentine flow channel with the highest pressure drop is then the most failure-resistant, achieving a CO partial current density of 205 mA/cm2 at 2.76 V. These findings are confirmed through selectivity measurements over time, double-layer capacitance measurements to estimate GDL flooding, and transport modeling of the spatial CO2 concentration.

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Salt precipitation is a problem in electrochemical CO2 reduction electrolyzers that limits their long-term durability and industrial applicability by reducing the active area, causing flooding and hindering gas transport. Salt crystals form when hydroxide generation from electrochemical reactions interacts homogeneously with CO2 to generate substantial quantities of carbonate. In the presence of sufficient electrolyte cations, the solubility limits of these species are reached, resulting in "salting out"conditions in cathode compartments. Detrimental salt precipitation is regularly observed in zero-gap membrane electrode assemblies, especially when operated at high current densities. This Perspective briefly discusses the mechanisms for salt formation, and recently reported strategies for preventing or reversing salt formation in zero-gap CO2 reduction membrane electrode assemblies. We link these approaches to the solubility limit of potassium carbonate within the electrolyzer and describe how each strategy separately manipulates water, potassium, and carbonate concentrations to prevent (or mitigate) salt formation.

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