The electrochemical fixation of CO2 as formate or oxalate is an interesting first step for CO2 utilization, and crucial to change CO2’s role from a greenhouse gas to a sustainable chemical feedstock. This is proven by the broad scientific, commercial and public interest in the technologies from our predecessor Liquid Light. CO2 based chemicals can be used in a broad variety of fields including novel polymers, cosmetics and cleaning products. In the last years, we have developed novel solutions for CO2 conversion. For the conversion of CO2 to oxalic acid through electrochemistry, we developed a new type of cell configuration at a size that has not been performed before. Subsequently, we convert oxalic acid to glycolic acid through selective hydrogenation with a novel catalyst. We have also scaled up the route from CO2 to formate using gas diffusion electrodes. The produced formate is then thermochemically converted to oxalic acid with a dedicated catalyst. We have now reached commercially relevant electrode sizes of up to 1m2 with stable runtimes above 1000 hours. This required us to develop a stable catalyst and electrode for the conversion of CO2. We had to figure out the key factors for suitable cell design and lastly automate and integrate the process into a working power or cement plant. Scaling this technology revealed many new parameters. Some did not influence the reaction at a smaller scale and now need controlling. Larger scales also changed the production and testing of catalysts and electrodes, and cells need to be designed differently. To integrate all steps from CO2 to polymers we optimized the electrochemical process to avoid costly separation steps between the chemical conversions. All of which required partnering with different parties involved in the overall process starting with CO2 producers and ending with plastic consumers. This talk will cover the scale up of CO2 reduction, share insights into catalyst development and performance, and highlight the importance of cell design. With two pilot projects, we would like to illustrate how we integrate and automate the electrochemical CO2 reduction with upstream CO2 production, and downstream processes towards valuable chemicals, such as new sustainable polymers with improved properties. Moreover, it portrays the benefit of diverse partnerships as a key to the success of multi-disciplinary projects.

Challenges and opportunities in scaling electrochemical CO2 conversion from lab to commercial scale: Catalyst design, cell design and process integration

Where thousands of chemistry professionals meet to share ideas and advance scientific and technical knowledge. Spring 2023 abstracts, posters, and presentations will launch at the end of March.

ACS Spring 2023

The official archive and repository for all ACS Meetings & Expositions abstracts and select posters or presentations.