(442d) Prototyping and Scale up of Electrochemical Reactors for CO2 Reduction

This talk delves into the development and optimization of model-driven approaches for Gen-1 (50 cm²) and Gen-2 (500 cm²) electrolyzer designs aimed at achieving targeted performance levels in CO₂ conversion. The scale-up methodology for the zero-gap electrolyzer focuses on maintaining kinetic and geometric similarity between small-scale and scaled-up systems. As electrochemical reactors are primarily planar, scale-up significantly impacts mass transfer, leading to surface heterogeneities and product distribution variations. To mitigate these effects, cells are restricted to sizes below 2000 cm², with desired production rates achieved through cell stacking. The scale-up philosophy emphasizes maintaining similarity between individual cells within a stack to ensure uniform voltage distribution. This necessitates the use of modeling and simulation tools for evaluating kinetic and geometric similarity. The first task is to evaluate potential and concentration distributions in small-scale electrolyzers for assessing reaction performance, followed by assessment of current distribution, pH gradient, and potential along the electrode surface in Gen-1 and Gen-2 electrolyzers, respectively. Through these efforts, we aim to optimize electrode designs and operating conditions for maximum CO₂ utilization rates with minimal power consumption. Additionally, the talk highlights strategies for overcoming mass and charge transport challenges in larger-scale electrolyzers while ensuring high activity and selectivity of catalysts. Furthermore, the development of a Multiphysics model-based diagnostic tool enables real-time monitoring and assessment of electrolyzer performance, facilitating efficient and reliable CO₂ conversion processes.