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Membrane-free CO2 electrolyzer design for economically efficient formic acid electro-synthesis.
Xiaotong Li1,2, Kainan Gao3, Mingliang Qu3
1Institute for Composites Science Innovation (InCSI), State Key Laboratory of Silicon and Advanced Semiconductor Materials, School of Materials Science and Engineering, Zhejiang University, Hangzhou, P. R. China.
Nature Communications
|October 17, 2025
Summary
This study presents a novel membrane-free CO2 electrolyzer for efficient formic acid synthesis. The design minimizes energy loss, achieving low electrical energy consumption for industrial viability.
Area of Science:
- Electrochemistry
- Chemical Engineering
- Sustainable Energy
Background:
- Industrial formic acid production relies on energy-intensive processes.
- Conventional CO2 electrolyzers suffer from high energy consumption due to oxygen evolution and ohmic losses.
- Electrolyzer engineering offers a pathway to improve energy efficiency beyond catalyst development.
Purpose of the Study:
- To develop a membrane-free CO2 electrolyzer for energy-efficient formic acid electro-synthesis.
- To reduce electrical energy consumption by pairing CO2 reduction with an all-liquid-phase anodic reaction.
- To assess the economic viability of the proposed electrolyzer design.
Main Methods:
- Designed and constructed a membrane-free CO2 electrolyzer.
- Integrated electrochemical CO2 reduction (CO2R) with an all-liquid-phase anodic reaction.
- Conducted techno-economic analysis (TEA) to evaluate economic feasibility.
Main Results:
- Achieved the lowest electrical energy consumption (<310 kJ mol⁻¹ formate) at cell voltages below 2.7 V across a wide current density range (0.05–0.4 A cm⁻²).
- Demonstrated stable operation at 2.25 V for over 313 hours with minimal increase in energy consumption (<20%).
- Dual production of formate at both electrodes was enabled, significantly reducing cell voltage.
Conclusions:
- The developed membrane-free electrolyzer design significantly enhances electrical energy utilization efficiency for formic acid electro-synthesis.
- The system shows potential for low-cost, energy-efficient, and economically viable industrial production of formic acid.
- This engineering strategy provides a roadmap for advancing CO2 reduction technologies.
