Integrated Capture and Electrochemical Conversion of CO2 into CO

Abstract

The capture and electrochemical conversion of CO2, powered by renewable electricity, is an attractive method of sustainably producing valuable chemicals and fuels (e.g. carbon monoxide (CO)), reducing atmospheric CO2, and storing intermittent renewable energy. Integrated capture and conversion (reactive capture) of CO2 presents a CO2-to-CO electrolysis pathway that eliminates most of the upstream capital and energy costs by releasing CO2 directly inside the electrolyzer using an internal pH-swing. The reactive capture system readily allows for the collection of produced gas products via phase separation, thus minimizing downstream separation costs.Industrial-scale integration of reactive capture systems with upgrading processes require a pure and consistent product stream. Previous studies using bicarbonate electrolytes have demonstrated high selectivity towards CO. However, the limited CO2 capture capacity of bicarbonate electrolytes dilute the cathode product gas stream with excess CO2. This mandates a secondary CO2 capture unit and increases the cost of downstream separation. Other studies using carbonate or carbamate electrolyte as the inlet feed did not simultaneously achieve high CO selectivity and long-term stability.This study sought to improve the Faradaic efficiency (FE) toward CO in our carbonate electrolysis system by engineering a novel membrane electrode assembly structure. We designed a composite CO2 diffusion layer (CDL) between the cathode and the membrane that attains high CO selectivity by simultaneously achieving high alkalinity and sufficient CO2 availability at the cathode. We determined that the thickness, wettability, and permeability of the CDL affected species transport and were important optimization parameters. Applying this strategy, we produced syngas, a mixture of CO and hydrogen (H2), with an industrial H2/CO ratio of 1.16 at 200 mA cm-2. This corresponded to a CO Faradaic efficiency (FE) of 46% and energy intensity of 52 GJ tsyngas-1. The syngas produced in this system was not diluted by CO2 and contained sufficient CO content to meet industrial standards. We further increased the FE towards CO by exploring different capture solutions and designing selective catalysts for energy efficient CO production. System parameters such as temperature and pressure effects were also investigated to improve the CO2 concentration at the cathode. This study illustrated the potential for the industrial implementation of an energy efficient and capital cost effective CO2-to-CO pathway via reactive capture.