Schematic shows how carbon dioxide can be electrochemically converted into valuable polymer and drug precursors. Source: Karin Calvinho/Rutgers University-New Brunswick

New uses are being developed for one of the primary agents of climate change. Carbon dioxide has previously been electrochemically converted into methanol, ethanol, methane and ethylene at relatively high yields, but the process is inefficient and cost-intensive.

A more commercially viable route demonstrated by Rutgers University researchers uses catalysts to electrochemically convert carbon dioxide and water into plastics, fabrics, resins and other products. The nickel and phosphorus electrocatalysts are the first materials, aside from enzymes, that can transform carbon dioxide and water into carbon building blocks containing one, two, three or four carbon atoms with more than 99% efficiency.

Two of the products produced — methylglyoxal (C3) and 2,3-furandiol (C4) — can be used as precursors for plastics, adhesives and pharmaceuticals. Toxic formaldehyde could be replaced by methylglyoxal, which is safer.

The researchers received patents for the electrocatalysts and formed a startup company called RenewCO₂. Electrolyzers for commercial use are now being designed and tested as the team delves into reactions that will yield diols and other products for the polymer industry, or hydrocarbons as renewable fuels.