Electrowetting limits electrochemical CO2 reduction in carbon-free gas diffusion electrodes

CO2 electrolysis might be a key process to utilize intermittent renewable electricity for the sustainable production of hydrocarbon chemicals without relying on fossil fuels. Commonly used carbon-based gas diffusion electrodes (GDEs) enable high Faradaic efficiencies for the desired carbon products at high current densities, but have limited stability. In this study, we explore the adaption of a carbon-free GDE from a Chlor-alkali electrolysis process as a cathode for gas-fed CO2 electrolysis. We determine the impact of electrowetting on the electrochemical performance by analyzing the Faradaic efficiency for CO at industrially relevant current density. The characterization of used GDEs with X-ray photoelectron spectroscopy (XPS) and X-Ray diffraction (XRD) reveals a potential-dependent degradation, which can be explained through chemical polytetrafluorethylene (PTFE) degradation and/or physical erosion of PTFE through the restructuring of the silver surface. Our results further suggest that electrowetting-induced flooding lets the Faradaic efficiency for CO drop below 40% after only 30 min of electrolysis. We conclude that the effect of electrowetting has to be managed more carefully before the investigated carbon-free GDEs can compete with carbon-based GDEs as cathodes for CO2 electrolysis. Further, not only the conductive phase (such as carbon), but also the binder (such as PTFE), should be carefully selected for stable CO2 reduction.