Improving the operational stability of electrochemical CO2 reduction reaction via salt precipitation understanding and management

Shaoyun Hao, Ahmad Elgazzar, Nandakishore Ravi, Tae-Ung Wi, Peng Zhu, Yuge Feng, Yang Xia, Feng-Yang Chen, Xiaonan Shan () and Haotian Wang ()
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Shaoyun Hao: Rice University
Ahmad Elgazzar: Rice University
Nandakishore Ravi: University of Houston
Tae-Ung Wi: Rice University
Peng Zhu: Rice University
Yuge Feng: Rice University
Yang Xia: Rice University
Feng-Yang Chen: Rice University
Xiaonan Shan: University of Houston
Haotian Wang: Rice University

Nature Energy, 2025, vol. 10, issue 2, 266-277

Abstract: Abstract The practical application of electrochemical carbon dioxide reduction reaction (CO2RR) technology remains hindered by poor stability, primarily owing to bicarbonate salt formation at the cathode, which blocks reactant CO2 mass flow. Here, using operando characterization tools, we tracked the salt formation process and quantified salt precipitation under varying device operational conditions, elucidating a potential mechanism and optimizing anolyte conditions for long-term (>1,000 h) operation CO2RR to CO under >100 mA cm–2. Liquid droplets carrying cations and (bi)carbonate ions were observed to migrate from the catalyst/membrane interface towards the backside of the gas diffusion electrode, driven by interfacial gas evolution and CO2 flow. These droplets eventually dried, forming bicarbonate salt precipitates that blocked the gas flow channels. On the basis of this observation, we applied a hydrophobic parylene coating to the cathode gas flow channel surface, facilitating the removal of the droplets and extending stability from ~100 h to over 500 h under 200 mA cm–2.

Date: 2025
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DOI: 10.1038/s41560-024-01695-4

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