Electrolysis has often been compared to a modern form of alchemy, transforming one chemical compound into another through electrochemical reactions. While it cannot create precious metals from ordinary materials, the technology has already proven capable of splitting water into hydrogen and oxygen to produce hydrogen fuel. Researchers are now applying similar concepts to carbon dioxide and carbon monoxide, aiming to convert excess carbon emissions into useful industrial products.

At Washington University in St. Louis, Feng Jiao, the Lauren and Lee Fixel Distinguished Professor in the McKelvey School of Engineering, is leading efforts to advance CO and CO2 electrolysis technologies from laboratory research to large-scale commercial applications. In a recent commentary published in Nature Chemical Engineering, Jiao and collaborators examined the technical and economic hurdles standing in the way of widespread deployment.

The electrolysis systems being developed consist of stacked metallic plates layered with separators that drive electrochemical reactions. Within the system, waste carbon gases can be transformed into a range of valuable products, including carbon monoxide, methanol, ethylene, acetate and formic acid. These materials can then be used to manufacture fuels, food ingredients, intermediary chemicals and advanced synthetic materials that may be recyclable or biodegradable alternatives to conventional plastics.

Jiao and his team have also gained industry insight through Lectrolyst, a startup company co-founded with co-authors Gregory Hutchings and Bradie Crandall. Their commercialization work has highlighted several major engineering challenges.

One issue involves achieving the correct level of compression within the electrolysis stack. Excessive compression can damage components, while insufficient compression may allow leaks of gases and chemicals. Temperature regulation is another major obstacle. As electrolysis systems grow larger, maintaining stable operating temperatures becomes increasingly difficult. Researchers are using modeling tools to identify optimal cell designs, flow patterns and operating conditions that improve thermal management while controlling costs.

The team is also focused on creating highly concentrated and pure product streams that can reduce downstream separation expenses, an important factor in making the technology economically viable.

Another challenge is transport behavior within larger systems. Smaller electrolysis devices maintain relatively uniform flow, but scaling up introduces uneven flow distribution and pressure imbalances that can disrupt reactions and reduce efficiency. Engineers must carefully optimize system design to balance pressure, flow rates and reaction performance.

While technical barriers remain significant, researchers say broader support from government and industry may ultimately determine whether the United States can compete globally in electrolyzer manufacturing and deployment. Europe and Asia have already increased investment in large-scale electrolyzer projects and manufacturing capacity, intensifying international competition in the sector.

The authors argue that long-term government support will be essential for attracting private investment and helping emerging electrolysis technologies achieve commercial-scale deployment.

For the original story, visit: https://engineering.washu.edu/news/2026/WashU-Expert-Scaling-up-the-circular-economy.html