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  4. Scaling Low Temperature CO2-to-Syngas Electroreduction: Insights into Engineering Bottlenecks and Mitigation Strategies
 
preprint

Scaling Low Temperature CO2-to-Syngas Electroreduction: Insights into Engineering Bottlenecks and Mitigation Strategies

Pachamuthu, Senthilkumar  
•
Gao, Jing  
•
Ozden, Adnan
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October 13, 2025

CO₂ electroreduction powered by renewable electricity offers a sustainable route to produce fuels and chemicals. The technology is entering the early stages of industrial adoption, with current low-temperature CO₂eR systems achieving reaction rates above 1 A cm⁻² and Faradaic efficiencies (FE) exceeding 90% for syngas production. The carbon monoxide: hydrogen (CO:H₂) ratio can be tuned between 1 and 5, enabling versatile downstream applications. In this review, we move beyond lab-scale performance metrics to identify the key challenges limiting CO₂-to-syngas commercialization, integrating insights from techno-economic and life-cycle analyses. We propose a roadmap protocol to bridge laboratory achievements and industrial implementation. An accelerated stress protocol defines standard, short, and extreme operational scenarios to monitor key performance indicators (KPIs) and interface stability. Emphasizing operational durability and energy efficiency (EE)—two decisive metrics for market-ready electrified syngas production—this framework outlines how rational materials design, system integration, and unified benchmarking can drive CO₂eR technologies toward industrial scale.

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Type
preprint
DOI
10.26434/chemrxiv-2025-pw37p
Author(s)
Pachamuthu, Senthilkumar  

École Polytechnique Fédérale de Lausanne

Gao, Jing  

École Polytechnique Fédérale de Lausanne

Ozden, Adnan

Khalifa University of Science and Technology

Legrand, Ulrich

Carbon180

Favaro, Marco

Helmholtz-Zentrum Berlin für Materialien und Energie

Isaacs, Mark A.

Rutherford Appleton Laboratory

de Arquer, F. Pelayo Garcı́a

Institute of Photonic Sciences

Azenha, Cátia

Universidade do Porto

Mendes, Adélio

Universidade do Porto

Sargent, Edward H.

University of Toronto

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Date Issued

2025-10-13

Publisher

American Chemical Society (ACS)

Written at

EPFL

EPFL units
LPI  
FunderFunding(s)Grant NumberGrant URL

European Commission

101068996

European Commission

101099284

Available on Infoscience
October 20, 2025
Use this identifier to reference this record
https://infoscience.epfl.ch/handle/20.500.14299/255115
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