Catalyst synthesis under CO2 electroreduction favours faceting and promotes renewable fuels electrosynthesis

The electrosynthesis of C2+ hydrocarbons from CO2 has attracted recent attention in light of the relatively high market price per unit energy input. Today’s low selectivities and stabilities towards C2+ products at high current densities curtail system energy efficiency, which limits their prospects for economic competitiveness. Here we present a materials processing strategy based on in situ electrodeposition of copper under CO2 reduction conditions that preferentially expose and maintain Cu(100) facets, which favour the formation of C2+ products. We observe capping of facets during catalyst synthesis and achieve control over faceting to obtain a 70% increase in the ratio of Cu(100) facets to total facet area. We report a 90% Faradaic efficiency for C2+ products at a partial current density of 520 mA cm−2 and a full-cell C2+ power conversion efficiency of 37%. We achieve nearly constant C2H4 selectivity over 65 h operation at 350 mA cm−2 in a membrane electrode assembly electrolyser. Electrocatalytic reduction of CO2 to multicarbon products is useful for producing high-value chemicals and fuels. Here the authors present a strategy that is based on the in situ electrodeposition of copper under CO2 reduction conditions that preferentially expose and maintain Cu(100) facets, which favour the formation of C2+ products.