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Updated: May 5, 2026

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Scaling CO₂ Electrolyzer Cell Area from Bench to Pilot.

Vivian E Nelson¹, Colin P O'Brien¹, Jonathan P Edwards¹

¹Department of Mechanical and Industrial Engineering, University of Toronto, 5 King's College Road, Toronto, ON M5S 3G8, Canada.

ACS Applied Materials & Interfaces

|September 10, 2024

Summary

This summary is machine-generated.

Scaling up carbon dioxide (CO2) electrolyzers is crucial for emissions reduction. This study found that improving electrode compression and CO2 flow in larger cells maintains ethylene selectivity, enabling industrial deployment.

Keywords:

carbon dioxide reduction reaction electrocatalysis ethylene gas product distribution large-scale membrane electrode assembly design

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Area of Science:

Electrochemistry
Chemical Engineering
Materials Science

Background:

Scaling up CO2 electrolyzer technology is essential for reducing carbon dioxide emissions.
Current bench-scale electrolyzers (<5 cm²) require significant scaling (100s-1000s cm²) for industrial viability.

Purpose of the Study:

To investigate the impact of increasing CO2 electrolyzer cell area on performance.
To identify key factors limiting performance during scale-up.
To develop strategies for maintaining selectivity and efficiency in larger-scale electrolyzers.

Main Methods:

Studied CO2 electrolyzer performance across two orders of magnitude in cell area (5 cm² to 800 cm²).
Instrumented an 800 cm² cell to diagnose performance losses.
Redesigned the 800 cm² cell focusing on compression uniformity and CO2 transport.

Main Results:

Directly scaling a 5 cm² cell design to 800 cm² resulted in a ~20% drop in ethylene selectivity and increased hydrogen evolution.
Nonuniform electrode compression and flow-influenced CO2 availability were identified as primary performance limitations.
Redesigning the 800 cm² cell for improved compression tolerance and CO2 transport restored hydrogen evolution efficiency comparable to the small-scale cell.

Conclusions:

Uniform electrode compression and optimized fluid flow are critical for successful CO2 electrolyzer scale-up.
CO2 electrolyzer area can be scaled over 100-fold while retaining high ethylene selectivity.
This work provides a pathway for industrial-scale CO2 electrolysis for emissions reduction.