Techno-Economically Viable, Rapid, and Scalable Sonochemical Synthesis of AgCl Nanocubes for CO₂ Electroreduction

The economic viability of the electrochemical CO₂ reduction reaction relies not only on efficient catalytic performance but also on the scalability and cost-efficiency of catalyst production. Herein, a rapid and scalable sonochemical synthesis of AgCl nanocubes (AgCl NCs), featuring efficient manufacturability, high CO selectivity, and long-term stability is reported. In a membrane electrode assembly, AgCl NC maintained exceptionally high CO Faradaic efficiencies (>95%) during 200 h of continuous operation. Techno-economic analysis (TEA) revealed that the outstanding performance of AgCl NC, coupled with its cost- and time-efficient synthesis, significantly lowered the levelized catalyst cost by 40% and the CO production cost by nearly 50% relative to conventional Ag nanoparticle systems. By linking catalyst production directly to system-level TEA outcomes, this study highlights manufacturability as a key yet often overlooked criterion in catalyst design and positions AgCl NC as a promising platform for industrial-scale application.