Room-temperature electrochemical acetylene reduction to ethylene with high conversion and selectivity

The selective hydrogenation of acetylene to ethylene in ethylene-rich gas streams is an important process in the manufacture of polyethylene. Conventional thermal hydrogenation routes require temperatures above 100 °C and excess hydrogen to achieve a satisfactory C₂H₂ conversion efficiency. Here, we report a room-temperature electrochemical acetylene reduction system based on a layered double hydroxide (LDH)-derived copper catalyst that offers an ethylene Faradaic efficiency of up to ~80% and inhibits alkane and hydrogen formation. The system affords an acetylene conversion of over 99.9% at a flow rate of 50 ml min⁻¹ in a simulated gas feed, yielding high-purity ethylene with an ethylene/acetylene volume ratio exceeding 10⁵ and negligible residual hydrogen (0.08 vol.%). These acetylene conversion metrics are superior to most other state-of-the-art strategies. The findings therefore conclusively demonstrate an electrochemical strategy as a viable alternative to current technologies for acetylene-to-ethylene conversions with potential advantages in energy and atom economies. [Figure not available: see fulltext.].