Development of a continuous reactor for the electro-reduction of carbon dioxide to formate - Part 1: Process variables

This paper reports an experimental investigation into the effects of five process variables on the performance of a bench-scale continuous electrochemical reactor used in the reduction of CO2 to potassium formate, and interprets the data in terms of reactor engineering for a (speculative) industrial process for electro-reduction of CO2. The process variables: temperature, catholyte species, catholyte conductivity, cathode specific surface area and cathode thickness were studied, along with CO2 pressure and current density, in a set of factorial and parametric experiments aimed to unravel their main effects and interactions. These variables showed complex interdependent effects on the reactor performance, as measured by the current efficiency and specific energy for generation of formate (HCO2-). The best result has a formate current efficiency of 86% at a superficial current density of 1.3 kA m(-2), with a product solution of 0.08 M KHCO2 and specific electrochemical energy of 260 kWh per kmole formate. The combined results indicate good prospects for process optimization that could lead to development of an industrial scale reactor.