The criteria dictating the performance of gas diffusion electrodes (GDEs) for CO2 electrolysis are not well understood, due to the complex and highly coupled relationships of the underlying physical and chemical phenomena. In addition, a number of key performance indicators (KPIs) have been identified (e.g., Faradaic efficiency, reaction selectivity, single-pass conversion, and productivity), and optimizing for any single metric often leads to inherent tradeoffs. Consequently, much recent work has focused on understanding how operational and architectural parameters control GDE performance. The porous catalyst supports and diffusion media in these devices are critical components as they mediate the transport and reactive processes. The microstructure of these components influences the balance between the electrochemical surface area, which dictates CO2 consumption, and mass transfer of the aqueous and gaseous species. Traditional porous media is often spatially homogeneous and provides limited opportunity to tailor this balance. In contrast, novel advanced manufacturing methods have now enabled researchers to create electrodes with variable porosity that can be tuned for optimal performance. To explore the impact of locally altering the porous media structure, we leverage previous modeling work by Weng et al. to allow for spatially varying porosity. Further, we couple the forward simulation to adjoint based optimization algorithms to determine optimal porosity distribution in the diffusion media and catalyst layer of a GDE. The cost functions for the optimization are derived from the previously mentioned KPIs. Finally, the performance of the resultant spatially varying porosity GDEs is compared to the performance of homogenous porosity GDEs, and we identify key features of the porosity distribution leading to improved performance. Weng, Lien-Chun, Alexis T. Bell, and Adam Z. Weber. "Modeling gas-diffusion electrodes for CO2 reduction." Physical Chemistry Chemical Physics 20.25 (2018): 16973-16984. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344. LLNL-ABS-830082

Carbon utilization is a crucially important performance characteristic of CO2electrolyzers; however, applications of simple and accurate descriptive models to experimental data on this topic are currently lacking. Here, we apply a simple analytical reactor model to parameterize single-pass conversion as a function of feed-gas flow rate and show that it captures a wide body of experimental data in the literature exceptionally well. In doing so, we demonstrate that this simple conceptual approach can characterize progress and capture recent innovations in reactor design. To validate the extracted parameters, we employ a well-established comprehensive model to confirm that the results agree with physical expectations. Finally, we explore the implications of the descriptive model by examining the inherent trade-off between single-pass conversion efficiency and reactor productivity. Understanding such trade-offs is crucially important for advancing this electrolyzer technology toward commercial applications.

Increased use of gas diffusion electrodes for CO2 electroreduction widens the experimental phase space that was previously inaccessible using foil electrodes, raising fundamental questions over the impacts of key variables that translate between liquid- and vapor-fed CO2 electrolysis systems. This work focuses on studying the interplay of current-potential profiles and electrochemically active surface area (ECSA) by implementing a Cu nanoflower catalyst morphology. The results show decreased overpotentials as much as 460 and 174 mV for foil and gas diffusion electrodes, respectively, while maintaining or improving multi-carbon product current density. These overpotential shifts and product activities normalized by ECSA lead to current-potential relationships akin to those of the Tafel description, which are found through a continuum model to be useful for describing the roughness dependence for both liquid- and vapor-fed systems. This analysis establishes a holistic approach for establishing catalyst design criteria to improve materials development for CO2 electrolysis technologies.