We performed H-cell and flow cell experiments to study the electrochemical reduction of CO2 to oxalic acid (OA) on a lead (Pb) cathode in various nonaqueous solvents. The effects of anolyte, catholyte, supporting electrolyte, temperature, water content, and cathode potential on the Faraday efficiency (FE), current density (CD), and product concentration were investigated. We show that a high FE for OA can be achieved (up to 90%) at a cathode potential of -2.5 V vs Ag/AgCl but at relatively low CDs (10-20 mA/cm2). The FE of OA decreases significantly with increasing water content of the catholyte, which causes byproduct formation (e.g., formate, glycolic acid, and glyoxylic acid). A process design and techno-economic evaluation of the electrochemical conversion of CO2 to OA is presented. The results show that the electrochemical route for OA production can compete with the fossil-fuel based route for the base case scenario (CD of 100 mA/cm2, OA FE of 80%, cell voltage of 4 V, electrolyzer CAPEX of $20000/m2, electricity price of $30/MWh, and OA price of $1000/ton). A sensitivity analysis shows that the market price of OA has a huge influence on the economics. A market price of at least $700/ton is required to have a positive net present value and a payback time of less than 10 years. The performance and economics of the process can be further improved by increasing the CD and FE of OA by using gas diffusion electrodes and eliminating water from the cathode, lowering the cell voltage by increasing the conductivity of the electrolyte solutions, and developing better OA separation methods.

Formic acid (FA) is an interesting hydrogen (H2) and carbon monoxide (CO) carrier that can be produced by the electrochemical reduction of carbon dioxide (CO2) using renewable energy. The separation of FA from water is challenging due to the strong (cross)association of the components and the presence of a high boiling azeotrope. For the separation of dilute FA solutions, liquid-liquid extraction is preferred over conventional distillation because distilling large amounts of water is very energy-intensive. In this study, we use 2-methyltetrahydrofuran (2-MTHF) to extract FA from the CO2 electrolysis process, which typically contains <20 wt % of FA. Vapor-liquid equilibrium (VLE) data of the binary system 2-MTHF-FA and liquid-liquid equilibrium (LLE) data of the ternary system 2-MTHF-FA-water are obtained. Continuous extraction and distillation experiments are performed to test the extraction power and recovery of 2-MTHF from the extract. The VLE and LLE data are used to design a hybrid extraction and distillation process to produce a commercial grade product (85 wt % of FA). A detailed economic analysis of this hybrid extraction-distillation process is presented and compared with the existing FA separation methods. It is shown that 2-MTHF is a cost-effective solvent for FA extraction from dilute streams (<20 wt % FA).

We use a high-pressure semicontinuous batch electrochemical reactor with a tin-based cathode to demonstrate that it is possible to efficiently convert CO₂ to formic acid (FA) in low-pH (i.e., pH < pK_a) electrolyte solutions. The effects of CO₂ pressure (up to 50 bar), bipolar membranes, and electrolyte (K₂SO₄) concentration on the current density (CD) and the Faraday efficiency (FE) of formic acid were investigated. The highest FE (?80%) of FA was achieved at a pressure of around 50 bar at a cell potential of 3.5 V and a CD of ?30 mA/cm². To suppress the hydrogen evolution reaction (HER), the electrochemical reduction of CO₂ in aqueous media is typically performed at alkaline conditions. The consequence of this is that products like formic acid, which has a pK_a of 3.75, will almost completely dissociate into the formate form. The pH of the electrolyte solution has a strong influence not only on the electrochemical reduction process of CO₂ but also on the downstream separation of (dilute) acid products like formic acid. The selection of separation processes depends on the dissociation state of the acids. A review of separation technologies for formic acid/formate removal from aqueous dilute streams is provided. By applying common separation heuristics, we have selected liquid-liquid extraction and electrodialysis for formic acid and formate separation, respectively. An economic evaluation of both separation processes shows that the formic acid route is more attractive than the formate one. These results urge for a better design of (1) CO₂ electrocatalysts that can operate at low pH without affecting the selectivity of the desired products and (2) technologies for efficient separation of dilute products from (photo)electrochemical reactors.