The Need

Industrial CO₂ electroreduction remains limited by high energy input, poor selectivity, and low formation rates of valuable multi‑carbon products. Conventional copper catalysts often favor hydrogen evolution or low‑value C₁ products such as methane, while catalysts that improve selectivity typically require high overpotentials or complex fabrication. Industry needs scalable, durable electrocatalysts that efficiently convert CO₂ into higher‑value C₂–C₃ chemicals at lower operating voltages and with improved carbon utilization.

The Technology

OSU researchers have developed nanoporous copper–ruthenium (Cu–Ru) catalysts engineered to promote efficient electrochemical conversion of CO₂ into multi‑carbon hydrocarbons and oxygenates. The catalyst architecture combines a high‑surface‑area porous copper framework with strategically incorporated ruthenium to tune reaction pathways. Under electrochemical operation, the material favors carbon–carbon coupling and suppresses undesired side reactions, enabling CO₂ conversion at lower onset potentials and with enhanced selectivity toward higher‑value products.

Commercial Applications

• Electrochemical production of ethylene and ethane from captured CO₂
• Sustainable synthesis of ethanol and propanol for fuels or chemicals
• Carbon utilization modules integrated with renewable‑powered electrolyzers
• On‑site CO₂ upgrading for industrial emitters and chemical manufacturers

Benefits/Advantages

• Lower energy requirements: Reduced onset potentials compared with conventional Cu catalysts
• Improved selectivity: Preferential formation of C₂–C₃ products with suppressed methane and hydrogen evolution
• Scalable fabrication: Compatible with established metal processing and electrode manufacturing methods
• Higher carbon efficiency: Greater conversion of CO₂ into value‑added chemical products