Electrochemical reduction of carbon dioxide (CO₂) to useful products is an emerging power-to-X concept, which aims to produce chemicals and fuels with renewable electricity instead of fossil fuels. Depending on the catalyst, a range of chemicals can be produced from CO₂ electrolysis at industrial-scale current densities, high Faraday efficiencies, and relatively low cell voltages. One of the main challenges for up-scaling the process is related to (bi)carbonate formation (carbonation), which is a consequence of performing the reaction in alkaline media to suppress the competing hydrogen evolution reaction. The parasitic reactions of CO₂ with the alkaline electrolytes result in (bi)carbonate precipitation and flooding in gas diffusion electrodes, CO₂ crossover to the anode, low carbon utilization efficiencies, electrolyte carbonation, pH-drift in time, and additional cost for CO₂ and electrolyte recycling. We present a critical review of the causes, consequences, and possible solutions for the carbonation effect in CO₂ electrolyzers. The mechanism of (bi)carbonate crossover in different cell configurations, its effect on the overall process design, and the economics of CO₂ and electrolyte recovery are presented. The aim is to provide a better understanding of the (bi)carbonate problem and guide research directions to overcome the challenges related to low-temperature CO₂ electrolysis in alkaline media.

One of the important parameters in water management of proton exchange membranes is the electro-osmotic drag (EOD) coefficient of water. The value of the EOD coefficient is difficult to justify, and available literature data on this for Nafion membranes show scattering from in experiments and simulations. Here, we use a classical all-atom model to compute the EOD coefficient and thermodynamic properties of water from molecular dynamics simulations for temperatures between 330 and 420 K, and for different water contents between λ = 5 and λ = 20. λ is the ratio between the moles of water molecules to the moles of sulfonic acid sites. This classical model does not capture the Grotthuss mechanism; however, it is shown that it can predict the EOD coefficient within the range of experimental values for λ = 5 where the vehicular mechanism dominates proton transfer. For λ > 5, the Grotthuss mechanism becomes dominant. To obtain the EOD coefficient, average velocities of water and ions are computed by imposing different electric fields to the system. Our results show that the velocities of water and hydronium scale linearly with the electric field, resulting in a constant ratio of ca. 0.4 within the error bars. We find that the EOD coefficient of water linearly increases from 2 at λ = 5 to 8 at λ = 20 and the results are not sensitive to temperature. The EOD coefficient at λ = 5 is within the range of experimental values, confirming that the model can capture the vehicular transport of protons well. At λ = 20, due to the absence of proton hopping in the model, the EOD coefficient is overestimated by a factor of 3 compared to experimental values. To analyze the interactions between water and Nafion, the partial molar enthalpies and partial molar volumes of water are computed from molecular dynamics simulations. At different water uptakes, multiple linear regression is used on raw simulation data within a narrow composition range of water inside the Nafion membrane. The partial molar volumes and partial molar excess enthalpies of water asymptotically approach the molar volumes and molar excess enthalpies of pure water for water uptakes above 5. This confirms the model can capture the bulklike behavior of water in the Nafion at high water uptakes.

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.

The electrochemical CO2 reduction reaction (CO2RR) is important for a sustainable future. Key insights into the reaction pathways have been obtained by density functional theory (DFT) analysis, but so far, DFT has been unable to give an overall understanding of selectivity trends without important caveats. We show that an unconsidered parameter in DFT models of electrocatalysts-the surface coverage of reacting species-is crucial for understanding the CO2RR selectivities for different surfaces. Surface coverage is a parameter that must be assumed in most DFT studies of CO2RR electrocatalysts, but so far, only the coverage of nonreacting adsorbates has been treated. Explicitly treating the surface coverage of reacting adsorbates allows for an investigation that can more closely mimic operating conditions. Furthermore, and of more immediate importance, the use of surface coverage-dependent adsorption energies allows for the extraction of ratios of adsorption energies of CO2RR intermediates (COOHads and HCOOads) that are shown to be predictive of selectivity and are not susceptible to systematic errors. This approach allows for categorization of the selectivity of several monometallic catalysts (Pt, Pd, Au, Ag, Zn, Cu, Rh, W, Pb, Sn, In, Cd, and Tl), even problematic ones such as Ag or Zn, and does so by only considering the adsorption energies of known intermediates. The selectivity of the further reduction of COOHads can now be explained by a preference for Tafel or Heyrovsky reactions, recontextualizing the nature of selectivity of some catalysts. In summary, this work resolves differences between DFT and experimental studies of the CO2RR and underlines the importance of surface coverage.

Recently, deep eutectic solvents (DES) have been considered as possible electrolytes for the electrochemical reduction of CO2 to value-added products such as formic and oxalic acids. The applicability of pure DES as electrolytes is hindered by high viscosities. Mixtures of DES with organic solvents can be a promising way of designing superior electrolytes by exploiting the advantages of each solvent type. In this study, densities, viscosities, diffusivities, and ionic conductivities of mixed solvents comprising DES (i.e., reline and ethaline), methanol, and propylene carbonate were computed using molecular simulations. To provide a quantitative assessment of the affinity and mass transport of CO2 and oxalic and formic acids in the mixed solvents, the solubilities and self-diffusivities of these solutes were also computed. Our results show that the addition of DES to the organic solvents enhances the solubilities of oxalic and formic acids, while the solubility of CO2 in the ethaline-containing mixtures are in the same order of magnitude with the respective pure organic components. A monotonic increase in the densities and viscosities of the mixed solvents is observed as the mole fraction of DES in the mixture increases, with the exception of the density of ethaline-propylene carbonate which shows the opposite behavior due to the high viscosity of the pure organic component. The self-diffusivities of all species in the mixtures significantly decrease as the mole fraction of DES approaches unity. Similarly, the self-diffusivities of the dissolved CO2 and the oxalic and formic acids also decrease by at least 1 order of magnitude as the composition of the mixture shifts from the pure organic component to pure DES. The computed ionic conductivities of all mixed solvents show a maximum value for mole fractions of DES in the range from 0.2 to 0.6 and decrease as more DES is added to the mixtures. Since for most mixtures studied here no prior experimental measurements exist, our findings can serve as a first data set based on which further investigation of DES-containing electrolyte solutions can be performed for the electrochemical reduction of CO2 to useful chemicals.

According to the ISO 14687-2:2019 standard, the water content of H2 fuel for transportation and stationary applications should not exceed 5 ppm (molar). To achieve this water content, zeolites can be used as a selective adsorbent for water. In this work, a computational screening study is carried out for the first time to identify potential zeolite frameworks for the drying of high-pressure H2 gas using Monte Carlo (MC) simulations. We show that the Si/Al ratio and adsorption selectivity have a negative correlation. 218 zeolites available in the database of the International Zeolite Association are considered in the screening. We computed the adsorption selectivity of each zeolite for water from the high-pressure H2 gas having water content relevant to vehicular applications and near saturation. It is shown that due to the formation of water clusters, the water content in the H2 gas has a significant effect on the selectivity of zeolites with a helium void fraction larger than 0.1. Under each operating condition, five most promising zeolites are identified based on the adsorption selectivity, the pore limiting diameter, and the volume of H2 gas that can be dried by 1 dm3 of zeolite. It is shown that at 12.3 ppm (molar) water content, structures with helium void fractions smaller than 0.07 are preferred. The structures identified for 478 ppm (molar) water content have helium void fractions larger than 0.26. The proposed zeolites can be used to dry 400-8000 times their own volume of H2 gas depending on the operating conditions. Our findings strongly indicate that zeolites are potential candidates for the drying of high-pressure H2 gas.

Direct electrochemical reduction of CO2 to C2 products such as ethylene is more efficient in alkaline media, but it suffers from parasitic loss of reactants due to (bi)carbonate formation. A two-step process where the CO2 is first electrochemically reduced to CO and subsequently converted to desired C2 products has the potential to overcome the limitations posed by direct CO2 electroreduction. In this study, we investigated the technical and economic feasibility of the direct and indirect CO2 conversion routes to C2 products. For the indirect route, CO2 to CO conversion in a high temperature solid oxide electrolysis cell (SOEC) or a low temperature electrolyzer has been considered. The product distribution, conversion, selectivities, current densities, and cell potentials are different for both CO2 conversion routes, which affects the downstream processing and the economics. A detailed process design and techno-economic analysis of both CO2 conversion pathways are presented, which includes CO2 capture, CO2 (and CO) conversion, CO2 (and CO) recycling, and product separation. Our economic analysis shows that both conversion routes are not profitable under the base case scenario, but the economics can be improved significantly by reducing the cell voltage, the capital cost of the electrolyzers, and the electricity price. For both routes, a cell voltage of 2.5 V, a capital cost of $10,000/m2, and an electricity price of <$20/MWh will yield a positive net present value and payback times of less than 15 years. Overall, the high temperature (SOEC-based) two-step conversion process has a greater potential for scale-up than the direct electrochemical conversion route. Strategies for integrating the electrochemical CO2/CO conversion process into the existing gas and oil infrastructure are outlined. Current barriers for industrialization of CO2 electrolyzers and possible solutions are discussed as well.

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).

Force field-based molecular simulations were used to calculate thermal expansivities, heat capacities, and Joule-Thomson coefficients of binary (standard) hydrogen-water mixtures for temperatures between 366.15 and 423.15 K and pressures between 50 and 1000 bar. The mole fraction of water in saturated hydrogen-water mixtures in the gas phase ranges from 0.004 to 0.138. The same properties were calculated for pure hydrogen at 323.15 K and pressures between 100 and 1000 bar. Simulations were performed using the TIP3P and a modified TIP4P force field for water and the Marx, Vrabec, Cracknell, Buch, and Hirschfelder force fields for hydrogen. The vapor-liquid equilibria of hydrogen-water mixtures were calculated along the melting line of ice Ih, corresponding to temperatures between 264.21 and 272.4 K, using the TIP3P force field for water and the Marx force field for hydrogen. In this temperature range, the solubilities and the chemical potentials of hydrogen and water were obtained. Based on the computed solubility data of hydrogen in water, the freezing-point depression of water was computed ranging from 264.21 to 272.4 K. The modified TIP4P and Marx force fields were used to improve the solubility calculations of hydrogen-water mixtures reported in our previous study [ Rahbari, A.;et al. J. Chem. Eng. Data 2019, 64, 4103-4115 ] for temperatures between 323 and 423 K and pressures ranging from 100 to 1000 bar. The chemical potentials of ice Ih were calculated as a function of pressure between 100 and 1000 bar, along the melting line for temperatures between 264.21 and 272.4 K, using the IAPWS equation of state for ice Ih. We show that at low pressures, the presence of water has a large effect on the thermodynamic properties of compressed hydrogen. Our conclusions may have consequences for the energetics of a hydrogen refueling station using electrochemical hydrogen compressors.

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.

Hydrogen is one of the most popular alternatives for energy storage. Because of its low volumetric energy density, hydrogen should be compressed for practical storage and transportation purposes. Recently, electrochemical hydrogen compressors (EHCs) have been developed that are capable of compressing hydrogen up to P = 1000 bar, and have the potential of reducing compression costs to 3 kWh/kg. As EHC compressed hydrogen is saturated with water, the maximum water content in gaseous hydrogen should meet the fuel requirements issued by the International Organization for Standardization (ISO) when refuelling fuel cell electric vehicles. The ISO 14687-2:2012 standard has limited the water concentration in hydrogen gas to 5 μmol water per mol hydrogen fuel mixture. Knowledge on the vapor liquid equilibrium of H₂O-H₂ mixtures is crucial for designing a method to remove H₂O from compressed H₂. To the best of our knowledge, the only experimental high pressure data (P > 300 bar) for the H₂O-H₂ phase coexistence is from 1927 [J. Am. Chem. Soc., 1927, 49, 65-78]. In this paper, we have used molecular simulation and thermodynamic modeling to study the phase coexistence of the H₂O-H₂ system for temperatures between T = 283 K and T = 423 K and pressures between P = 10 bar and P = 1000 bar. It is shown that the Peng-Robinson equation of state and the Soave Redlich-Kwong equation of state with van der Waals mixing rules fail to accurately predict the equilibrium coexistence compositions of the liquid and gas phase, with or without fitted binary interaction parameters. We have shown that the solubility of water in compressed hydrogen is adequately predicted using force-field-based molecular simulations. The modeling of phase coexistence of H₂O-H₂ mixtures will be improved by using polarizable models for water. In the Supporting Information, we present a detailed overview of available experimental vapor-liquid equilibrium and solubility data for the H₂O-H₂ system at high pressures.

A high pressure semicontinuous batch electrolyzer is used to convert CO₂ to formic acid/formate on a tin-based cathode using bipolar membranes (BPMs) and cation exchange membranes (CEMs). The effects of CO₂ pressure up to 50 bar, electrolyte concentration, flow rate, cell potential, and the two types of membranes on the current density (CD) and Faraday efficiency (FE) for formic acid/formate are investigated. Increasing the CO₂ pressure yields a high FE up to 90% at a cell potential of 3.5 V and a CD of ∼30 mA/cm². The FE decreases significantly at higher cell potentials and current densities, and lower pressures. Up to 2 wt % formate was produced at a cell potential of 4 V, a CD of ∼100 mA/cm², and a FE of 65%. The advantages and disadvantages of using BPMs and CEMs in electrochemical cells for CO₂ conversion to formic acid/formate are discussed.

In this work a model of an elevated pressure CO₂ electrolyzer producing primarily formate or formic acid is presented. It consists of three parts: A model of the bulk electrolyte, the diffusion layer, and the electrode surface. Data from the literature was used to validate both the bulk portion of the model, as well as the overall model. Results from the literature were further explored and explained by reference to the model and faradaic efficiency is predicted very well (R-Square of 0.99 for the fitted data, and 0.98 for the non-fitted data). The primary effect of increasing the pressure on a CO₂ electrolyzer is seen to be increasing the maximum attainable partial current density, while the faradaic efficiency and specific energy of formation plateau at pressures above 10-20 bar, at 95% and of 3.7 kWh/kg, respectively. Unlike the efficiencies, the profitability of running a reactor increases with pressure, following a similar trend as partial current density, showing the importance of this quantity as a performance metric of a CO₂ electrolyzer. In general this work shows the utility of a model of this sort in the design, evaluation and operation of CO₂ electrolyzers.

Carbon dioxide (CO₂) can electrochemically be converted to a range of products including formic acid (HCOOH) and acetic acid (CH₃COOH). The yield of the products in an electrolysis cell depends on the solubility of CO₂ in the (aqueous) mixture. In absence of experimental data, Monte Carlo simulations in the Gibbs ensemble are used to compute the VLE of the binary systems, CO₂-H₂O, CO₂-HCOOH and CO₂-CH₃COOH, and the ternary systems, CO₂-HCOOH-H₂O and CO₂-CH₃COOH-H₂O. In addition, the PC-SAFT equation of state (EoS) is used to model the VLE of these strongly associating mixtures. Both methods correctly predicts the liquid-phase compositions, but the gas-phase compositions are less accurately described. The challenges to model these systems are related to the simultaneous formation of dimers, rings, and chains, which requires accurate force fields and advanced biasing schemes in MC simulations, and association theories that can account for this effect.