Scientists Unveil a Roadmap to Watch and Control Copper Catalysts as They Transform During CO2 Electrolysis

Copper has long been the darling of electrochemists chasing the dream of turning carbon dioxide back into useful fuels and chemicals. It is the only metal catalyst that reliably converts CO2 into valuable multicarbon products such as ethylene and ethanol at meaningful rates. Yet copper harbors a frustrating secret: the catalyst that goes into the electrolyzer is rarely the catalyst that does the work. Under the punishing conditions of electrochemical CO2 reduction, copper surfaces restructure continuously—atoms migrate, oxides dissolve and reform, facets evolve, and entire surface chemistries shift. A team of researchers at the Institute of Chemistry, Chinese Academy of Sciences, led by Libing Zhang, Xiaofu Sun and Buxing Han, has now published a comprehensive protocol in Nature Protocols that turns this elusive, dynamic behavior from a source of confusion into something scientists can systematically probe, understand and, crucially, control.

The new work arrives at a moment when CO2 electroreduction stands at a crossroads. Laboratory demonstrations of copper-based catalysts converting carbon dioxide into ethylene, ethanol and other multicarbon products have multiplied rapidly over the past decade, but translating those results into industrial electrolyzers capable of gigatonne-scale operation demands catalysts that remain active, selective and stable for thousands of hours. Catalyst reconstruction sits at the heart of that challenge. When a copper catalyst reorganizes itself under operating conditions, its activity can rise or fall, its product selectivity can drift toward desired chemicals or toward wasteful hydrogen evolution, and its lifetime can be cut dramatically short. Until now, the field has lacked a standardized, reproducible methodology for investigating these transformations—leaving individual laboratories to improvise their own approaches, with results that are often difficult to compare or reproduce.

The protocol is organized around what the authors call a ‘reconstruction–understanding–intervention’ workflow, a modular pipeline that guides researchers from the first observation of structural change all the way to deliberate control of the catalyst’s final state. The first stage involves the identification and taxonomy of reconstruction phenomena, classifying the many ways a copper surface can transform: morphological reshaping, chemical state changes such as the reduction of copper oxides to metallic copper or the persistence of transient copper(I) species, and compositional evolution in alloyed or bimetallic systems. By establishing a common vocabulary and systematic identification procedures, the protocol addresses one of the field’s most persistent problems—different groups describing fundamentally different phenomena under the same broad label of ‘reconstruction’.

The second stage tackles the question of what drives these transformations in the first place. Reconstruction is governed by an interplay of electrochemical and environmental factors: applied potential, local pH, the identity and concentration of electrolyte cations and anions, mass transport of CO2 to the surface, and the adsorption of reaction intermediates such as carbon monoxide. The protocol lays out quantitative methods for disentangling these variables, allowing researchers to determine whether a particular restructuring event is triggered by potential cycling, by the accumulation of hydroxyl species, by the migration of alkali metal cations into the interfacial layer, or by some combination of influences. This quantitative grounding is essential, because interventions can only be rationally designed once the governing factors are known.

At the technical core of the protocol lies a battery of complementary in situ and operando characterization techniques, each chosen to illuminate a different aspect of the catalyst’s evolving structure. Operando Raman spectroscopy tracks surface oxides, adsorbed intermediates and the formation of species such as copper carbonyl in real time under working conditions. Infrared spectroscopy, including surface-enhanced variants based on attenuated total reflection, probes the vibrational fingerprints of adsorbed molecules and interfacial water networks. X-ray absorption spectroscopy, typically performed at synchrotron facilities, reveals changes in the oxidation state and local coordination environment of copper atoms deep within the working electrode. Quasi-in situ X-ray photoelectron spectroscopy bridges the gap between fully operando measurements and conventional ex situ analysis: the protocol describes a compact titanium-alloy transfer cell, sized to pass through a glovebox antechamber, that allows electrodes to be interrogated at defined electrochemical states without exposure to air, preserving chemical information that would otherwise be lost.

The methodological rigor extends to the hardware itself. The protocol provides detailed descriptions of electrochemical cell configurations—flow cells, gas diffusion electrode assemblies and spectroscopy-compatible electrolytic cells—because the authors emphasize that the very design of the cell influences how catalysts reconstruct. Extended data accompanying the article specify, for example, the geometry of an operando Raman flow cell built from polyetheretherketone with a titanium flow field and quartz optical window, and the configuration of an operando XAS cell sealed with Kapton film and oriented at 45 degrees to the incident X-ray beam. Standardizing these details means that structural dynamics observed in one laboratory can be meaningfully compared with results from another, a prerequisite for building a reliable, field-wide picture of copper’s behavior under reaction conditions.

With identification and diagnosis in hand, the protocol’s third pillar moves into territory that sets it apart: active intervention. Rather than treating reconstruction as an inevitable degradation process to be tolerated, the authors present three primary strategies for steering it toward desired active states. The first is catalyst structure modulation, in which the starting material—its composition, oxide content, strain and dopant profile—is engineered so that the reconstruction pathway terminates at a favorable configuration. The second is electrochemical operation regulation, including pulsed or intermittent electrolysis protocols that periodically reset or regenerate the catalyst surface. The third is reaction microenvironment management, in which the electrolyte composition, local hydrophobicity, cation distribution and interfacial water structure are tuned to stabilize particular surface states and suppress destructive pathways.

The methodology was validated across representative classes of copper catalysts, demonstrating its breadth. Commercial metallic copper foil, oxide-derived copper—the family of catalysts in which pre-formed oxides reorganize during reaction to create highly active surfaces—and bimetallic copper-based systems denoted Cu–X, where a second metal tunes copper’s electronic structure, all serve as test cases. In each case, the workflow linked specific reconstruction dynamics to catalytic behavior and showed that deliberate control strategies enhanced both performance and stability of CO2 reduction. The validation examples map onto the team’s own published record, including work on oxophilicity-controlled multicarbon alcohol production over Lewis-acid-doped copper, lanthanide-induced tensile-strained copper oxide catalysts, acid-fed lanthanum–copper spheres operating at ampere-level currents, in situ periodic regeneration of catalysts, and self-adaptive catalysts for CO2 electroreduction.

The broader significance of the protocol extends well beyond copper. The authors explicitly frame the workflow as an adaptable framework for investigating dynamic surface evolution in other electrocatalytic reactions, from nitrate reduction to ammonia—where correlated operando microscopy and spectroscopy have similarly revealed restructuring—to carbon monoxide reduction and beyond. As the global push toward carbon neutrality intensifies, the ability to design ‘self-adaptive’ electrocatalysts that respond constructively to their operating environment, rather than degrading under it, is emerging as a defining goal of the field. By providing a reproducible, modular and quantitative path from observation to mechanistic insight to rational control, this protocol gives the community a shared toolkit for reaching that goal. In effect, it transforms one of electrocatalysis’s most stubborn complications into an engineering variable—one that can be measured, modeled and ultimately mastered in the service of converting waste carbon dioxide into the fuels and chemicals of a sustainable economy.

The scientific backdrop to this protocol is a decade of discoveries that progressively dismantled the assumption of a static copper surface. Operando studies have shown that metallic copper can fragment into active nanograins under reaction conditions, while solution-based transient copper(I) species have been identified as mediators of surface reconstruction. Other work has revealed that oxygen trapped within oxide-derived copper can diffuse and persist during catalysis, and that hydroxyl radicals play a decisive role in reoxidizing reduced copper surfaces. Adsorbed hydroxide itself has been described as a double-edged sword, simultaneously promoting carbon–carbon coupling and destabilizing the catalyst. Each of these findings underscores why a single snapshot of a catalyst before or after electrolysis is insufficient: the active state may exist only transiently, sandwiched between structural configurations that are themselves catalytically inert.

The protocol also responds to a subtler problem: the observation itself can depend on how it is made. Recent comparative studies have demonstrated that cell configuration measurably alters how copper reconstructs, since flow geometry, electrolyte layer thickness and local mass transfer shape the interfacial chemical environment. Operando X-ray absorption work has quantified these mass-transfer effects directly, showing that concentration gradients near the electrode influence both the reaction pathway and the structural evolution of the catalyst. By specifying standardized cell geometries and measurement procedures, the protocol helps ensure that apparent differences between catalysts reflect genuine materials behavior rather than apparatus artifacts.

Another theme the protocol consolidates is the mechanistic link between reconstruction and selectivity. Spectroscopic observations of carbon monoxide bridge species forming on dynamically restructured copper, together with reconstruction-dependent coordination descriptors, suggest that the evolving surface geometry directly tunes how intermediates bind and couple. This reframes selectivity in CO2 electrolysis as a property of a moving target. The practical consequence is that stability and performance can no longer be optimized independently; a protocol that treats the catalyst’s trajectory through time as the design object, rather than its initial composition, aligns catalyst development with how these materials actually behave in operating electrolyzers.

Subject of Research: Dynamic reconstruction of copper-based catalysts during electrochemical CO2 reduction and methods for probing and controlling it

Article Title: Probing and controlling Cu catalyst reconstruction during CO2 electroreduction

Article References: Zhang, L., Zheng, C., Xu, L., Feng, J., Jia, S., Wu, L., Song, X., Zhang, M.-D., Wang, R., Zhang, X., Zhao, Z., Sun, X., & Han, B. (2026). Probing and controlling Cu catalyst reconstruction during CO2 electroreduction. Nature Protocols. https://doi.org/10.1038/s41596-026-01430-1

Image Credits: AI Generated

DOI: 10.1038/s41596-026-01430-1

Keywords: CO2 electroreduction, copper catalyst, catalyst reconstruction, electrocatalysis, operando spectroscopy, Raman spectroscopy, X-ray absorption spectroscopy, X-ray photoelectron spectroscopy, multicarbon products, catalyst stability, oxide-derived copper, carbon neutrality