Next-Generation Self-Supported Electrocatalysts for Direct Conversion of Flue Gas into Ethylene (FG2E)

Objective

Capturing emitted CO2 from industrial processes and valorizing that through electrochemical processes to high-value chemicals, which are largely demanded in different sectors, is a promising measure to address environmental challenges and expedite the green transition. However, a fully featured CO2 electrolyzer, as the cornerstone of this process, is the unmet need in this pathway. Such electrolyzers, in particular, critically miss electrocatalysts at high durability, electrochemical activity, etc. as well as a precise porous microstructure to facilitate maximum mass transfer and surface-to-volume ratio. These are essential to get the entire process offering competitive cost-effectiveness, chemical output selectivity, Faradaic efficiency, etc. Hence, this project (FG2E) proposes and validates a game-changing approach for optimal design and fabrication of self-supported electrodes/electrocatalysts (SSEs) with high micro-resolution for CO2 electrolyzers. FG2E pursues several specific research objectives, including 1) thermal-fluidic and electrochemical simulation of the SSE, 2) structure-based optimization of the SSE to enhance mass transfer efficiency, 3) new hydrogel-based material development and volumetric 3D printing, and 4) post-conditioned structuring and testing for experimental validation of the concept. The proposed FG2E’s SSE is expected to improve selectivity and production efficiency of ethylene (as a benchmark product here). This will be very promising not only for paving the path toward mass production of high-purity ethylene from industrial flue gas streams but also other electrochemical to processes for producing high value chemicals from CO2-rich waste streams.