Publications

Sustainable Energy Materials &
Processes Laboratory

Journals

Flooding-Resistant Nickel Foam-Based GDE Design for Enhanced Electrocatalytic CO2 Reduction
Author
Jun Won Oh, Young Jin Doh, Seng Woo Kim, Ki Tae Park*
Journal
Journal of CO2 Utilization
Status
Under review
Year
2025

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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.