2.1. Hydrogenation Activity Measurements
The steady state CO
2 conversion as a function of temperature for different CO
2 to H
2 ratios was first investigated. The results displayed in
Figure 1 show that the conversion of CO
2 increases with increasing temperature reaching a maximum of 17.6% under reaction conditions of CO
2 to H
2 feeding ratio of 1:2. Under conditions of CO
2 to H
2 of 1:1 the conversion drops to 12 % and is smallest with 6 % and 2 % at CO
2 to H
2 ratios of 2:1 and 4:1, respectively.
Figure 2 shows the CH
4 and CO production rates at steady state as a function of temperature. The rate of the methanation reaction was found to be highest for a gas feed ratio of CO
2 to H
2 of 1:2. With increasing CO
2 partial pressure in the reaction mixture, i.e., a CO
2 to H
2 ratio of 1:1, 2:1 and 4:1 the observed CH
4 formation rate is very low and almost independent of temperature.
Figure 2b suggests that the RWGS reaction prevails over the Sabatier reaction. Moreover, as shown in
Figure 3, CO appears to be the main product under all feeding CO
2 to H
2 ratios of this study and its selectivity is higher than 96%, while CH
4 selectivity is smaller than 4%. The reaction rate values of the RWGS reaction are more than one order of magnitude higher than those of the methanation one.
Figure 4 and
Figure 5 depict the transient effect of constant applied positive (
Figure 4) and negative (
Figure 5) current on the catalytic rate and turnover frequency (TOF) for the formation of CH
4 and CO at a CO
2 to H
2 ratio of 1:2 at 380
oC. Initially, as presented in
Figure 4, at t < 0, the circuit is open and the steady-state formation rates of CH
4 and of CO are equal to 0.38 x10
-9 mols
-1 and 9.2 x10
-9 mols
-1 respectively. At t = 0, a constant anodic current (I = + 0.8 mA) is applied between the catalyst and counter electrode, which causes an applied potential of U
WR = +1.2 V. Oxygen ions, O
2-, are transferred from the YSZ support to the Rh catalyst-electrode at a rate of I/2F equal to approximately 10
-3 s
-1. The rate of CH
4 increases and approaches a new steady state value (r
CH4 = 0.62 x10
-9 mols
-1). This increase of the CH
4 catalytic rate (Δr = 0.24 x 10
-9 mols
-1) is 1.7 times greater than the initial rate achieved under open circuit conditions. The CO formation rate decreases under anodic current application to 8.0 x 10
-9 mols
-1, resulting in a rate enhancement value of ρ = 0.84. After current interruption, the CH
4 rate of formation returns to its initial open circuit value (reversible behaviour), while the CO formation rate returns only to a value above the initial open circuit rate (non-reversible behaviour). A very similar trend is observed under cathodic current application, as shown in
Figure 5. The decrease in CO formation rate is less pronounced with a rate enhancement ratio, ρ, (see Equation (5) in
Section 3.3) equal to 0.94. After current interruption, the rate does not return to its initial open circuit value. Under cathodic current application, CH
4 formation rate is increased and a rate enhancement ρ-value of 2.7 is estimated.
The time constant, τ, given in both
Figure 4 and
Figure 5, is defined as the time required for the rate increase Δr to reach 63% of its new steady state value during a galvanostatic transient [
70]. When an O
2- ion conductor is used, the magnitude of τ can be generally predicted by
where N
G (mol) is the reactive oxygen uptake on the metal catalyst. The time constant τ expresses the time required to form a monolayer of O
δ- on the metal surface, while N
G expresses, approximately, the surface mols of metal, here Rh. The average active catalyst surface area, N
G, which is equal to 7.62 x 10
-7 mol Rh, has been calculated based on 6 galvanostatic transients. The estimated value of N
G agrees well with the values found in previous studies of Rh catalyst-electrodes supported on YSZ [
50,
51,
67,
71]. The average N
G value obtained was used to calculate turnover frequencies (TOFs) for CH
4 and CO formation. TOFs for CH
4 formation are found to be small and in the order of 10
-4 s
-1, which is in good agreement with literature data [
21].
The non-reversible behaviour of CO formation has been further investigated by repeated current and/or potential application, which have generally shown, that upon current an/or potential interruption the rate of CO formation does not return to its initial open circuit value.
Figure 6 summarises the results for potentiostatic transient operation at different CO
2 to H
2 feed ratios. The bottom part of the figure shows that the increase in CH
4 formation rate under anodic and cathodic polarization (+ and -1.5 V), which is more pronounced at high H
2 to CO
2 feeding ratios, is reversible. However, the CO formation rate, as shown in the top part of
Figure 6, exhibits a “permanent”, non-reversible NEMCA behaviour [
69,
70]. The guide (dotted) lines, clearly show, that this non-reversible effect of current and/or potential application is more pronounced at higher CO
2 to H
2 feed ratios.
The “permanent” rate enhancement ratio γ, was defined for the first time by Comninellis et al. [
70] as
where
is the “permanent” promoted catalytic rate after current or potential interruption, and
is the unpromoted rate (i.e., the open-circuit catalytic rate).
Figure 7 displays the non-reversibility magnitude of CO formation for different gas feed ratios. Under reaction conditions of a CO
2 to H
2 ratio of 1:2, the γ/ρ ratio is higher than 1, expressing, that the CO formation rate observed under potential application partially returns to its initial open circuit value. However, γ/ρ ratio equals to 1 for a reaction mixture with a CO
2 to H
2 ratio of 4:1 and a significant “permanent” NEMCA behaviour is observed.
In the general case of an oxidation reaction on catalysts deposited on O
2− conductors, like YSZ, the ionic species migrating in the solid electrolyte is participating in the electrochemical reaction leading to distinct values of apparent Faradaic efficiency, |Λ| > 1 (see Equations (6)–(8),
Section 3.3). In the present case however, in which oxygen is not a reactant, any positive current or positive potential-induced catalytic rate change denotes electrochemical promotion, even when |Λ| < 1 [
38]
Figure 8 summarizes the results of steady state potential application on the rate of CH
4 formation at T = 430
oC, for which the highest rate enhancement ratio, ρ has been found. The observed currents (not shown in
Figure 5) do not depend on gas feed conditions, that means they are almost equal at a given potential and do not depend on the CO
2 to H
2 ratios. This observation is one of the very first hints that the overall oxidation state of the film, remains relatively unchanged during the course of the reaction. The rate of CH
4 production displays an inverted volcano type behavior i.e., it increases with increasing and decreasing catalyst potential as shown in
Figure 8a. Maximum changes in the CH
4 rate are observed under reaction conditions of a CO
2 to H
2 ratio of 1:2, but the highest rate enhancement ratios are achieved at conditions of CO
2:H
2=1:1 with ρ reaching values of up to 11. If the partial pressure of CO
2 is further increased, i.e., CO
2 to H
2 ratios of 2:1 and 4:1, methane formation is found to be small with values below 0.6 10
-9 mols
-1. Despite this, however, methane formation can be electrochemically promoted with ρ-values of up to 5. Product selectivity towards CH
4 is electrochemically promoted under anodic and cathodic polarization; and it is highest under reaction conditions of a CO
2 to H
2 ratio of 1:2, but does not exceed 10%, as seen in
Figure 9.
2.2. Catalyst Characterization
The morphology and chemical state of the Rh/YSZ film was assessed with XRD (X-ray diffraction), SEM (Scanning Electron Microscopy) and XPS (X-ray Photoelectron Spectroscopy). The characterization studies were carried out on two different samples, designated as fresh and used, which correspond to the freshly reduced (i.e., after treatment in 15% H2 in He) and a post experiment (i.e., after exposure to different CO2: H2 gas feed compositions) Rh/YSZ catalyst-electrode, respectively.
The diffractograms displayed in
Figure 10 and show no major differences in the phase distribution of the fresh and used sample. More specifically both diffractograms show clear reflections at 2θ = 30.3°, 35.0°, 50.4°, 59.9°, 62.9°,74.1° and 81.9° which correspond to the (111), (200), (220), (311), (222), (400), (331) planes of YSZ [
74,
75]. In addition, both diffractograms show clear reflections at 41.5°, 48.4°, and 70.7° which correspond to the (111), (200), and (220) phases Rh particles in their metallic (Rh
0) state [
73]. No reflections corresponding to RhO
2 or Rh
2O
3 were detected in the XRD measurements suggesting that the chemical state of the Rh film is mostly metallic before and after use.
The mean Rh crystallite size of the fresh and used samples were calculated by means of the Scherrer equation [
74] by assuming a spherical crystallite shape and averaging the crystalline domain diameter obtained for the (111), (200) and (220) reflections. The size of the Rh crystallites in the fresh sample (19.9 ± 0.8 nm) was found to be slightly smaller as compared to the used sample (24 ± 1 nm) which suggests that some degree of crystallite size increase during the course of the electrocatalytic reaction due to agglomeration.
Previous XRD studies on Rh/YSZ systems have shown that after reduction and prior to experimental measurements the metallic phase of Rh is mainly present in the sample with only tracers of metal oxides being detectable [
75]. Using metalorganic paste (Engelhard 8826) as a precursor, Jimenez et al. reported rhodium crystallite sizes equal to 58.5 ± 0.3 nm, calculated by the XRD patterns of the reduced sample [
75]. The observed size variation and the Rh
0: Rh oxide ratio was attributed to the different conditions of calcination and reduction conditions of the working Rh-catalyst electrode.
Top view and cross section SEM images of the fresh and used catalyst-film are shown in
Figure 11 and
Figure 12, respectively. Overall, the sample preparation method followed in this work has led to a continuous rhodium film, sufficiently porous which facilitates the efficient access of both reactants and products on the Rh active sites, and well attached to the YSZ support to ensure an electrochemically active interface. The apparent average particle size is estimated to be 40 nm, which is roughly twice the crystallite size calculated from the XRD spectra. It is worth mentioning here that particle size estimation from the SEM images is limited by the resolution of the instrument. Both the morphology and structure of the Rh film appears to be unchanged comparing the images from the sample prior experiment and after exposing it to reaction conditions. The thickness of the catalyst film was estimated from the cross section micrograph and was found to be in the range of 6.5-10 μm, which is a common thickness for films prepared by applying metalorganic pastes [
59].
Figure 13a shows the Rh 3d spectra of the freshly reduced and post reaction (used) sample. The Rh 3d
5/2 peak of the fresh sample is centred at approximately 307.2 eV which indicates that the Rh catalyst film is mostly in the metallic state, without excluding of course the possibility of some minor Rh oxide quantities being also present [
76]. The post reaction data suggest that the surface chemical state of the Rh electrocatalyst film has not changed significantly. A rather small shift of ~0.2 eV towards lower binding energy is observed suggesting that a minor oxide component may be present in the fresh sample which has been reduced after reaction leading to the apparent shift. To clarify this point the raw Rh3d spectra were deconvoluted using an asymmetric peak shape for the metallic state and Gaussian-Lorentzian peak shape for the oxidized state.
Figure 13a shows that the metallic Rh3d
5/2 component (solid line) is centred at ~307 eV while the oxidized Rh3d
5/2 component (dashed line) is centred at ~308 eV. The ratio of metallic Rh to oxidised Rh is 1:9 confirming that Rh film is nearly metallic both before and after reaction. It is worth noting here that the post reaction spectra have been acquired after testing the catalyst under reaction conditions of CO
2 to H
2 of 1:4. The XPS results are in close agreement with the XRD data presented above (
Figure 10) with the two techniques suggesting the absence of any substantial quantity of Rh oxide on the surface or bulk of the Rh film. Minor quantities of carbon was present on both the fresh and used samples (
Figure 13b). More crucially, the amount of carbon was not found to increase in the post reaction sample, which indicates that there is no carbon deposition on the catalyst surface during the reaction, especially under feed conditions of P
CO2:P
H2 ratios of 4:1.