Publication date: 22nd July 2026
Electrochemical CO2 reduction (eCO2RR) is a promising pathway for sustainable carbon utilization, but its industrial deployment depends on overcoming key challenges in long-term stability and reactor scale-up. This presentation focuses on bridging fundamental electrochemical degradation mechanisms with practical engineering solutions to enable efficient, durable formate production.
Investigations into carbon-free metal-based gas diffusion electrodes (GDEs), specifically those using tin (Sn) and bismuth (Bi), reveal that performance decline is largely driven by process-level phenomena such as localized pH shifts and conductivity loss, rather than intrinsic catalyst degradation. By addressing these root causes through electrolyte management and anodic pulsing, the operational lifespan of Bi-based GDEs can be successfully extended past 4,000 hours at a steady current density of 100 mA cm⁻² [1].
To tackle the secondary bottleneck of scalability, the performance of VITO CORE® GDEs was analyzed across a range of reactor sizes from 10 cm² up to 400 cm². Findings demonstrate that while numbering-up via reactor stacking presents significant mass-transport and fluid-dynamic complications, utilizing a single, large-area 400 cm² reactor yields a high coulombic efficiency of 73% while concurrently reducing energy demands [2]. Ultimately, merging these mechanistic insights with targeted reactor engineering clears a pathway toward highly durable, industrial-scale CO2 electrolysis systems.
The authors acknowledge the support of the VIVALDI project under the European Union's Horizon 2020 research and innovation programme (grant agreement 101000441) and FUELS-C project under the Horizon Europe program (grant agreement 101147442).
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