Flooding-Resistant Nickel Foam-Based GDE Design for Enhanced Electrocatalytic CO2 Reduction
- Journal
- Journal of CO2 Utilization
- Status
- Under review
- Year
- 2025
The electrocatalytic CO2
reduction reaction (CO2RR) powered by renewable electricity offers a
sustainable pathway for converting CO2 into valuable products, presenting a
promising strategy to mitigate atmospheric CO2 concentrations. The design of
gas diffusion electrodes (GDEs) plays a crucial role in enhancing the CO2RR
performance and stability in membrane-electrode assembly (MEA)-type
electrolyzers. One of the primary challenges in industrializing CO2RR
technologies is the flooding of GDEs, which significantly reduces the stability
of CO2RR performance. Here, we design a flooding-resistant GDE by incorporation
of macrochannels into GDE employing a nickel (Ni) foam substrate to mitigate
GDE flooding and improve CO2RR performance and stability. The macrochannels in
GDE ensures sufficient mass transfer of CO2 to the catalyst layer, even under
conditions of electrowetting and electrolyte presence. The GDE designed with
macrochannels exhibits significantly higher through-plane conductivity and gas
permeability compared to conventional carbon paper-based GDEs and retains
its hydrophobicity even after prolonged operation. This GDE demonstrates higher
CO current density (jCO) and lower cell voltage, maintaining excellent
stability with a high CO Faradaic efficiency (FECO) of 88.4% over 50 h of
continuous operation. These findings emphasize the importance of GDE designs
with enhanced mass transfer capabilities to effectively address flooding
challenges and improve the scalability and efficiency of CO2RR in MEA-type electrolyzers.