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The electrochemical reduction of CO2 to ethylene has the potential to reduce greenhouse gas emissions while producing commodity chemicals for plastics; however, a scalable and feasible system for this remains a challenge. Herein, we report an efficient and stackable electrode design for the electrolysis of CO2 to ethylene. Using KOH-incorporated Cu nanoparticle (Cu-KOH) as the cathode in a zero-gap electrolyzer, Faradaic efficiency of 78.7% for C2 products was achieved at a current density of 281 mA cm–2. Among C2 products, ethylene with a 54.5% FE was dominant product. For mass production, three membrane electrode assemblies (MEAs) were stacked and operated. Operando X-ray absorption spectroscopy under the zero-gap electrolyzer suggested mainly metallic Cu state with some persistent oxide-derived Cu species in Cu-KOH, including Cu2O and Cu(OH)2, which expected a synergistic effect for the conversion of CO2 to C2H4. Our findings provide a new strategy for converting CO2 to C2H4, which is expected to accelerate the commercialization of high-value chemical production through electrochemical CO2 reduction.
KOH incorporated Cu electrode in zero-gap electrolyzer achieved a current density of 281 mA cm–2 with a Faraday efficiency of 54.5% toward C2H4. Operando X-ray Absorption Spectroscopy reveals that the presence of Cu2O and Cu(OH)2 species during CO2RR condition exhibit synergistic effect to improve selectivity and kinetics for CO2 conversion to C2H4. Furthermore, 3-cell stack operation result suggests the possibility of industrial development. [Display omitted]
•KOH incorporated Cu in zero-gap electrolyzer achieved a current density of 281 mA cm–2 with a FE of 54.5% toward C2H4.•Operando X-ray Absorption Spectroscopy suggests the presence of Cu2O and Cu(OH)2 species during CO2RR condition.•Synergistic effect of Cu2O and Cu(OH)2 species improve selectivity and kinetics for CO2RR to C2H4.•C2H4 FE of 50% at a current density of 200 mA cm2 for 6 h was achieved in a 3-cell stack.•3-cell stack operation result suggests the possibility of industrial development.