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<p>Electrocatalytic CO₂ reduction (ECO₂R) presents a sustainable pathway for industrial decarbonization by converting CO₂ into carbon-neutral fuels and chemicals. Despite progress in catalyst design, industrial scalability is hindered by slow mass-transfer kinetics. Here, we introduce a high-diffusion-flux gas diffusion electrode (HDF-GDE) that overcomes this limitation in alkali-cation-free systems, achieving CO₂ conversion rates at industrial current densities. Kinetic analysis demonstrates that conversion is governed by mass transfer efficiency rather than flow rate. By optimizing the GDE structure to maximize CO₂ diffusion and GDE utilization, we realize a kW-scale ECO₂R system with stability (&gt;1000 hours), producing CO or C₂H₄ depending on the catalyst. Operating with a 3 L/min CO₂ flow rate, the system delivers 144 kg of CO (1.29 kW) or 17 kg of C<sub>2</sub>H<sub>4</sub> (1.95 kW) over 1000 h. The alkali-cation-free ECO<sub>2</sub>R system, equipped with HDF-GDEs, demonstrates economic viability for large-scale ECO<sub>2</sub>R-to-CO/C<sub>2</sub>H<sub>4</sub> production. Our findings bridge the gap between lab innovation and real-world deployment, advancing carbon-neutral chemical manufacturing.</p>

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Kilowatt-scale alkali-cation-free CO2 electrolysis via accelerating mass transfer

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年2月12日

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  • Xiaojie She,
  • Zhihang Xu,
  • Qiang Ma,
  • Qiming Qian,
  • Hui Shi,
  • Molly Meng-Jung Li,
  • Pei Xiong,
  • Ye Zhu,
  • Mengxia Ji,
  • Huaming Li,
  • Hui Xu,
  • Junlin Zheng,
  • Tongwen Xu,
  • Weimin Yang,
  • Jingzheng Ren,
  • Shu Ping Lau

摘要

Electrocatalytic CO₂ reduction (ECO₂R) presents a sustainable pathway for industrial decarbonization by converting CO₂ into carbon-neutral fuels and chemicals. Despite progress in catalyst design, industrial scalability is hindered by slow mass-transfer kinetics. Here, we introduce a high-diffusion-flux gas diffusion electrode (HDF-GDE) that overcomes this limitation in alkali-cation-free systems, achieving CO₂ conversion rates at industrial current densities. Kinetic analysis demonstrates that conversion is governed by mass transfer efficiency rather than flow rate. By optimizing the GDE structure to maximize CO₂ diffusion and GDE utilization, we realize a kW-scale ECO₂R system with stability (>1000 hours), producing CO or C₂H₄ depending on the catalyst. Operating with a 3 L/min CO₂ flow rate, the system delivers 144 kg of CO (1.29 kW) or 17 kg of C2H4 (1.95 kW) over 1000 h. The alkali-cation-free ECO2R system, equipped with HDF-GDEs, demonstrates economic viability for large-scale ECO2R-to-CO/C2H4 production. Our findings bridge the gap between lab innovation and real-world deployment, advancing carbon-neutral chemical manufacturing.