A team of researchers, including Zhenxing Feng and Alvin Chang from Oregon State University, has developed a novel dual-site electrocatalyst that significantly enhances the conversion of carbon dioxide (CO₂) into methanol. This advancement offers a promising route toward sustainable chemical production, cleaner fuels, and the mitigation of greenhouse gas emissions.
Li, J., Zhu, Q., Chang, A., Cheon, S., Gao, Y., Shang, B., Li, H., Rooney, C. L., Ren, L., Jiang, Z., Liang, Y., Feng, Z., Yang, S., Robert Baker, L., & Wang, H. (2025). Molecular-scale CO spillover on a dual-site electrocatalyst enhances methanol production from CO2 reduction. Nature Nanotechnology, 20(4), 515–522. https://doi.org/10.1038/s41565-025-01866-8
Methanol is an important industrial chemical and a potential renewable fuel, used in everything from plastics and solvents to fuel cells and internal combustion engines. Traditional production methods rely on fossil fuels or intensive chemical processing. Electrochemical reduction of CO₂ offers a more sustainable alternative, but single-site catalysts have been limited by low selectivity and efficiency, wasting significant electrical energy.
The researchers designed a hybrid catalyst that integrates nickel tetramethoxyphtyalocyanine and cobalt tetraaminophthalocyanine on carbon nanotubes. These two catalytic sites are separated by approximately 2 nanometers, enabling a stepwise reaction: carbon dioxide is first converted to carbon monoxide at the nickel site, which is then further reduced to methanol at the cobalt site.
Zhenxing Feng from Oregon State University stated,
“The hybrid catalyst was found to exhibit unprecedented high catalytic efficiencies, nearly 1.5 times higher than observed before. Advanced vibrational and X-ray spectroscopy revealed that the improvement is because of a carbon monoxide transfer from a nickel site to a cobalt site on the same carbon nanotube.”
This dual-site arrangement facilitates molecular-scale CO spillover, where the intermediate CO efficiently migrates between the two sites. The effect is a notable improvement in methanol production rates and Faradaic efficiency, reaching around 50% compared to less than 30% for conventional single-site catalysts. By effectively partitioning the reaction steps, the catalyst reduces energy waste and improves overall reaction selectivity.
Advanced characterization techniques, including vibrational spectroscopy and X-ray spectroscopy, confirmed that the nickel-cobalt dual-site structure promotes efficient intermediate transfer without compromising the stability of the catalyst. This structural precision is critical for ensuring reproducible performance and scaling the technology for larger applications.
The new method addresses two key limitations of prior CO₂ electroreduction approaches. First, it increases the rate of methanol production, allowing more chemical output per unit of electrical energy. Second, it provides greater selectivity, reducing by-products and improving overall energy efficiency.
Beyond methanol as a chemical feedstock, this technology has broader implications for sustainable energy systems. Methanol can serve as a low-emission fuel for transportation and electricity generation and can be produced from carbon dioxide captured from industrial emissions or even agricultural and municipal waste. In this way, CO₂ conversion technologies like this could contribute to closing the carbon loop, turning a greenhouse gas into valuable energy carriers.
While the results are promising, scaling this technology from laboratory-scale experiments to industrial applications remains a challenge. Reactor design, catalyst durability under prolonged operation, and consistent CO₂ feedstock availability are all critical considerations. Optimizing electrode architectures and exploring alternative hybrid catalyst combinations could further enhance efficiency and stability.
Moreover, controlling reaction conditions at the molecular level is essential to avoid side reactions, maintain selectivity, and preserve the long-term structural integrity of the catalyst. The research team is exploring strategies to integrate the dual-site catalyst into larger electrochemical systems that could eventually operate at commercial scales.
This dual-site electrocatalyst represents a significant step forward in electrochemical CO₂ reduction. By combining precise molecular engineering with an understanding of reaction intermediates and site interactions, researchers have demonstrated a method that not only improves methanol production efficiency but also contributes to the broader effort to reduce greenhouse gas emissions.
If successfully scaled, this approach could provide a renewable, sustainable source of methanol for chemical production, fuels, and energy storage, supporting the transition to a more carbon-neutral economy. Continued research into multi-site catalysts and optimized reactor systems will be essential to realizing the full potential of this technology.
Adrian graduated with a Masters Degree (1st Class Honours) in Chemical Engineering from Chester University along with Harris. His master’s research aimed to develop a standardadised clean water oxygenation transfer procedure to test bubble diffusers that are currently used in the wastewater industry commercial market. He has also undergone placments in both US and China primarely focused within the R&D department and is an associate member of the Institute of Chemical Engineers (IChemE).
