Development of Durable Large-Sized CO2 Electrolysis Cells for Industrial Applications

Abstract

Utilization of carbon dioxide (CO2) as a feedstock of valuable chemicals is necessary to achieve carbon neutrality. Toshiba is developing the low-temperature zero-gap type CO2 electrolysis cells to produce carbon monoxide (CO) [1,2]. CO can further be converted into various chemicals and fuels by catalytic reactions with hydrogen. To make the CO2 electrolysis technology industrially feasible, it is necessary to establish high-throughput system by expanding the electrode area and stacking the cells. Large-sized cells and stacks often suffer from low Faradaic efficiency for the CO production, which is related to insufficient and nonuniform supply of reactant CO2 gas to the cathode reaction sites. This time we focused on the development of large-sized single cells and fabricated an electrolysis cell with 400 cm2 electrodes. With properly designed gas flow plates and gaskets, the cell voltage and the CO Faradaic efficiency of the fabricated cell at a current density of 400 mA cm-2 were comparable to those of the previously developed smaller cells with 4 cm2 electrodes. The CO concentration in the cathode outlet gas reached ca. 80% by controlling the inlet CO2 flow rate. Stability is another essential property of CO2 electrolysis cells required for the industrial application. Cathode flooding and salt precipitation are major stability issues characteristic of relatively short-term operations, whose detailed mechanism is still in debate [3]. To mitigate those stability issues, we focused on the cathode inlet humidity and the pressure difference between the cathode and the anode. The former is related to the salt concentration in electrolyte solution around the cathode reaction sites, and the latter is related to the convection of electrolyte from the anode side to the cathode side. By controlling those parameters, stable performance over 100 h was achieved.Part of this work was commissioned by Ministry of the Environment, Government of Japan.[1] Y. Kofuji, A. Ono, Y. Sugano, A. Motoshige, Y. Kudo, M. Yamagiwa, J. Tamura, S. Mikoshiba, and R. Kitagawa, Chem. Lett., 50, 482-484 (2021).[2] Y. Kiyota, Y. Kofuji, A. Ono, S. Mikoshiba, and R. Kitagawa, 242nd ECS Meeting, I05-1942 (2022).[3] M. Sassenburg, M. Kelly, S. Subramanian, W. A. Smith, and T. Burdyny, ACS Energy Lett., 8, 321-331 (2023).