The integration of renewable energy with industrially relevant CO2 electrolyzers provides a promising pathway to achieving sustainable fuels and chemical generation. In this work, mass transport phenomena in a zero-gap membrane-electrode-assembly (MEA) are investigated by varying the thickness of the gaskets used during cell assembly, which in turn determines the overall applied cell compression (Figure 1a). X-ray computed tomography characterization (XCT) shows changes in the gas diffusion electrode (GDE) thickness and porosity as a result of changing the applied cell compression. Using the experimentally measured GDE properties, a computational model of the electrolyzer is developed to study mass transport effects on the performance of the Ag catalyst for CO2 to CO conversion. Applying high cell compression is found to decrease electrode porosity and increase liquid saturation in the cathode catalyst layer and diffusion media, thereby limiting the mass transport of CO2. The two MEAs assembled and tested (MEA-008 and MEA-010) with 0.008” and 0.010” thick gaskets, respectively, show CO Faradaic efficiencies that are very similar to the model results (Figure 1b). MEA-010, which has higher porosity and thicker GDE, outperforms MEA-008 at high current densities (>100 mA cm-2) due to improved mass transport. However, MEA-010 shows increased cell resistance due to the reduced compression of the conductive fibers, resulting in higher operating cell voltages, highlighting the important trade-off between product selectivity and the voltage required to run the electrolyzer. Figure 1
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