The development of advanced catalysts with innovative nanoarchitectures is critical for addressing energy and environmental challenges such as the electrochemical CO₂ reduction reaction (CO₂ RR). Herein, the synthesis of an innovative copper–sulfur planar structure, Cu–S–BDC, within a metal–organic framework (MOF) catalyst is presented, which demonstrates 100% selectivity toward formate as the sole carbon product. Structural analysis and surface characterizations reveal that Cu–S–BDC exhibits quasi-2D inorganic building units, with Cu bonded to two S-CH (Formula presented.) groups and one BDC linker, while carboxylate groups adopt a bridging coordination mode. This unique arrangement not only imparts remarkable structural stability but also enhances the electronic properties of the MOF, as evidenced by a narrow bandgap of 1.203 eV that facilitates efficient charge transfer and increased electrochemical current density in CO (Formula presented.) RR. Notably, it offers a Faradaic efficiency of 92% for formate at an overpotential as low as −0.4 V versus the reversible hydrogen electrode (RHE) in an aqueous electrolyte of 1 m KOH, as well as a current density of −25.8 mA cm² at −0.9 V versus RHE, averaged over 24 h of electrolysis. This study highlights a fresh perspective in the field of MOF electrocatalysts by demonstrating that engineering the metal coordination environment can significantly enhance the electronic properties and consequently improve the electrocatalytic performance of these materials.

Electrochemical CO₂ reduction (CO₂R) to chemicals and fuels has made tremendous progress since the introduction of gas diffusion electrodes (GDEs) to overcome mass-transfer limitations and enable industrial-scale current densities. The advancement in the field, however, has come with new challenges that are related to the stability and degradation of the GDE due to flooding issues, which currently hinder the scale-up. Here, we investigated the effect of six different binding materials (Nafion, polytetrafluoroethylene, Fumion, Pention, poly(vinyl alcohol), and polypyrrole) on the stability and performance of Ag-based GDEs for CO₂R to CO in alkaline media. All binders show a decrease in the Faraday efficiency (FE) of CO and increase in hydrogen evolution reaction over time. The most hydrophilic GDE based on polypyrrole can uphold a higher FE of CO for longer times, which is contrary to a common belief that low wettability is required for long-term stability. By using a range of tools (SEM-EDX, SEM-FIB, X-ray diffraction, and contact angle measurements) for the postelectrolysis characterization of the GDEs, we show that the performance loss is related to flooding, bi(carbonate) precipitation, and catalyst agglomeration. These results contribute to a better understanding of the stability issues in GDE-based CO₂ electrolyzers.

Titanium dioxide (TiO₂) has been widely used as a photocatalyst in CO₂ reduction reaction (CO₂RR) due to its low cost, high stability, and strong absorption in the close-to-visible ultra-violet (UV) range. However, TiO₂ films suffer from poor selectivity in CO₂ reduction due to their unfavorable electronic properties. In this work, we address this challenge by fabricating ultra-thin (14 nm) defective TiO₂ films (TiO₂-DTF) to enhance the selectivity of CO₂RR towards formate. TiO₂ sol was prepared using a facile and reproducible sol-gel method and directly deposited onto the surface of the electrode, forming a uniform, ultra-thin TiO₂ layers with a high number of defects. The activity of the TiO₂-DTF catalyst was studied in both photochemical and photoelectrochemical CO₂RR, indicating that the applied potential increases both the yield and selectivity of CO₂RR to formate. The TiO₂-DTF photocathode exhibited remarkable formate production during CO₂ reduction, achieving exceptional Faradaic efficiencies of up to 45 %. To elucidate the mechanism of photoelectrochemical CO₂RR on TiO₂-DTF, an in-situ attenuated total reflection Fourier-transform infrared spectroscopy (in-situ ATR-FTIR) was used and experimental results were supported by density functional theory (DFT) calculations. This study demonstrates that ultra-thin highly defective TiO₂ film, prepared using the cost-effective and environmentally friendly sol-gel method, can be used as photoelectrocatalyst for CO₂ reduction.

Computation of the excess entropy (Formula presented.) from the second-order density expansion of the entropy holds strictly for infinite systems in the limit of small densities. For the reliable and efficient computation of (Formula presented.) it is important to understand finite-size effects. Here, expressions to compute (Formula presented.) and Kirkwood–Buff (KB) integrals by integrating the Radial Distribution Function (RDF) in a finite volume are derived, from which (Formula presented.) and KB integrals in the thermodynamic limit are obtained. The scaling of these integrals with system size is studied. We show that the integrals of (Formula presented.) converge faster than KB integrals. We compute (Formula presented.) from Monte Carlo simulations using the Wang–Ramírez–Dobnikar–Frenkel pair interaction potential by thermodynamic integration and by integration of the RDF. We show that (Formula presented.) computed by integrating the RDF is identical to that of (Formula presented.) computed from thermodynamic integration at low densities, provided the RDF is extrapolated to the thermodynamic limit. At higher densities, differences up to (Formula presented.) are observed.

Methane pyrolysis is a promising route for low-emission hydrogen (H₂) production, with solid carbon as a potentially valuable byproduct. Despite this potential, the economic feasibility of Catalytic Methane Pyrolysis (CMP) with fluidized bed reactors (FBR) has been insufficiently studied. This study develops a conceptual CMP plant using two novel isothermal reactor models—based on continuous stirred-tank reactor (CSTR) and plug-flow reactor (PFR) assumptions—to represent the operational extremes of FBRs. Our reactor models incorporate reaction and catalyst deactivation kinetics from experiments with nickel-supported catalysts, and the framework enables process simulations that account for the catalyst rate required to sustain reactor activity. These models address the lack of proper reduced-order FBR models and the reliance on oversimplified assumptions in the literature. In the baseline scenario, the conceptual plant yields an LCOH ranging from $3.89 to $4.79 per kilogram, defining the expected cost bounds for an FBR-based CMP plant. At a H₂ selling price of $5.00 per kilogram, the process achieves favorable payback time and net present value. Monte Carlo and sensitivity analyses indicate that CMP remains cost-competitive under economic uncertainties. Increased carbon sales could make CMP more economical than steam methane reforming, while unsold byproducts may incur costly sequestration. Reactor heating assessment shows methane combustion with carbon capture minimizes both cost and emissions. Overall, this work demonstrates the economic potential of CMP for H₂ production and provides a practical modeling framework for process evaluation.

Cyclopentyl methyl ether (CPME) is a promising green solvent due to its eco-friendly properties; it is produced by adding methanol (MeOH) to cyclopentene. Separation of the resulting product mixture containing CPME and MeOH is critical, and it requires vapor-liquid equilibrium (VLE) data. In this work, isobaric VLE data were measured experimentally using an ebulliometer in a 60.0–101.3 kPa pressure range for a binary system of CPME + MeOH. VLE data were modeled using excess Gibbs (G (Formula presented.)) energy-based models such as Wilson, NRTL, and UNIQUAC. The formation of an azeotrope was analyzed. Flash point, surface tension, Gibbs adsorption, and thickness of surface layer were estimated using the Wilson model, which can help in determining molecule interaction and overall behavior of the system. Atmospheric and high-pressure distillation columns were designed using Aspen Plus to study the separation of CPME + MeOH, and an economic evaluation of the same was carried out.

Experimentally determining thermophysical properties for various compositions commonly found in CO₂ transportation systems is extremely challenging. To overcome this challenge, we performed Monte Carlo (MC) and Molecular Dynamics (MD) simulations of CO₂ rich mixtures to compute thermophysical properties such as densities, thermal expansion coefficients, isothermal compressibilities, heat capacities, Joule-Thomson coefficients, speed of sound, and viscosities at temperatures of (235-313) K and pressures of (20-200) bar. We computed thermophysical properties of pure CO₂ and CO₂ rich mixtures with N₂, Ar, H₂, and CH₄ as impurities of (1-10) mol % and showed good agreement with available Equations of State (EoS). We showed that impurities decrease the values of thermal expansion coefficients, isothermal compressibilities, heat capacities, and Joule-Thomson coefficients in the gas phase, while these values increase in the liquid and supercritical phases. In contrast, impurities increase the value of speed of sound in the gas phase and decrease it in the liquid and supercritical phases. We present an extensive data set of thermophysical properties for CO₂ rich mixtures with various impurities, which will help to design the safe and efficient operation of CO₂ transportation systems.

The competitiveness of hydrogen as a sustainable energy carrier depends greatly on its transportation and storage costs. Liquefying hydrogen offers advantages such as enhanced purity, versatility, and higher density, yet current industrial liquefaction processes face efficiency and cost challenges. Although various large-scale and efficient liquefaction concepts exist in the literature, they often overlook the economic and technical viability of such plants. Here, we addresses this issue by establishing a framework for modeling a large-scale hydrogen liquefaction concept and conducting both technical and economic assessments, with a specific focus on 125 tonnes per day (TPD) high-pressure hydrogen Claude-cycle concept. The technical analysis involves preliminary designs of key process components, while the economic assessment utilizes Aspen Process Economic Analyzer. Our findings indicate that at an electricity price of €0.1/kWh, the Claude-cycle liquefier concept yields a specific liquefaction cost (SLC) of €1.55/kg_LH2. A sensitivity analysis was performed, which shows that electricity price has a significant influence on the economics. Further investigation on the compressors design shows that incorporating high-speed centrifugal compressors could reduce the SLC by 5.42% and potentially more. Scaling up to 250 and 500 TPD reveals further cost improvements, while cost projections indicate substantial declines as the technology matures. Ultimately, this paper presents novel cost-scaling and experience curves of hydrogen liquefaction technology, demonstrating the compelling economic viability of integrating large-scale hydrogen liquefaction into sustainable energy infrastructure.

Electrochemical ammonia synthesis via the nitrogen reduction reaction (NRR) has been poised as one of the promising technologies for the sustainable production of green ammonia. In this work, we developed extensive process models of fully integrated electrochemical NH ₃ production plants at small scale (91 tonnes per day), including their techno-economic assessments, for (Li-)mediated, direct and indirect NRR pathways at ambient and elevated temperatures, which were compared with electrified and steam-methane reforming (SMR) Haber-Bosch processes. The levelized cost of ammonia (LCOA) of aqueous NRR at ambient conditions only becomes comparable with SMR Haber-Bosch at very optimistic electrolyzer performance parameters (FE > 80% at j ≥ 0.3 A cm ⁻²) and electricity prices (<$0.024 per kW h). Both high temperature NRR and Li-mediated NRR are not economically comparable within the tested variable ranges. High temperature NRR is very capital intensive due the requirement of a heat exchanger network, more auxiliary equipment and an additional water electrolyzer (considering the indirect route). For Li-mediated NRR, the high lithium plating potentials, ohmic losses and the requirement for H ₂, limits its commercial competitiveness with SMR Haber-Bosch. This incentivises the search for materials beyond lithium.

Aqueous electrolytes used in CO2 electroreduction typically have a CO2 solubility of around 34 mM under ambient conditions, contributing to mass transfer limitations in the system. Non-aqueous electrolytes exhibit higher CO2 solubility (by 5–8-fold) and also provide possibilities to suppress the undesired hydrogen evolution reaction (HER). On the other hand, a proton donor is needed to produce many of the products commonly obtained with aqueous electrolytes. This work investigates the electrochemical CO2 reduction performance of copper in non-aqueous electrolytes based on dimethylformamide (DMF), n-methyl-2-pyrrolidone (NMP), and acetonitrile (ACN). The main objective is to analyze whether non-aqueous electrolytes are a viable alternative to aqueous electrolytes for hydrocarbon production. Additionally, the effects of aqueous/non-aqueous anolytes, membrane, and the selection of a potential window on the electrochemical CO2 reduction performance are addressed in this study. Experiments with pure DMF and NMP mainly produced oxalate with a faradaic efficiency (FE) reaching >80%; however, pure ACN mainly produced hydrogen and formate due to the presence of more residual water in the system. Addition of 5% (v/v) water to the non-aqueous electrolytes resulted in increased HER and formate production with negligible hydrocarbon production. Hence, we conclude that aqueous electrolytes remain a better choice for the production of hydrocarbons and alcohols on a copper electrode, while organic electrolytes based on DMF and NMP can be used to obtain a high selectivity toward oxalate and formate.

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.

Due to the intermittency of renewable energy sources, alkaline water electrolyzers are typically operated at partial load compared to the nominal design value. It is well-known that gas crossover is dominant at low current densities leading to higher anodic hydrogen content and higher cathodic oxygen content in the separator tanks. High anodic hydrogen content is tantamount to loss of product hydrogen which results in an explosive atmosphere in the gas phase if the volumetric hydrogen content in oxygen exceeds 4%. We have developed a transient model of a multi-cell stack which can describe the operation of the electrolyzer with mixed electrolyte flows (anolyte and catholyte), separated flows, or a combination thereof (dynamic switching). This is a major extension of the steady-state model developed by Haug et al. (International Journal of Hydrogen Energy, 2017, 42, 15,689–15707). In sharp contrast to the steady-state model by Haug et al., the transient model can calculate the gas crossover as the operating conditions (e.g. electrolyte flow cycles) dynamically change in time. Depending on the size of the stack and the separator tanks, the model estimates different rates for impurities to build up. The transient model is validated using independent experimental results by Haug et al. and Brauns et al. (Electrochimica Acta, 2022, 404, 139,715) The results show that the dynamic model can follow experimental results for fluctuating current densities for a period of several days. We found that the dynamic response and transition time to steady state depend significantly on the geometrical volume of the gas separators with respect to the single-cell stack. For a multi-cell stack, we find that the impurities build-up faster when increasing the number of cells in the stack. This model serves as a tool for sizing and process management of the electrolyzer system and the separator tanks especially with respect to explosion safety.

The removal of acid gas impurities from synthesis gas or natural gas can be achieved using several physical solvents. Examples of solvents applied on a commercial scale include methanol (Rectisol), poly(ethylene glycol) dimethyl ethers (Selexol), n-methyl-2-pyrrolidone (Purisol), and propylene carbonate (Fluor solvent). Continuous Fractional Component Monte Carlo (CFCMC) simulations in the osmotic ensemble were used to compute the Henry coefficients of the pure gases CO (Formula presented.), CH (Formula presented.), C (Formula presented.) H (Formula presented.), CO, H (Formula presented.), N (Formula presented.), N (Formula presented.) O, and H (Formula presented.) S in the aforementioned solvents. The predicted Henry coefficients are in good agreement with the experimental results. The Monte Carlo method correctly predicts the gas solubility trend in these physical solvents, which obeys the following order: H (Formula presented.) S > CO (Formula presented.) > C (Formula presented.) H (Formula presented.) > CH (Formula presented.) > CO > N (Formula presented.) > H (Formula presented.). The gas separation selectivities for the precombustion process and the natural gas sweetening process are calculated from the pure gas Henry coefficients. The CO (Formula presented.) /N (Formula presented.) O analogy is verified for the solubility in these solvents.

Vapor-liquid equilibrium (VLE) data for the binary systems tetrahydrofuran (THF) + acetic acid (AA) and THF + trichloroethylene (TCE) were measured under isobaric conditions using an ebulliometer. The boiling temperatures for the systems (THF + AA/THF + TCE) are reported for 13/15 compositions and five/six different pressures ranging from 50.2/60.0 to 101.1/101.3 kPa, respectively. The THF + AA system shows simple phase behavior with no azeotrope formation. The THF + TCE system does not exhibit azeotrope formation but seems to have a pinch point close to the pure end of TCE. The nonrandom two-liquid (NRTL) and universal quasichemical (UNIQUAC) activity coefficient models were used to accurately fit the binary (PTx) data. Both models were able to fit the binary VLE data satisfactorily. However, the NRTL model was found to be slightly better than UNIQUAC model in fitting the VLE data for both systems. The results can be used for designing liquid-liquid extraction and distillation processes involving mixtures of THF, AA, and TCE.

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.

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.

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.

There is a growing interest in the development of routes to produce formic acid from CO2, such as the electrochemical reduction of CO2 to formic acid. The solubility of CO2 in the electrolyte influences the production rate of formic acid. Here, the dependence of the CO2 solubility in aqueous HCOOH solutions with electrolytes on the composition and the NaCl concentration was studied by Continuous Fractional Component Monte Carlo simulations at 298.15 K and 1 bar. The chemical potentials of CO2, H2O, and HCOOH were obtained directly from single simulations, enabling the calculation of Henry coefficients and subsequently considering salting in or salting out effects. As the force fields for HCOOH and H2O may not be compatible due to the presence of strong hydrogen bonds, the Gibbs-Duhem integration test was used to test this compatibility. The combination of the OPLS/AA force field with a new set of parameters, in combination with the SPC/E force field for water, was selected. It was found that the solubility of CO2 decreases with increasing NaCl concentration in the solution and increases with the increase of HCOOH concentration. This continues up to a certain concentration of HCOOH in the solution, after which the CO2 solubility is high and the NaCl concentration has no significant effect.