InterPore2026

Processing–Structure–Performance Relationships in Pristine and Recycled Catalyst Layers for CO₂ Electrolysis

21 May 2026, 12:50

15m

Oral Presentation (MS17) Electrochemical Processes in Porous Media MS17

Speaker

Dr Ashkan Irannezhad (University of Toronto)

Description

Global warming and the urgency of achieving net-zero greenhouse-gas emissions by 2050, as articulated by international frameworks such as the Paris Agreement (IPCC 2023) [1], require scalable electrochemical CO2 reduction (CO2R) technologies powered by renewable electricity [2]. A critical component of CO2R systems is the catalyst layer—a reactive porous medium in which coupled multiphase, multicomponent transport and electrochemical reactions occur—and whose physicochemical properties (e.g., catalyst dispersion, ionomer distribution, wettability, and porosity) directly govern activity, selectivity, and stability of the system [3]. Despite its importance, catalyst-layer fabrication remains a major bottleneck: conventional ink-based methods often suffer from poor reproducibility, as minor variations in formulation and processing strongly affect catalyst distribution, wetting behavior, and mass transport [4]. Moreover, catalyst layers frequently rely on resource-intensive materials that are difficult to reclaim at end-of-life, and recycled catalyst materials often exhibit degraded performance due to surface chemical modification and catalyst agglomeration [5].
Here, we examine how catalyst-ink preparation methods influence ink composition, dispersion state, and deposition method, towards decoupling intrinsic catalyst properties from processing-induced variability in CO2R electrodes. The produced catalyst layers are characterized using scanning and transmission electron microscopy (SEM, TEM), X-ray diffraction, and operando electrochemical diagnostics, to extract structure–transport–reaction descriptors. We will discuss how properties—including pore size distribution, tortuosity, ionomer coverage, catalyst agglomeration, and gas–liquid–solid interfacial accessibility—govern activity, selectivity, and stability of the system. Beyond pristine systems, we extend this methodology to inks formulated from reclaimed catalyst materials.