Abstract: An electro catalytic CO2 reduction method including forming a gas diffusion cathode including a porous layer and gas diffusion layer. The method includes electrocatalyzing the gas diffusion cathode by electrochemically depositing a CO2 reduction catalyst using a pulse current or pulse reverse current passed between the gas diffusion cathode and a counter electrode in a bath containing ions of the catalyst to balance nucleation/growth of the catalyst particles resulting in a more uniform deposition of catalyst particles of predominantly less than 20 nm. The electro catalyzed gas diffusion cathode is utilized in an electrochemical reactor along with an anode and voltage source connected to the cathode and anode to convert CO2 to another chemical (e.g., formic acid).

Abstract: A system for recycling machined metal produced by an electrochemical material removal process. The system includes a machining unit and an electrowinning unit. The machining unit includes an anode to receive a workpiece, a cathode tool, and a first pulse generator to provide a voltage or current waveform between the anode and the cathode tool. The electrowinning unit includes an electrowinning cathode, an electrowinning anode, and a second pulse generator to provide a voltage or current waveform between the electrowinning anode and the electrowinning cathode. The machining unit is in fluid communication with the electrowinning unit.

Abstract: A system for recycling machined metal produced by an electrochemical material removal process. The system includes a machining unit and an electrowinning unit. The machining unit includes an anode to receive a workpiece, a cathode tool, and a first pulse generator to provide a voltage or current waveform between the anode and the cathode tool. The electrowinning unit includes an electrowinning cathode, an electrowinning anode, and a second pulse generator to provide a voltage or current waveform between the electrowinning anode and the electrowinning cathode. The machining unit is in fluid communication with the electrowinning unit.

Abstract: A method for recycling metallic material produced by an electrochemical material removal process. The method includes flowing an electrolyte solution between an anode workpiece and a cathode tool in a first electrolytic process, the first electrolytic process including applying a first electrolytic current and voltage between the anode workpiece and the cathode tool and thereby causing metal ions to be removed from the anode workpiece and dissolved and substantially retained in the electrolyte solution. The electrolyte solution with the metal ions therein is passed between an electrowinning cathode and an electrowinning anode in a second electrolytic process, the second electrolytic process including applying a second electrolytic current and voltage between the electrowinning cathode and the electrowinning anode and thereby causing the metal ions to be removed from the electrolyte solution and deposited onto the electrowinning cathode.

Abstract: A method for recycling metallic material produced by an electrochemical material removal process. The method includes flowing an electrolyte solution between an anode workpiece and a cathode tool in a first electrolytic process, the first electrolytic process including applying a first electrolytic current and voltage between the anode workpiece and the cathode tool and thereby causing metal ions to be removed from the anode workpiece and dissolved and substantially retained in the electrolyte solution. The electrolyte solution with the metal ions therein is passed between an electrowinning cathode and an electrowinning anode in a second electrolytic process, the second electrolytic process including applying a second electrolytic current and voltage between the electrowinning cathode and the electrowinning anode and thereby causing the metal ions to be removed from the electrolyte solution and deposited onto the electrowinning cathode.