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<p>Reducing the electrical energy consumption for formic acid electro-synthesis is indispensable for advancing its industrial implementation. In a conventional CO<sub>2</sub> electrolyzer, most input electrical energy is consumed by the unprofitable anodic oxygen evolution reaction (OER) and ohmic drop. Electrolyzer engineering provides a promising platform to boost electrical energy utilization efficiency beyond catalyst optimization. Herein, we demonstrate a membrane-free CO<sub>2</sub> electrolyzer design that pairs electrochemical CO<sub>2</sub> reduction (CO<sub>2</sub>R) with an all-liquid-phase anodic reaction, enabling dual production of formate at both electrodes with significantly reduced cell voltage. The optimized design exhibits the lowest electrical energy consumption (&lt; 310 kJ mol<sup>-1</sup><sub>formate</sub>) at cell voltages below 2.7 V across a current density range of 0.05–0.4 A cm<sup>-2</sup>. This cell also maintains stable operation at 2.25 V for 313 h with a &lt; 20 % increase in electrical energy consumption. Systematic techno-economic analysis (TEA) evaluates the economic viability of this design for formic acid electro-synthesis, revealing a potential roadmap towards low-cost formic acid production. This strategy provides guidelines for CO<sub>2</sub>R electrolyzer engineering toward energy-efficient, economically viable production of valuable chemicals.</p>

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Membrane-free CO2 electrolyzer design for economically efficient formic acid electro-synthesis

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年10月17日

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  • Xiaotong Li,
  • Kainan Gao,
  • Mingliang Qu,
  • Nanhui Li,
  • Xiangzhou Lv,
  • Xiuju Wu,
  • Qingyang Lin,
  • Hao Bin Wu

摘要

Reducing the electrical energy consumption for formic acid electro-synthesis is indispensable for advancing its industrial implementation. In a conventional CO2 electrolyzer, most input electrical energy is consumed by the unprofitable anodic oxygen evolution reaction (OER) and ohmic drop. Electrolyzer engineering provides a promising platform to boost electrical energy utilization efficiency beyond catalyst optimization. Herein, we demonstrate a membrane-free CO2 electrolyzer design that pairs electrochemical CO2 reduction (CO2R) with an all-liquid-phase anodic reaction, enabling dual production of formate at both electrodes with significantly reduced cell voltage. The optimized design exhibits the lowest electrical energy consumption (< 310 kJ mol-1formate) at cell voltages below 2.7 V across a current density range of 0.05–0.4 A cm-2. This cell also maintains stable operation at 2.25 V for 313 h with a < 20 % increase in electrical energy consumption. Systematic techno-economic analysis (TEA) evaluates the economic viability of this design for formic acid electro-synthesis, revealing a potential roadmap towards low-cost formic acid production. This strategy provides guidelines for CO2R electrolyzer engineering toward energy-efficient, economically viable production of valuable chemicals.