Industrialization of Electrocatalytic Co₂ Reduction: Analysis of Full-Chain Bottlenecks and Synergistic Solutions

Electrocatalytic CO₂ reduction (CO₂RR) converts CO₂ into high-value chemicals and fuels using renewable electricity, serving as a core technology for recycling of carbon resources and supporting the carbon neutrality goal. Nevertheless, multiple bottlenecks hinder its transition toward industrial-scale application. These include poor catalyst stability under industrial-level high current density, uneven mass transfer and limited durability of key components during electrolyzer scale-up, high energy consumption together with difficult product separation and purification, mismatches between intermittent renewable energy supply and continuous electrolysis operation, as well as insufficient synergy between fundamental research and engineering applications. Economic factors also constrain industrialization, such as weak cost competitiveness, long investment-return periods, and imperfect carbon-pricing mechanisms. Aiming at the full-chain industrial implementation of CO₂RR, this paper systematically analyzes the challenges and underlying mechanisms of four core modules: catalysts, electrolysis systems, product separation, and system integration. It reviews the latest technological breakthroughs and feasible solutions, emphasizing the importance of fundamental research-engineering synergy, policy support, and interdisciplinary integration. This work provides a systematic reference and rational development direction for scientific research breakthroughs and industrial transformation of CO₂RR technology.