CO2 electrolyzers require gaseous CO2 or
saturated CO2 solutions to achieve high energy efficiency
(EE) in flow reactors. However, CO2 capture and delivery
to electrolyzers are in most cases responsible for the inefficiency
of the technology. Recently, bicarbonate zero-gap flow electrolyzers
have proven to convert CO2 directly from bicarbonate solutions,
thus mimicking a CO2 capture medium, obtaining high Faradaic
efficiency (FE) and partial current density (CD) toward carbon products.
However, since bicarbonate electrolyzers use a bipolar membrane (BPM)
as a separator, the cell voltage (VCell) is high, and the
system becomes less efficient compared to analogous CO2 electrolyzers. Due to the role of the bicarbonate both as a carbon
donor and proton donor (in contrast to gas-fed CO2 electrolyzers),
optimization by using know-how from conventional gas-fed CO2 electrolyzers is not valid. In this study, we have investigated
how different engineering aspects, widely studied for upscaling gas-fed
CO2 electrolyzers, influence the performance of bicarbonate
zero-gap flow electrolyzers when converting CO2 to formate.
The temperature, flow rate, and concentration of the electrolyte are
evaluated in terms of FE, productivity, V
Cell, and EE in a broad range of current densities (10–400 mA
cm–2). A CD of 50 mA cm–2, room
temperature, high flow rate (5 mL cm–2) of the electrolyte,
and high carbon load (KHCO3 3 M) are proposed as potentially
optimal parameters to benchmark a design to achieve the highest EE
(27% is obtained this way), one of the most important criteria when
upscaling and evaluating carbon capture and conversion technologies.
On the other hand, at high CD (>300 mA cm–2),
low
flow rate (0.5 mL cm–2) has the highest interest
for downstream processing (>40 g L–1 formate
is
obtained this way) at the cost of a low EE (<10%).