Recent advances in electrocatalytic urea synthesis via N2 and CO2 coupling: mechanisms, catalyst design and reactor engineering.

Abstract

As a pivotal nitrogen fertilizer and versatile industrial feedstock, urea (CO(NH2)2) is predominantly synthesized via the Bosch-Meiser process, which is a high-temperature, high-pressure catalytic route, accompanied by substantial energy consumption and considerable CO2 emissions. In light of global imperatives for carbon neutrality and sustainable development, electrocatalytic urea synthesis from N2 and CO2 under ambient conditions using renewable electricity has emerged as a promising green alternative. This review critically examines the fundamental scientific challenges and strategic significance of electrocatalytic N2/CO2 coupling for urea production. We systematically analyze the surface activation mechanisms of both N2 and CO2 on heterogeneous catalysts, elucidate the energetically demanding C-N bond-forming steps, and comprehensively survey recent advances in rational catalyst design and optimization strategies. Furthermore, we assess emerging innovations in electrochemical reactor configurations and process integration, identify persistent bottlenecks, and outline actionable pathways to mitigate them. By synthesizing current advances and projecting future research trajectories, this work aims to establish a coherent conceptual and methodological framework to accelerate the translational development of electrocatalytic urea synthesis toward practical implementation.