Diaphragm-based carbon monoxide electrolyzers for multicarbon production under alkaline conditions

Wanyu Deng, Siyang Xing, Guilherme Warwick Parker Maia, Zhaoxi Wang, Bradie S. Crandall and Feng Jiao ()
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Wanyu Deng: Washington University in St. Louis
Siyang Xing: Washington University in St. Louis
Guilherme Warwick Parker Maia: Washington University in St. Louis
Zhaoxi Wang: Washington University in St. Louis
Bradie S. Crandall: Lectrolyst
Feng Jiao: Washington University in St. Louis

Nature Communications, 2025, vol. 16, issue 1, 1-11

Abstract: Abstract Transforming waste carbon into valuable fuels and chemicals is a key step toward sustainable manufacturing. One promising approach is the electrochemical conversion of carbon monoxide (CO), a product of CO2 recycling, into energy-rich multicarbon (C2+) compounds. However, current CO electrolyzers rely on anion exchange membranes (AEMs) that degrade over time when exposed to organic intermediates, limiting their practical use. Here we show that low-cost diaphragm materials, such as Zirfon, can serve as robust alternatives to AEMs in alkaline CO electrolysis. We evaluate a range of diaphragms and identify candidates that match or exceed the performance of commercial AEMs across a wide range of operating conditions (50 to 400 mA cm−2). At 60 °C, Zirfon-based cells maintain 45% Faradaic efficiencies for acetate over 250 hours, while state-of-the-art AEMs fail within 150 hours. Moreover, a 100 cm2 Zirfon cell operates stably for 700 hours at 200 mA cm−2. These findings demonstrate that diaphragms offer a scalable and durable pathway for CO electrolysis, helping reduce system costs and enhance compatibility with renewable energy inputs.

Date: 2025
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DOI: 10.1038/s41467-025-63004-1

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