Proceedings of MATSUS Fall 2026 Conference (MATSUSFall26)
Publication date: 22nd July 2026
Electrochemical CO2 reduction (eCO2RR) using copper-based gas diffusion electrodes offers a promising route for converting carbon dioxide into value-added chemicals and fuels at industrially relevant current densities [1,2]. However, even trace impurities in the CO2 feed may affect catalyst selectivity and long-term stability. This study investigates the influence of 100 ppm SO2 on Cu-based gas diffusion electrodes prepared by thermal evaporation and magnetron sputtering.
Cu layers with thicknesses of 100, 150, and 200 nm were evaluated in a micro-flow cell using 1 M KHCO3 electrolyte at current densities of -140, -170, and -200 mA cm-2. Product selectivity was monitored during electrolysis, while changes in electrode morphology and composition were examined using SEM, XPS, XRF and X-ray absorption spectroscopy.
Ethylene was the dominant C2 product, reaching a maximum Faradaic efficiency of approximately 31,8% for the 200 nm Cu layer at -200 mA cm-2. Magnetron-sputtered Cu electrodes generally showed higher selectivity toward ethylene than thermally evaporated electrodes. The introduction of SO2 decreased hydrocarbon production and progressively reduced the differences between the investigated Cu layers during extended operation.
Post-reaction characterization revealed morphological changes and the presence of sulfur-containing species within the electrode structure. The combined results suggest their preferential accumulation at the buried Cu/GDE interface. Overall, the Cu deposition method and layer thickness influenced the initial eCO2RR performance, whereas interfacial sulfur accumulation likely contributed to the progressive loss of catalyst activity during extended operation.
This research was funded by the National Science Centre, Poland, under grant no. 2024/55/D/ST8/02754. This research was partially supported by the programme "Excellence Initiative - Research University" for the AGH University of Krakow.
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