Coupled Thermal and Electrochemical Optimization of Industrial Carbon-Dioxide Conversion Systems

Authors

  • Yassine Khalfallah LASEM Laboratory, Department of Mechanical Engineering, National Engineering School of Sfax (ENIS), University of Sfax, Sfax 3038, Tunisia
  • Youssef Ben Salah LASEM Laboratory, Department of Mechanical Engineering, National Engineering School of Sfax (ENIS), University of Sfax, Sfax 3038, Tunisia
  • Najat H. Saidi LASEM Laboratory, Department of Mechanical Engineering, National Engineering School of Sfax (ENIS), University of Sfax, Sfax 3038, Tunisia

Keywords:

Carbon Dioxide Conversion, Electrochemical Optimization, Thermal Management, Industrial Scalability

Abstract

The mitigation of anthropogenic greenhouse gas emissions necessitates the development of highly efficient industrial systems for carbon dioxide utilization. Electrochemical reduction of carbon dioxide presents a promising pathway for converting waste emissions into valuable chemical feedstocks and synthetic fuels. However, scaling this technology from laboratory prototypes to industrial-scale continuous systems poses significant operational challenges, primarily regarding energy efficiency, catalyst stability, and product selectivity. This paper investigates the coupled thermal and electrochemical optimization of large-scale carbon dioxide conversion systems, emphasizing the synergistic effects of integrated heat management and advanced cell architectures. By treating the electrolyzer as a strictly coupled multiphysics environment, this study demonstrates that localized thermal gradients drastically influence electrochemical reaction kinetics and membrane integrity. A comprehensive methodological framework is introduced to model and optimize these interacting phenomena, focusing on heat recovery loops that recycle exothermic energy from the anode to pre-heat cathodic reactant streams. The analysis reveals that operating within tightly controlled optimal thermal windows can significantly suppress parasitic hydrogen evolution while enhancing the faradaic efficiency of multi-carbon products. Through detailed evaluation of system architectures, performance trajectories, and industrial scalability, this research establishes that decoupled approaches are insufficient for commercial viability. Ultimately, the integration of real-time thermal regulation with electrochemical parameter control provides a robust pathway toward achieving net-zero chemical manufacturing capabilities.

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Published

2026-08-02

Issue

Vol. 4 No. 2 (2026): International Journal of Innovative Research

Section

Articles

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Copyright (c) 2026 Yassine Khalfallah, Youssef Ben Salah, Najat H. Saidi

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