Electrolyte flooding in porous catalyst layers on gas diffusion electrodes (GDE) limits the stability and high-current performance of CO2 and CO electrolyzers. Here, we demonstrate the in situ electroreduction of graphene oxide (GO) to reduced graphene oxide (r-GO) within a silver catalyst layer on a carbon GDE. The r-GO introduces hydrophobicity regions in the catalyst layer that help mitigate electrolyte flooding during high current density CO2 electrolysis to CO. The flooding-resistant r-GO/Ag-coated GDE achieves a sustained Faradaic efficiency of CO at 94% for more than 8 h, compared to a rapid drop from 95% to 66% in an Ag-coated GDE without r-GO at 100 mA·cm–2. We found that GO enhances the electrochemically active surface area of the catalyst layer during CO2 electrolysis tests because the incorporation of GO increases the roughness of the catalyst layer. The in situ method of electrochemically reducing GO to r-GO provides a low-cost, practical approach that can be applied during standard spray-deposition procedures to develop flooding-resistant GDEs.@en

To explore the effects of solvent-ionomer interactions in catalyst inks on the structure and performance of Cu catalyst layers (CLs) for CO₂ electrolysis, we used a “like for like” rationale to select acetone and methanol as dispersion solvents with a distinct affinity for the ionomer backbone or sulfonated ionic heads, respectively, of the perfluorinated sulfonic acid (PFSA) ionomer Aquivion. First, we characterized the morphology and wettability of Aquivion films drop-cast from acetone- and methanol-based inks on flat Cu foils and glassy carbons. On a flat surface, the ionomer films cast from the Aquivion and acetone mixture were more continuous and hydrophobic than films cast from methanol-based inks. Our study’s second stage compared the performance of Cu nanoparticle CLs prepared with acetone and methanol on gas diffusion electrodes (GDEs) in a flow cell electrolyzer. The effects of the ionomer-solvent interaction led to a more uniform and flooding-tolerant GDE when acetone was the dispersion solvent (acetone-CL) than when we used methanol (methanol-CL). As a result, acetone-CL yielded a higher selectivity for CO₂ electrolysis to C₂₊ products at high current density, up to 25% greater than methanol-CL at 500 mA cm^-2. Ethylene was the primary product for both CLs, with a Faradaic efficiency for ethylene of 47.4 ± 4.0% on the acetone-CL and that of 37.6 ± 5.5% on the methanol-CL at a current density of 300 mA cm^-2. We attribute the enhanced C₂₊ selectivity of the acetone-CL to this electrode’s better resistance to electrolyte flooding, with zero seepage observed at tested current densities. Our findings reveal the critical role of solvent-ionomer interaction in determining the film structure and hydrophobicity, providing new insights into the CL design for enhanced multicarbon production in high current densities in CO₂ electrolysis processes.

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We report a new strategy to improve the reactivity and durability of a membrane electrode assembly (MEA)-type electrolyzer for CO2 electrolysis to CO by modifying the silver catalyst layer with urea. Our experimental and theoretical results show that mixing urea with the silver catalyst can promote electrochemical CO2 reduction (CO2R), relieve limitations of alkali cation transport from the anolyte, and mitigate salt precipitation in the gas diffusion electrode in long-term stability tests. In a 10 mM KHCO3 anolyte, the urea-modified Ag catalyst achieved CO selectivity 1.3 times better with energy efficiency 2.8-fold better than an untreated Ag catalyst, and operated stably at 100 mA cm-2 with a faradaic efficiency for CO above 85% for 200 h. Our work provides an alternative approach to fabricating catalyst interfaces in MEAs by modifying the catalyst structure and the local reaction environment for critical electrochemical applications such as CO2 electrolysis and fuel cells.

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Achieving operational stability at high current densities remains a challenge in CO2 electrolyzers due to flooding of the gas diffusion layer (GDL) that supports the electrocatalyst. We mitigated electrode flooding at high current densities using a vacuum-assisted infiltration method to embed 200-400 nm-sized polytetrafluoroethylene (PTFE) particles at the interface of the microporous layer (MPL) and carbon cloth in a commercial GDL. In CO2 electrolysis to CO over a silver nanoparticle catalyst on the GDL, the PTFE-embedded GDL not only just exhibited less than 10% of the electrolyte seepage rates observed in untreated GDLs at a current density of 300 mA·cm-2 but also expanded the electrochemical active area across the testing conditions. The PTFE-embedded GDL also maintained a Faradaic efficiency for CO2 electrolysis to CO above 80% for more than 100 h at 100 mA·cm-2, which was a 50-fold improvement in the stable operation time of the electrolyzer.

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