Method and system for fuel production

Abstract

The present disclosure provides systems and methods for producing a carbon product from a fluid stream comprising a carbonaceous material (e.g., carbon dioxide) by electrochemical reduction. The electrochemical reduction systems and methods of the present disclosure may include microstructured or nanostructured membranes for separation and catalysis processes. Electrochemical reduction systems and methods may utilize renewable energy sources to produce a carbon product (C1 + product) comprising one or more carbon atoms, such as a fuel. This can be carried out at substantially low (or near zero) net negative carbon emissions.

Description

[0001] This application is a divisional application of the Chinese patent application with the application date of December 17, 2019, application number 201980084050.3, and invention name “Method and system for fuel production” (the application date of the corresponding PCT application is December 17, 2019, and the application number is PCT / US2019 / 066787).

[0002] Cross-references

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 781,149, filed on December 18, 2018, and U.S. Patent Application No. 16 / 503,165, filed on July 3, 2019, each of which is hereby incorporated by reference in its entirety for all purposes. Background Art

[0004] The amount of carbon-containing compounds such as carbon monoxide (CO) and carbon dioxide (CO2) in the atmosphere is increasing. This increase in the amount of carbon-containing compounds may have an adverse effect on the global temperature, thereby causing global warming. Summary of the invention

[0005] It is recognized herein that there is an increased need for efficient methods of producing fuels and other chemical commodities from non-petroleum sources. Such methods can utilize carbon monoxide (CO) and / or carbon dioxide (CO2) as a carbon source for producing organic molecules to minimize the carbon footprint of producing and consuming the produced fuels and chemicals. The production of durable chemical products (e.g., polymers) may even generate a net carbon sink for products produced using atmospheric carbon monoxide and / or carbon dioxide.

[0006] On the one hand, a system for producing a carbon product (C1+ product) containing one or more carbon atoms is provided, comprising a first compartment, a second compartment, and a separation unit separating the first compartment and the second compartment, wherein the separation unit comprises (i) an anode, (ii) a cathode, and (iii) a membrane comprising a plurality of pores, wherein the plurality of pores are configured to enable fluid communication between the first compartment and the second compartment, wherein the cathode and the anode are configured to reduce the carbonaceous material to the C1+ product in the first compartment while applying a voltage between the cathode and the anode, and wherein the plurality of pores are configured to direct the C1+ product from the first compartment to the second compartment.

[0007] In some embodiments, the system further comprises a gas contactor in fluid communication with the first compartment, wherein the gas contactor is configured to contact the carbonaceous material with water to produce a solution comprising the carbonaceous material. In some embodiments, the membrane comprises one or more materials selected from carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene, and porous pyrolytic carbon.

[0008] In some embodiments, the cathode further comprises a catalyst. In some embodiments, the catalyst comprises metal nanoparticles. In some embodiments, the metal nanoparticles comprise a metal selected from copper, nickel, platinum, iridium, ruthenium, palladium, tin, silver and gold. In some embodiments, the catalyst is N-doped.

[0009] In some embodiments, the system further comprises a voltage source configured to supply the voltage. In some embodiments, the voltage source comprises a renewable power source. In some embodiments, the voltage source comprises one or more members selected from photovoltaic power sources, wind power sources, geothermal power sources, hydroelectric power sources, tidal power sources, and nuclear power sources.

[0010] In some embodiments, the system further includes an ion exchange membrane between the cathode and the anode.

[0011] In some embodiments, the system is configured to have a single pass selectivity to the C1+ product of at least about 70%.

[0012] In some embodiments, the pores in the plurality of pores have a pore size of less than or equal to about 5 microns. In some embodiments, the pore size is less than or equal to about 500 nanometers. In some embodiments, the pore size is less than or equal to about 100 nanometers. In some embodiments, the pore size is less than or equal to about 50 nanometers. In some embodiments, the pore size is less than or equal to about 10 nanometers. In some embodiments, the pore size is less than or equal to about 5 nanometers.

[0013] In some embodiments, the C1+ product comprises one or more members selected from methanol, ethanol, propanol, and butanol.

[0014] In some embodiments, the first compartment comprises a cathode and the second compartment comprises an anode. In some embodiments, the first compartment comprises a cathode and a membrane. In some embodiments, the separation unit further comprises an extractor. In some embodiments, the extractor comprises a second compartment and a membrane.

[0015] On the other hand, a method for producing a carbon product (C1+ product) containing one or more carbon atoms using a carbon-containing material is provided, comprising providing an electrochemical first compartment; a second compartment; and a separation unit, wherein the separation unit separates the first compartment and the second compartment, wherein the separation unit comprises (i) an anode, (ii) a cathode and (iii) a membrane comprising a plurality of pores, wherein the plurality of pores are configured to enable fluid communication between the first compartment and the second compartment, an electrolyte solution containing the carbon-containing material is introduced into the first compartment so that the electrolyte solution contacts the cathode, wherein the anode and the cathode are electrically connected to each other through the electrolyte solution, and wherein a voltage is applied between the cathode and the anode, and while applying a voltage between the cathode and the anode, the carbon-containing material in the electrolyte solution is reduced to produce the C1+ product, the C1+ product is directed to the second compartment through the plurality of pores, and the C1+ product is recovered from the second compartment of the electrochemical system.

[0016] In some embodiments, the cathode further comprises a catalyst. In some embodiments, the catalyst is used to reduce the carbonaceous material in the electrolyte.

[0017] In some embodiments, the carbonaceous material includes carbon monoxide (CO) and / or carbon dioxide (CO2).

[0018] In some embodiments, the electrolyte solution comprises an aqueous substance produced by the interaction of the carbonaceous material with water. In some embodiments, the aqueous substance comprises one or more members selected from bicarbonate ions, carbonate ions, and formate ions.

[0019] In some embodiments, the method further comprises, before the second step, introducing a carbonaceous material into the water using a gas contactor. In some embodiments, the membrane comprises one or more materials selected from carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene, and porous pyrolytic carbon.

[0020] In some embodiments, the film further comprises a catalyst. In some embodiments, the catalyst comprises metal nanoparticles. In some embodiments, the metal nanoparticles comprise a metal selected from copper, nickel, platinum, iridium, ruthenium, palladium, tin, silver and gold. In some embodiments, the catalyst is N-doped.

[0021] In some embodiments, the voltage is applied by a power source including a renewable power source. In some embodiments, the renewable power source includes one or more members selected from photovoltaic power generation, wind power generation, geothermal power generation, hydroelectric power generation, tidal power generation and nuclear power generation.

[0022] In some embodiments, the method further comprises introducing the carbonaceous material into the electrochemical system by using an electrochemically generated hydroxide.

[0023] In some embodiments, the cathode operates at a temperature of about 10° Celsius (C) to 40°C.

[0024] In some embodiments, the C1+ product is recovered from the electrochemical reduction system in the absence of a distillation unit.

[0025] In some embodiments, the electrochemical system further comprises an ion exchange membrane.

[0026] In some embodiments, the C1+ product is recovered from the electrochemical reduction system with a single pass selectivity of at least about 70%.

[0027] In some embodiments, the cathode includes pores having a pore size no greater than about 5 microns.

[0028] In some embodiments, the C1+ product comprises one or more members selected from methanol, ethanol, propanol, and butanol.

[0029] In some embodiments, the average cross-sectional dimension of the pores is no more than about 5 microns. In some embodiments, the average cross-sectional dimension is no more than about 500 nanometers. In some embodiments, the average cross-sectional dimension is no more than about 100 nanometers. In some embodiments, the average cross-sectional dimension is no more than about 50 nanometers. In some embodiments, the average cross-sectional dimension is no more than about 10 nanometers. In some embodiments, the average cross-sectional dimension is no more than about 5 nanometers.

[0030] On the other hand, a method for producing a carbon product (C1+ product) containing one or more carbon atoms using a carbon-containing material is provided, which includes providing an electrochemical system, which includes: a first compartment; a second compartment, and a separation unit, the separation unit including (i) an anode, (ii) a cathode and (iii) a membrane having a microstructure or a nanostructure including pores, wherein the cathode contains a catalyst, wherein the separation unit separates the first compartment and the second compartment, and wherein the first compartment is fluidly connected to the second compartment through the pores, an electrolyte solution containing the carbon-containing material is introduced into the first compartment so that the electrolyte solution contacts the cathode, wherein the anode and the cathode are electrically connected to each other through the electrolyte solution, and wherein a voltage is applied between the cathode and the anode, and while applying a voltage between the cathode and the anode, the carbon-containing material in the electrolyte solution is reduced using the catalyst to produce the C1+ product, the C1+ product is guided to the second compartment through the pores, and the C1+ product is recovered from the second compartment of the electrochemical system.

[0031] In some embodiments, the carbonaceous material includes carbon monoxide (CO) and / or carbon dioxide (CO2).

[0032] In some embodiments, the anode comprises one or more catalysts.

[0033] In some embodiments, the electrolyte solution comprises an aqueous substance produced by the interaction of the carbonaceous material with water. In some embodiments, the aqueous substance comprises one or more members selected from bicarbonate ions, carbonate ions, and formate ions.

[0034] In some embodiments, the method further comprises, before the second step, introducing the carbonaceous material into the water using a gas contactor. In some embodiments, the gas contactor comprises a membrane. In some embodiments, the membrane comprises one or more nanomaterials selected from carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene, and porous pyrolytic carbon.

[0035] In some embodiments, the microstructured or nanostructured film includes one or more materials selected from carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene, and porous pyrolytic carbon.

[0036] In some embodiments, the microstructured or nanostructured film further comprises a catalyst. In some embodiments, the catalyst comprises metal nanoparticles. In some embodiments, the metal nanoparticles comprise a metal selected from copper, nickel, platinum, iridium, ruthenium, palladium, tin, silver and gold. In some embodiments, the catalyst is N-doped.

[0037] In some embodiments, the voltage is applied by a power source including a renewable power source. In some embodiments, the renewable power source includes one or more members selected from photovoltaic power generation, wind power generation, geothermal power generation, hydroelectric power generation, tidal power generation and nuclear power generation.

[0038] In some embodiments, the method further comprises introducing the carbonaceous material into the electrochemical system by using an electrochemically generated hydroxide.

[0039] In some embodiments, the cathode operates at a temperature of about 10° Celsius (C) to 40°C.

[0040] In some embodiments, the C1+ product is recovered from the electrochemical reduction system in the absence of a distillation unit.

[0041] In some embodiments, the electrochemical system further includes an ion exchange membrane configured to minimize a distance between the cathode and the anode.

[0042] In some embodiments, the C1+ product is recovered from the electrochemical reduction system with a single pass selectivity of at least about 70%.

[0043] In some embodiments, the cathode comprises pores having a pore size no greater than about 5 microns.

[0044] In some embodiments, the C1+ product comprises one or more members selected from methanol, ethanol, propanol, and butanol.

[0045] In some embodiments, the average cross-sectional dimension of the holes does not exceed about 5 microns. In some embodiments, the average cross-sectional dimension does not exceed about 500 nanometers. In some embodiments, the average cross-sectional dimension of the holes does not exceed about 100 nanometers. In some embodiments, the average cross-sectional dimension of the holes does not exceed about 50 nanometers. In some embodiments, the average cross-sectional dimension of the holes does not exceed about 10 nanometers. In some embodiments, the average cross-sectional dimension of the holes does not exceed about 5 nanometers.

[0046] Another aspect of the present disclosure provides a non-transitory computer-readable medium comprising machine-executable code that, when executed by one or more computer processors, implements any of the methods described above or elsewhere herein.

[0047] Another aspect of the present disclosure provides a system including one or more computer processors and a computer memory coupled thereto. The computer memory includes machine executable code that, when executed by the one or more computer processors, implements any method above or elsewhere herein.

[0048] Other aspects and advantages of the present disclosure will become apparent to those skilled in the art through the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. It will be appreciated that the present disclosure is capable of other and different embodiments, and that its several details are capable of modification in various obvious respects, all without departing from the present disclosure. Therefore, the drawings and description are to be regarded as illustrative in nature, and not restrictive.

[0049] Incorporation by reference

[0050] All publications and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] The novel features of the present invention are particularly set forth in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by referring to the following detailed description which sets forth illustrative embodiments in which the principles of the present invention are utilized and the accompanying drawings (also referred to herein as "Figures"), in which:

[0052] Figure 1A A schematic diagram depicting the cross-section and face orientation of a membrane material containing a microstructure or nanostructure of nanotubes. Arrows indicate pores that allow the selective passage of specific chemical species.

[0053] Figure 1B A schematic diagram depicting the cross-section and face orientation of a membrane material containing a microstructure or nanostructure of nano-onions. Arrows indicate pores that allow the selective passage of specific chemicals.

[0054] Figure 1C A schematic diagram depicting the cross-section and face orientation of a membrane material comprising a microstructure or nanostructure of a pyrolyzed porous material. Arrows indicate pores that can selectively allow the passage of specific chemical species.

[0055] Figure 1D Schematic diagram of the cross-section and face orientation of a membrane material comprising a microstructure or nanostructure of a graphene-like material. Arrows indicate pores that can selectively allow specific chemical species to pass through.

[0056] Figure 2 A diagram depicting carbon nanotubes embedded in a membrane material.

[0057] Figure 3A Microstructured or nanostructured membranes configured in cylindrical forms such as hollow fibers are depicted.

[0058] Figure 3B A detailed illustration of a small area of ​​the membrane surface containing carbon nanotubes is shown.

[0059] Figure 4 Representative graphene-like materials of the present invention are shown.

[0060] Figure 5 Shown is a diagram of catalyst nanoparticles associated with carbon nanotubes as provided in the present disclosure.

[0061] Figure 6 A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0062] Figure 7 A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0063] Figure 8A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0064] Fig. 9 A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0065] Fig.10 A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0066] Fig.11 A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0067] Fig.12 A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0068] Fig.13 A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0069] Fig.14 A schematic diagram of another embodiment of an electrochemical reduction system for converting CO or CO2 to hydrocarbons is depicted.

[0070] Fig.15 A schematic diagram of a computer system useful with the present invention is shown.

[0071] Fig.16A Depicted is a schematic diagram of a separation cell comprising a first compartment having a cathode and a second compartment having an anode.

[0072] Fig. 16B Depicted is a schematic diagram of a separation unit comprising a first compartment containing a cathode.

[0073] Fig. 16C Depicted is a schematic diagram of a separation unit comprising an extractor unit comprising a membrane and a second compartment. DETAILED DESCRIPTION

[0074] Although various embodiments of the present invention have been shown and described herein, it will be readily understood by those skilled in the art that these embodiments are provided by way of example only. A variety of changes, modifications and substitutions may be envisioned by those skilled in the art without departing from the present invention. It should be understood that various alternatives to the embodiments of the present invention described herein may be employed.

[0075] Whenever the term "at least", "greater than", or "greater than or equal to" precedes the first value in a series of two or more values, the term "at least", "greater than", or "greater than or equal to" applies to each value in the series. For example, greater than or equal to 1, 2, or 3 is equivalent to greater than or equal to 1, greater than or equal to 2, or greater than or equal to 3.

[0076] Whenever the term "not more than," "less than," or "less than or equal to" precedes the first value in a series of two or more values, the term "not more than," "less than," or "less than or equal to" applies to every value in the series. For example, less than or equal to 3, 2, or 1 is equivalent to less than or equal to 3, less than or equal to 2, or less than or equal to 1.

[0077] As used herein, the terms "C1+" and "C1+ compounds" generally refer to compounds containing one or more carbon atoms, for example, one carbon atom (C1), two carbon atoms (C2), etc. C1+ compounds include, but are not limited to, alkanes (e.g., methane, CH4), alkenes (e.g., ethylene, C2H2), alkynes, and aromatic compounds containing two or more carbon atoms. In some cases, C1+ compounds include aldehydes, ketones, esters, and carboxylic acids. Examples of C1+ compounds include, but are not limited to, methane, ethane, ethylene, acetylene, propane, propylene, butane, butene, etc.

[0078] As used herein, the term "unit" generally refers to a unit operation, which is a basic operation in a process. A unit operation may involve a physical change or chemical transformation, for example, separation, crystallization, evaporation, filtration, polymerization, isomerization, conversion, and other reactions. A given process may require one or more unit operations to obtain a desired product from a starting material or feedstock.

[0079] As used herein, the term "carbonaceous material" generally refers to any material containing at least one carbon atom. In some examples, the carbonaceous material is carbon monoxide (CO), carbon dioxide (CO2), or a mixture of CO and CO2. The carbonaceous material can be a material derived from CO and / or CO2, such as bicarbonate or bicarbonate ions.

[0080] Provided herein are systems and methods for producing various chemical products, including hydrocarbon fuels, from a source including a carbonaceous material, such as carbon monoxide (CO) and / or carbon dioxide (CO2). The source may be a gas source or a liquid source. In some cases, the gas source containing CO or CO2 may be air extracted directly from the atmosphere. In other cases, the gas source containing CO or CO2 may be an exhaust gas, such as flue gas from a combustion process. In the present invention, a gas stream containing CO or CO2 may be sucked into an electrochemical reduction system that converts CO or CO2 into hydrocarbons. The described system may include one or more additional chemical conversion processes that allow hydrocarbons derived from CO or CO2 to be converted into other valuable chemical products.

[0081] Various configurations of electrochemical reduction systems for converting CO or CO2 into hydrocarbons are also provided herein. In some cases, the electrochemical reduction system can operate at ambient temperature. The electrochemical reduction system may include one or more membranes comprising microstructured or nanostructured materials such as carbon nanotubes (CNTs) or graphene.

[0082] Microstructured materials may have a size of about 1 micron to 1000 microns, or 1 micron to 100 microns, or 1 micron to 10 microns. Nanostructured materials may have a size of about 1 nanometer to 1000 nanometers, 1 nanometer to 100 nanometers, or 1 nanometer to 10 nanometers.

[0083] Microstructured materials may have dimensions less than or equal to 1000 microns, 100 microns, 10 microns, 1 micron, or less. Nanostructured materials may have dimensions less than or equal to 1000 nanometers, 100 nanometers, 10 nanometers, 1 nanometer, or less.

[0084] In some cases, the microstructured or nanostructured membrane can be capable of selectively separating CO or CO2 from a mixed gas stream. In other cases, the microstructured or nanostructured membrane can be capable of selectively separating certain hydrocarbons from a liquid or gaseous medium. Also provided herein is a microstructured or nanostructured membrane comprising a catalyst for converting CO or CO2 into hydrocarbons. In some cases, the microstructured or nanostructured membrane can be configured to include an anode or cathode in an electrochemical reduction system.

[0085] Various products that can be produced by the system and method described herein are provided herein. The electrochemical reduction system can produce alkanes, olefins, alcohols or other organic molecules of different chain lengths. The product of the described electrochemical reduction system can be further processed into other fuels and chemical products, such as polymers. The selectivity of the microstructure or nanostructured film used in the electrochemical reduction system can make chemical products produce with customized molecular weight ranges, and improve purity from processing byproducts (e.g., metals, salts and other undesirable inputs or products).

[0086] Also provided herein are systems of various scales for producing chemicals from gas streams containing CO or CO2. In some cases, chemicals can be produced from chemical plants including one or more CO or CO2 electrochemical reduction systems. In other cases, chemicals can be produced from CO or CO2 as a subsystem of a larger facility (e.g., as a scrubber on a power generation facility). In other cases, small or even micro devices can be used to produce chemicals. In some cases, an electrochemical reduction system utilizing a gas source containing CO or CO2 can be coupled with a renewable power source (e.g., photovoltaic cells) to produce a completely sustainable method for chemical production. In some cases, the systems and methods described herein can be net carbon negative (i.e., the carbon they sequester is more than the carbon they produce). In some cases, the systems described herein can reduce the energy input of a chemical production process by at least about 50%.

[0087] Chemical products

[0088] Various chemical products and reaction mixtures produced by electrochemical reduction of CO or CO2 derived from a gas source are described herein. The chemical product may include any process stream output from a chemical processing system, or any process stream that does not pass through other reactive processes. The reaction mixture may include any process mixture, reagent, or compound in a process stream within a chemical reactor, a reactor system, or between chemical reactors or reactor systems. The chemical products and reaction mixtures of the present invention may include organic molecules in which one or more constituent carbon atoms are derived from CO or CO2. In some cases, the chemical product or reaction mixture may contain only carbon atoms derived from CO or CO2. In other cases, the chemical product may contain carbon atoms derived from CO or CO2 and carbon atoms derived from other sources (e.g., fossil fuels). In some cases, the chemical products of the present invention may have a unique carbon isotopic signature consistent with the carbon isotopic signature of CO or CO2 derived from the atmosphere. In some cases, the chemical products and reaction mixtures of the present invention may have a unique carbon isotopic signature consistent with the carbon isotopic signature of CO or CO2 derived from non-atmospheric sources (such as the combustion of fossil fuels). The carbon isotopic signature of the chemical product or reaction mixture can be determined by 14 C: 12 C or 13 C: 12 In some cases, the isotopic signature of a chemical product or reaction mixture can be measured as the percentage difference between the natural isotope ratio of carbon and the measured isotope ratio. 14 The percentage difference between the isotope ratios of C 14 C can be calculated as:

[0089]

[0090] The natural isotope ratio of carbon and 13 The percentage difference Δ between the measured isotope ratios of C 13 C can be calculated as:

[0091]

[0092] Δ of chemical product or reaction mixture 14 C can be about -100%, -10%, 0%, 5%, 10%, 20%, 30%, 40%, 45%, 50%, or about 100%. 13 C may be about -40%, -35%, -30%, -28%, -26%, -24%, -22%, -20%, -15%, -10%, -8%, or about -5%.

[0093] Chemical products or reaction mixtures of the present invention may include gaseous, liquid or solid substances. Chemical products and reaction mixtures of the present invention may include one or more organic compounds. Chemical products and reaction mixtures may be miscible or immiscible in water. Chemical products and reaction mixtures may be polar or non-polar. Chemical products and reaction mixtures may be acidic, alkaline or neutral. Organic compounds may include alkanes, olefins, alkynes, cycloalkanes, cycloolefins, cycloalkynes, substituted alkanes, substituted alkenes, substituted alkynes, alcohols, esters, carboxylic acids, ethers, amines, amides, amides, aromatic compounds, heteroaromatic compounds, sulfides, sulfones, sulfates, mercaptans, aldehydes, ketones, amides and halogenated compounds. Chemical products and reaction mixtures may include branched or straight chain compounds. Chemical products and reaction mixtures may include oxygen, methane, ethane, ethylene, propane, butane, hexane, octane, decane, carbon monoxide, methanol, ethanol, propanol, butanol, hexanol, octanol and formate. Chemical products and reaction mixtures may include organometallic compounds. The chemical products and reaction mixtures of the present disclosure may include compounds intended for consumer use or industrial use, such as fuels, solvents, additives, polymers, food additives, food supplements, pharmaceuticals, fertilizers, agricultural chemicals, coatings, lubricants, and building materials. The chemical products and reaction mixtures of the present disclosure may include precursors, components, substitutes, or substrates for products produced by further processing.

[0094] The organic compounds of the present disclosure may contain one or more carbon atoms. In some cases, the organic compound may contain about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50, 55, 60, 65 or about 70 carbon atoms. In some cases, the organic compound can include at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50, 55, 60, 65, or about 70 or more carbon atoms. In some cases, the organic compound can include no more than about 70, 65, 60, 55, 50, 45, 40, 35, 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or fewer carbon atoms. The organic compounds of the present disclosure may contain one or more carbon atoms derived from CO or CO. In some cases, the organic compounds may contain about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50, 55, 60, 65, or about 70 carbon atoms derived from CO or CO. In some cases, the organic compound may contain at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50, 55, 60, 65, or about 70 or more carbon atoms derived from CO or CO2. In some cases, the organic compound may contain no more than about 70, 65, 60, 55, 50, 45, 40, 35, 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or fewer carbon atoms derived from CO or CO2.

[0095] The chemical product or reaction mixture of the present disclosure can contain more than one chemical substance. The chemical product or reaction mixture can be a mixture of about 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or about 100 detectable compounds. The chemical product or reaction mixture can be a mixture of at least about 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or about 100 or more detectable compounds. The chemical product or reaction mixture can be a mixture of no more than about 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 29, 28, 27, 26, 25, 24, 23, 22, 21, 20, 19, 18, 17, 16, 15, 14, 13, 11, 10, 9, 8, 7, 6, 5, 4 or no more than about 3 or fewer detectable compounds.

[0096] The chemical product of the present disclosure or reaction mixture may include a specific compound accounting for a specific weight percentage or molar percentage of total chemical product or reaction mixture. For example, a specific chemical product may include at least about 50wt% ethanol. In another example, a specific chemical product may include water that is no more than about 1wt%. In some cases, at least about 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99% or more of a chemical product or reaction mixture may be a specific compound based on weight or mole. In some cases, no more than about 99%, 98%, 97%, 96%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, or no more than about 10% or less of the chemical product or reaction mixture is a particular compound based on weight or moles.

[0097] The chemical product or reaction mixture of the present disclosure may include compounds in a specific range of molecular weight or carbon number. In some cases, at least about 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99% or more of the chemical product or reaction mixture may include compounds in a specific molecular weight range or carbon number range. In some cases, no more than about 99%, 98%, 97%, 96%, 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15% or no more than about 10% or less of the chemical product or reaction mixture may include compounds in a specific molecular weight range or carbon number range. The chemical product or reaction mixture may include a molecular weight range of about 15 g / mol to about 30 g / mol, about 15 g / mol to about 60 g / mol, about 15 g / mol to about 100 g / mol, about 15 g / mol to about 200 g / mol, about 15 g / mol to about 400 g / mol, about 15 g / mol to about 600 g / mol, about 15 g / mol to about 1000 g / mol, about 30 g / mol to about 60 g / mol, about 30 g / mol to about 100 g / mol, about 30 g / mol to about 200 g / mol, about 30 g / mol to about 400 g / mol, about 30 g / mol to about 600 g / mol, about 30 g / mol to about 1000 g / mol, about 60 g / mol to about 200 g / mol, about 60 g / mol to about 400 g / mol, about 60 g / mol to about 600 g / mol, about 60 g / mol to about 1000 g / mol, about 100 g / mol to about 200 g / mol, about 100 g / mol to about 400 g / mol, about 100 g / mol to about 600 g / mol, about 100 g / mol to about 1000 g / mol, about 200 g / mol to about 400 g / mol, about 200 g / mol to about 600 g / mol, about 200 g / mol to about 1000 g / mol / mol, about 400 g / mol to about 600 g / mol, about 30 g / mol to about 1000 g / mol, about 30 g / mol to about 100 g / mol, about 30 g / mol to about 200 g / mol, about 30 g / mol to about 400 g / mol, about 30 g / mol to about 600 g / mol, about 400 g / mol to about 1000 g / mol, or about 600 g / mol to about 1000 g / mol.The chemical product or reaction mixture may include carbon numbers ranging from about C1 to about C2, about C1 to about C3, about C1 to about C4, about C1 to about C5, about C1 to about C6, about C1 to about C8, about C1 to about C10, about C1 to about C20, about C1 to about C30, about C1 to about C40, about C2 to about C3, about C2 to about C4, about C2 to about C5, about C2 to about C6, about C2 to about C8, about C2 to about C10, about C2 to about C20, about C2 to C30, about C2 to C40, about C3 to about C4, about C3 to about C5, about C3 to about C6, about C3 to about C8, about C3 to about C10, about C3 to about C20, about C3 to about C30, about C3 to about C40, about C3 to about C4 From about C5 to about C6, from about C4 to about C8, from about C4 to about C10, from about C4 to about C20, from about C4 to about C30, from about C4 to about C40, from about C5 to about C6, from about C5 to about C8, from about C5 to about C10, from about C5 to about C20, from about C5 to about C30, from about C5 to about C40, from about C6 to about C8, from about C6 to about C10, from about C6 to about C20, from about C6 to C30, from about C6 to about C40, from about C8 to about C10, from about C8 to about C20, from about C8 to C30, from about C8 to C40, from about C10 to about C20, from about C10 to about C30, from about C10 to about C40, from about C20 to about C30, from about C20 to about C40, or from about C30 to about C40.

[0098] The chemical product or reaction mixture of the present disclosure may contain one or more impurities. Impurities may originate from reactant streams, reactor contaminants, decomposition products of organic compounds, catalyst compounds, or side reactions in electrochemical reduction systems or other chemical conversion systems described herein. The chemical product or reaction mixture may contain one or more organic impurities, such as formate or higher molecular weight alcohols. The chemical product or reaction mixture may contain carbon or non-carbon nanomaterial impurities. The chemical product or reaction mixture may contain one or more inorganic impurities from sources such as leaching and corrosion of catalyst degradation or process equipment. Inorganic impurities may include sodium, magnesium, potassium, calcium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, aluminum, silicon, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, silver, cadmium, indium, tin, antimony, tantalum, tungsten, osmium, platinum, gold, mercury and lead. Inorganic impurities may exist in an oxidized or reduced oxidation state. Inorganic impurities may exist in the form of organometallic complexes. Impurities in chemical products or reaction mixtures can be detected by any common analytical techniques, such as gas or liquid chromatography, mass spectrometry, infrared or ultraviolet-visible spectroscopy, Raman spectroscopy, X-ray photoelectron spectroscopy, X-ray diffraction or other methods. The detectable amount of one or more impurities can be at least about one billionth (ppb), 5ppb, 10ppb, 50ppb, 100ppb, 250ppb, 500ppb, 750ppb, one millionth (ppm), 5ppm, 10ppm, 50ppm, 100ppm or more. The detectable amount of one or more impurities can be no more than about 100ppm, 50ppm, 10ppm, 5ppm, 1ppm, 750ppb, 500ppb, 250ppb, 100ppb, 50ppb, 10ppb, 5ppb or no more than about 1ppb or less.

[0099] Chemical product can have specific purity level.In some cases, chemical product can have enough purity to reach specific grade or standard.Chemical product can be ACS grade, reagent grade, USP grade, NF grade, laboratory grade, refined grade or technical grade.The purity of chemical product can exceed azeotropic composition, for example, ethanol>95%.Gaseous chemical product of the present invention can have about N1.0, N2.0, N3.0, N4.0, N5.0, N6.0 or higher purity level.Chemical product can reach the purity level of definite international standard.For example, ASTM D-1152 / 97 standard of methanol purity.

[0100] In some cases, the chemical product or reaction mixture from the electrochemical reduction system may not contain detectable amounts of certain impurities. In some cases, the chemical product or reaction mixture may not contain detectable amounts of biomolecules or derivatives thereof. The chemical product or reaction mixture may not contain detectable amounts of lipids, carbohydrates, proteins, nucleic acids, amino acids, spores, bacteria, viruses, protozoa, fungi, animal or plant cells, or any components thereof.

[0101] Chemical feed

[0102] Electrochemical conversion systems and related systems may require one or more feed streams. The feed stream may comprise a solid, a liquid, or a gas. The feed stream may comprise a slurry, a paste, a powder, a granule, or a bed material. In some cases, the feed stream may comprise one or more chemical reactants. In other cases, the feed stream may comprise a catalyst, a co-catalyst, an activator, an inhibitor, a buffer, or a reactive scavenger. In some cases, the feed stream may comprise an inert substance.

[0103] The feed stream may comprise a gas or a gas mixture. In some cases, the gas stream may comprise CO, CO , nitrogen, nitric oxide, oxygen, ozone, argon, hydrogen, helium, methane, ethane, ethylene, propane, propylene, hydrogen sulfide, sulfur oxides, silane, aromatic compounds, chlorine, hydrochloric acid, sulfuric acid, nitric acid, water vapor and other gases. In some cases, the gas stream may comprise air extracted directly from the atmosphere. In other cases, the gas stream may comprise waste gas from industry or other sources. In some cases, the gas stream may comprise suspended particles, such as soot, pollen, spores, dust and minerals or ashes. The gas stream may comprise an aerosol. The gas stream may be filtered or washed to remove particles or unwanted chemicals. The gas stream may undergo one or more operations before entering a chemical conversion process or other process to change its composition or otherwise prepare a gas stream for use. The gas stream may be separated or purified to enrich a specific component (e.g., CO ) or remove unwanted components (e.g., hydrogen sulfide).

[0104] The feed stream may comprise a liquid or a liquid mixture. In some cases, the liquid stream may comprise a chemical reactant. In other cases, the liquid stream may comprise a solvent carrying the chemical reactant. The liquid stream may comprise a buffer solution, for example, a bicarbonate solution. The liquid stream may comprise one or more alkanes, olefins, alkynes, cycloalkanes, cycloolefins, cycloalkynes, substituted alkanes, substituted alkenes, substituted alkynes, alcohols, esters, carboxylic acids, ethers, amines, amides, aromatic compounds, heteroaromatic compounds, sulfides, sulfones, sulfates, mercaptans, aldehydes, ketones, amides and halogenated compounds.

[0105] The liquid feed stream may comprise an aqueous solution. The aqueous solution may be buffered to maintain a specific pH. The feed stream may have a pH of about 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 or about 14. The feed stream may have a pH of at least about 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or more. The feed stream may have a pH of no more than about 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0 or less.

[0106] The feed stream may be a multiphase stream. The feed stream may contain gas entrained in a liquid or solids entrained in a liquid, such as a slurry. The feed stream may exist in a phase equilibrium between a solid phase and a liquid phase, a liquid phase and a gas phase, or a solid phase and a gas phase.

[0107] The feed stream may contain one or more impurities or tracer compounds. Impurities in the feed stream may come from the process that produces them or the transport method for transporting the feed stream material from production to the system of the present disclosure. Impurities may include organic or inorganic chemicals, particulates (e.g., dirt, dust, rust or ash) and biomaterials. Impurities may be harmful to the performance of the electrochemical reduction system or related systems. Inorganic impurities may include sodium, magnesium, potassium, calcium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, aluminum, silicon, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, silver, cadmium, indium, tin, antimony, tantalum, tungsten, osmium, platinum, gold, mercury and lead. Inorganic impurities may exist in an oxidized or reduced oxidation state. Inorganic impurities may exist in the form of an organometallic complex. Before being used in an electrochemical reduction system or a related system, the feed stream may be purified before being used to remove one or more impurities. Tracer compounds may include low but detectable chemicals in the feed stream. The tracer compound may be present in a specific feed stream reagent, or may be added to the feed stream before the feed stream enters a conversion or other process. The tracer compound may be an inert substance. The tracer compound may be a compound that is selectively converted, separated, or otherwise changed in certain processes and is not affected by other processes. The impurity or tracer compound may have a measured concentration in the feed stream. The impurities or tracer compounds in the chemical product may be detected by any common analytical techniques, such as gas or liquid chromatography, mass spectrometry, infrared or ultraviolet-visible spectroscopy, Raman spectroscopy, X-ray photoelectron spectroscopy, X-ray diffraction or other methods. The detectable amount of one or more impurities or tracer compounds may be at least about 1 ppb, 5 ppb, 10 ppb, 50 ppb, 100 ppb, 250 ppb, 500 ppb, 750 ppb, 1 ppm, 5 ppm, 10 ppm, 50 ppm, 100 ppm or more. The detectable amount of one or more impurities or tracer compounds may be no more than about 100 ppm, 50 ppm, 10 ppm, 5 ppm, 1 ppm, 750 ppb, 500 ppb, 250 ppb, 100 ppb, 50 ppb, 10 ppb, 5 ppb, or no more than about 1 ppb or less.

[0108] Structured membrane

[0109] The present disclosure can provide reactors and separation systems comprising microstructured or nanostructured membranes. Microstructured or nanostructured membranes can be used to selectively separate one or more chemical substances from a mixture comprising more than one chemical substance. Microstructured or nanostructured membranes can also provide additional utility in chemical processing systems that include physically separated product streams and components of an electric cathode or anode included in an electrochemical system.

[0110] The microstructured or nanostructured film may comprise one or more micro- or nanoscale material features (e.g., including positive features such as micro- or nanoscale structures and / or negative features such as micro- and nanoscale pores or micro- and nanoscale depressions). In some cases, the film may comprise carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene-like materials, or pyrolyzed porous carbon materials (see Figure 2 and Figure 4 ). The membrane may include a microstructure or nanostructure material synthesized from a non-carbon material. The membrane may include a carbon nanomaterial doped with other elements (such as nitrogen, sulfur and boron). The microstructure or nanostructure material may be embedded, fixed or otherwise combined to one or more other substrates or materials to form a membrane. The microstructure or nanostructure material embedded in the substrate or material may produce holes in the structured membrane. The holes may allow certain chemicals to pass selectively. Other substrates or materials in the membrane may be selected based on material properties including rigidity, strength and conductivity. Other substrates or materials in the microstructure or nanostructure membrane may include polymers, such as polysulfones, metals and ceramics. The microscale or nanoscale features can have a maximum dimension of at least about 0.4 nanometers (nm), 0.6 nm, 0.8 nm, 1 nm, 1.2 nm, 1.4 nm, 1.6 nm, 1.8 nm, 2.0 nm, 2.5 nm, 3.0 nm, 3.5 nm, 4.0 nm, 4.5 nm, 5.0 nm, 5.5 nm, 6.0 nm, 6.5 nm, 7.0 nm, 7.5 nm, 8.0 nm, 8.5 nm, 9.0 nm, 9.5 nm, 0 nm, 20 nm, 30 nm, 40 nm, 50 nm, 60 nm, 70 nm, 80 nm, 90 nm, 100 nm, 200 nm, 300 nm, 400 nm, 500 nm, 600 nm, 700 nm, 800 nm, 900 nm, 1 micron, 10 microns, 100 microns, or more. In some cases, the maximum dimension may be at most about 100 microns, 10 microns, 1 micron, 900 nm, 800 nm, 700 nm, 600 nm, 500 nm, 400 nm, 300 nm, 200 nm, 100 nm, 90 nm, 80 nm, 70 nm, 60 nm, 50 nm, 40 nm, 30 nm, 20 nm, 10 nm, 9.5 nm, 9.0 nm, 8.5 nm, 8 nm, 7.5 nm, 7.0 nm, 6.5 nm, 6.0 nm, 5.5 nm, 5.0 nm, 4.5 nm, 4.0 nm, 3.5 nm, 3.0 nm, 2.5 nm, 2.0 nm, 1.8 nm, 1.6 nm, 1.4 nm, 1.2 nm, 1.0 nm, 0.8 nm, 0.6 nm, or 0.4 nm, or less.

[0111] Depending on the application, the microstructured or nanostructured membrane may include a specific shape, structure. In some cases, the membrane may have a cylindrical structure such as in the form of a hollow fiber membrane (see Figure 3A and Figure 3B ), or have a substantially flat sheet structure. The membrane may partially or completely enclose a volume or void space. The surface area of ​​the membrane disposed toward the enclosed or void space may be defined as the lumen side of the membrane. In some cases, mass transfer across the membrane may be driven by a chemical potential, pressure difference, or temperature difference between the lumen side and the non-lumen side of the membrane. The membrane may further include additional structures, such as a frame or fittings that secure the membrane to other parts of the system.

[0112] Microstructured or nanostructured membranes can be composed of embedded micromaterials or nanomaterials to produce pores within the membrane. The micromaterials or nanomaterials can be selected based on the characteristic pore size they can produce. Without being bound by theory, a pore can be defined as a void space or volume within a solid material through which liquid or gas molecules can flow or diffuse. Chemicals can pass through carbon nanotubes (see Figure 1A ) through the inner diameter space of the nanoparticles (e.g., clustered nanotubes or nano-onions) (see Figure 1B ) through the porous carbon (see Figure 1C ) or through the graphene-like material (see Figure 1D) layers. Micron or nano materials can have a characteristic length scale, such as diameter, pore size or interlayer spacing, sufficient to allow chemicals to pass through the void space in the material. In some cases, the characteristic length can be at least about 0.4 nanometers (nm), 0.6nm, 0.8nm, 1nm, 1.2nm, 1.4nm, 1.6nm, 1.8nm, 2.0nm, 2.5nm, 3.0nm, 4.0nm, 5.0nm or larger. In some cases, the characteristic length can be no more than about 5.0nm, 4.0nm, 3.0nm, 2.5nm, 2.0nm, 1.8nm, 1.6nm, 1.4nm, 1.2nm, 1.0nm, 0.8nm, 0.6nm or about 0.4nm or smaller. The diameter of the hole can be greater than the length. The length of the hole can be greater than the diameter. The aspect ratio of the pores may be about 1:10, 1:5, 1:2, 1:1, 2:1, 5:1, 10:1, 100:1, or about 1000:1. The aspect ratio of the pores may be at least about 1:10, 1:5, 1:2, 1:1, 2:1, 5:1, 10:1, 100:1, or about 1000:1. The aspect ratio of the pores may not exceed about 1000:1, 100:1, 10:1, 5:1, 2:1, 1:1, 1:2, 1:5, or about 1:10 or less. The pores may include substantially straight paths, such as spaces between carbon nanotubes or horizontal layers of graphene-like materials. In certain materials, such as mesoporous or nanoporous carbons, the pores may have diagonal, inclined, or curved paths.

[0113] The membrane may include a material with a characterized porous structure. The material may include nanopores, mesopores and micropores. In some cases, the nanopore may be characterized as having an average pore size of about 2nm or less. In some cases, the mesopore may be characterized as having an average pore size between about 2nm and about 20nm. In some cases, the micropore may be characterized as having an average pore size of about 20nm or more. The membrane may include a structure (e.g., nanopores and mesopores) with an pore size within the entire pore size range. The membrane may include a structure (e.g., mesopores only) with an pore size within a specific pore size classification. The hole may have a circular, elliptical, non-circular or irregular pore shape or pore cross-sectional profile. The pore size may be characterized as an average characteristic cross-sectional size (e.g., pore size or cross-sectional area). The membrane may comprise pores (e.g., micropores or nanopores) having an average cross-sectional dimension of at least about 0.5 nm, 1 nm, 5 nm, 10 nm, 15 nm, 20 nm, 30 nm, 40 nm, 50 nm, 100 nm, 250 nm, 500 nm, 1 micrometer (μm), or at least about 5 μm or more. The membrane may comprise pores having an average cross-sectional dimension of no more than about 5 μm, 1 μm, 500 nm, 250 nm, 100 nm, 50 nm, 40 nm, 30 nm, 20 nm, 15 nm, 10 nm, 5 nm, 1 nm, 0.5 nm, or less.

[0114] The membrane comprising microstructure or nanostructure material can allow one or more chemical substances to transfer across the membrane. The membrane comprising microstructure or nanostructure material can be selective to a particular species. In some cases, the membrane comprising microstructure or nanostructure material can selectively transfer CO or CO2 from a gas stream. In some cases, the membrane comprising microstructure or nanostructure material can selectively transfer gaseous ethylene or ethanol from a gas mixture. In some cases, the membrane comprising microstructure or nanostructure material can selectively transfer hydrocarbons from an aqueous liquid mixture. The membrane comprising microstructure or nanostructure material can transfer specific chemical substances by diffusion or convection mass transfer. In some cases, mass transfer can be enhanced by applying an external force or field. In certain cases, mass transfer can be driven or enhanced by applying a magnetic field or electric field. In other cases, mass transfer can be driven by a pressure gradient (e.g., vacuuming on one side of the membrane). In some cases, the selectivity of the membrane can be reversed by reversing the field or force applied. In other cases, the membrane can have a unidirectional or constant mass transfer selectivity.

[0115] The membrane of microstructure or nanostructure can have the best or preferred operating temperature and operating pressure. In some cases, the system including the membrane of microstructure or nanostructure can be operated at ambient pressure or temperature. In some cases, the system including the membrane of microstructure or nanostructure can be operated under elevated pressure or under vacuum or reduced pressure. Pressure gradient can be used to drive the mass transfer of the transmembrane system. The membrane of microstructure or nanostructure can be used in the system of about -30 ℃, -20 ℃, -10 ℃, 0 ℃, 5 ℃, 10 ℃, 15 ℃, 20 ℃, 25 ℃, 30 ℃, 35 ℃, 40 ℃, 50 ℃, 60 ℃, 70 ℃ or about 80 ℃. The membrane of microstructure or nanostructure can be used in the system of at least about -30 ℃, -20 ℃, -10 ℃, 0 ℃, 5 ℃, 10 ℃, 15 ℃, 20 ℃, 25 ℃, 30 ℃, 35 ℃, 40 ℃, 50 ℃, 60 ℃, 70 ℃ or about 80 ℃ or higher. The microstructured or nanostructured films can be used in systems where the operating temperature does not exceed about 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, 20°C, 15°C, 10°C, 5°C, 0°C, -5°C, -10°C, -20°C, or about -30°C or less.

[0116] The film of microstructure or nanostructure can be used in the system of about 0bar, 1bar, 2bar, 3bar, 4bar, 5bar, 6bar, 7bar, 8bar, 9bar, 10bar, 15bar, 20bar, 30bar, 40bar, 50bar or higher in the operating pressure. The film of microstructure or nanostructure can be used in the system of at least about 1bar, 2bar, 3bar, 4bar, 5bar, 6bar, 7bar, 8bar, 9bar, 10bar, 15bar, 20bar, 30bar, 40bar, 50bar or higher in the operating pressure. The film of microstructure or nanostructure can be used in the system of no more than about 50bar, 40bar, 30bar, 20bar, 15bar, 10bar, 9bar, 8bar, 7bar, 6bar, 5bar, 4bar, 3bar, 2bar, 1bar or lower in the operating pressure.

[0117] The membrane of microstructure or nanostructure can be capable of allowing a specific flow rate of CO or CO2 to pass through the membrane. The flow rate of CO or CO2 can be driven by a pressure gradient across the membrane. In some cases, the pressure gradient can be driven by a gas flow containing CO or CO2 at a pressure higher than the ambient pressure. In other cases, a pressure gradient can exist by evacuating one side of the membrane (e.g., the cavity side). The membrane of microstructure or nanostructure can allow about 0.1 kg of gas / m 2 Membrane / hr(kg / m 2 / hr)、0.5kg / m 2 / hr、1kg / m 2 / hr、2kg / m 2 / hr、3kg / m 2 / hr、4kg / m 2 / hr、5kg / m 2 / hr、6kg / m 2 / hr、7kg / m 2 / hr、8kg / m 2 / hr、9kg / m 2 / hr or about 10kg / m 2 / hr CO or CO2 flow rate. The microstructured or nanostructured membrane can allow at least about 0.1 kg / m 2 / hr、0.5kg / m 2 / hr、1kg / m 2 / hr、2kg / m 2 / hr、3kg / m 2 / hr、4kg / m 2 / hr、5kg / m 2 / hr、6kg / m 2 / hr、7kg / m 2 / hr、8kg / m 2 / hr、9kg / m 2 / hr or at least about 10kg / m 2 / hr CO or CO2 flow rate. Microstructured or nanostructured membranes can allow no more than about 10 kg / m 2 / hr、9kg / m 2 / hr、8kg / m 2 / hr、7kg / m 2 / hr、6kg / m 2 / hr、5kg / m 2 / hr、4kg / m 2 / hr、3kg / m 2 / hr、2kg / m 2 / hr、1kg / m 2 / hr、0.5kg / m 2 / hr or about 0.1kg / m 2 / hr or less CO or CO2 flow rate.

[0118] The microstructured or nanostructured membrane may be capable of allowing a specific flow rate of hydrocarbons to pass through the membrane. The flow rate of hydrocarbons may be driven by a pressure gradient across the membrane. In some cases, the pressure gradient may be driven by a gas flow or liquid flow containing hydrocarbons at a pressure higher than the ambient pressure. In other cases, a pressure gradient may exist by evacuating one side of the membrane (e.g., the cavity side). The microstructured or nanostructured membrane may allow about 0.1 kg of hydrocarbons / m 2 Membrane / hr(kg / m 2 / hr)、0.5kg / m 2 / hr、1kg / m 2 / hr、2kg / m 2 / hr、3kg / m 2 / hr、4kg / m 2 / hr、5kg / m 2 / hr、6kg / m 2 / hr、7kg / m 2 / hr、8kg / m 2 / hr、9kg / m 2 / hr or about 10kg / m 2 / hr hydrocarbon flow. The microstructured or nanostructured membrane can allow at least about 0.1 kg / m 2 / hr、0.5kg / m 2 / hr、1kg / m 2 / hr、2kg / m 2 / hr、3kg / m 2 / hr、4kg / m2 / hr、5kg / m 2 / hr、6kg / m 2 / hr、7kg / m 2 / hr、8kg / m 2 / hr、9kg / m 2 / hr or at least about 10kg / m 2 / hr hydrocarbon flow. Microstructured or nanostructured membranes can allow no more than about 10 kg / m 2 / hr、9kg / m 2 / hr、8kg / m 2 / hr、7kg / m 2 / hr、6kg / m 2 / hr、5kg / m 2 / hr、4kg / m 2 / hr、3kg / m 2 / hr、2kg / m 2 / hr、1kg / m 2 / hr、0.5kg / m 2 / hr or about 0.1kg / m 2 / hr or less hydrocarbon flow rate.

[0119] The membrane with enhanced selectivity for one or more chemical substances can enhance the phase equilibrium of chemical conversion or conversion system. Without being bound by theory, the selective enrichment of one or more chemical substances in the void or pore of the microstructure or nanostructure component of the membrane can increase the volume concentration of one or more chemical substances in the void or pore. In some cases, the kinetic rate enhancement or the offset of phase equilibrium of a specific chemical reaction may be driven by one or more chemical substances, and the volume concentration of the chemical substance in the membrane is higher than the volume concentration predicted by the bulk phase concentration on either side of the membrane. In certain cases, the selective mass transfer of one or more chemical substances by the membrane may cause the concentration of one or more chemical substances in the boundary layer adjacent to the membrane surface to increase. The increase of the boundary layer concentration of one or more chemical substances can increase the utilization of one or more chemical substances to the catalyst deposited on the membrane surface. In another example, the catalyst can be deposited in the void or pore of the microstructure or nanostructure material in the membrane, thereby allowing the mass transfer of the increased one or more chemical substances to be directly transferred to the catalyst by the overall flow.

[0120] The mass transfer selectivity of the membrane to one or more chemical substances can result in a measurable increase in the reaction rate of one or more chemical reactions in a chemical conversion system comprising such a membrane. In some cases, the reaction rate of one or more chemical reactions can increase by at least about 5%, 10%, 20%, 30%, 40%, 50%, 75%, 100%, 150%, 200%, 500% or about 1000% or higher. In some cases, due to other synergistic effects such as electric field enhancement of catalyst activity, the reaction rate of one or more chemical reactions can be higher than the rate predicted by using the measured reactant concentration. In some cases, the mass transfer selectivity of the membrane to one or more chemical substances can result in a measurable reduction in the reaction rate of one or more unwanted chemical reactions (e.g., side reactions, degradation reactions) in a chemical conversion system comprising such a membrane. In some cases, the reaction rate of one or more unwanted chemical reactions can be reduced by at least about 5%, 10%, 20%, 30%, 40%, 50%, 75%, 100%, 150%, 200%, 500%, or about 1000% or more.

[0121] The film comprising microstructure or nanostructure material may further comprise one or more catalyst materials. Catalyst materials may be attached, combined, deposited or functionalized to the surface of microstructure or nanostructure material. In some cases, the catalyst may be located on the surface of the film. The catalyst may be located in a specific region of the film or in a specific region of the microstructure or nanostructure material to control the position where a catalytic chemical reaction may occur. The catalyst may be located in a hole or a porous structure in the film. The chemical reaction catalyzed by the catalyst may occur in a specific region of the film or in a hole or a porous space of the film. The catalyst may comprise metal atoms, metal complexes or metal particles. The catalyst may comprise metals such as titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, aluminum, silicon, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, silver, cadmium, indium, tin, antimony, tantalum, tungsten, osmium, platinum, gold, mercury or lead. In some cases, the doped carbon nanomaterial may comprise a catalyst. In certain cases, the N-doped carbon nanotube may comprise a catalyst. In another case, carbon nanotubes with electrodeposited platinum, nickel or copper nanoparticles may comprise a catalyst (see Figure 5 ). The membrane may contain more than one catalyst. In some cases, one or more catalysts may be deposited on one or more regions or surfaces of the membrane, and one or more different catalysts may be deposited on one or more different regions or surfaces of the membrane. When mass transfer occurs in a particular direction across the membrane, the membrane may be able to catalyze one or more chemical reactions, and when mass transfer occurs in a different direction across the membrane, the membrane may be able to catalyze one or more different chemical reactions.

[0122] Electrochemical reduction processes utilizing microstructured or nanostructured catalyst membranes may utilize methods or assemblies to minimize catalyst poisoning. Microstructured or nanostructured membranes containing catalysts may be restored or regenerated to mitigate the effects of catalyst poisoning and other unwanted deposition of materials. In some cases, the membrane may be removed from the electrochemical reduction system for catalyst regeneration. In other cases, the membrane may be rinsed with an acid to dissolve or remove catalyst particles and then new catalyst particles may be deposited on the membrane surface or nanoparticle surface.

[0123] The film comprising microstructure or nanostructure material can have enhanced electrical properties. In some respects, due to the electrical properties of microstructure or nanostructure material, film can be conductive. In some cases, film can be semiconductor (e.g., carbon nanotubes with specific chirality). Film can be configured to serve as an electrode in an electrochemical system. Film can allow electric current to be transmitted to one or more catalysts associated therewith. Electric current can enhance the reactivity of catalyst to specific catalytic chemical reactions. In some cases, the selective mass transfer of specific chemical substances on the film across microstructure or nanostructure can increase the current density realized at the membrane electrode.

[0124] The membrane comprising microstructure or nanostructure material can be used for various purposes. In some cases, the membrane can allow the mass transfer of chemical substances from the first gas mixture to the second gas mixture. In some cases, the membrane can allow the mass transfer of chemical substances from the gas phase to the liquid phase. In some cases, the membrane can allow the mass transfer of chemical substances from the first liquid mixture to the second liquid mixture. In some cases, the membrane can allow the mass transfer of chemical substances to the catalytic site where chemical reactions may occur. In some cases, the membrane can be utilized to carry out chemical separation and catalysis. In some cases, the membrane can be circulated between separation and catalysis by applying an electric field or other fields or forces in a directional manner. In other cases, the membrane can be capable of simultaneously catalyzing and carrying out chemical separation.

[0125] Chemical conversion system

[0126] The invention of the present disclosure includes chemical conversion systems for converting carbon dioxide into other chemicals (e.g., C1+ products) by electrochemical reduction. Many embodiments of the present invention can be conceived on a wide range of processing scales. The CO or CO2 conversion system may include a micro fuel production facility, an independent chemical production system that produces tens to hundreds of kilograms of a specific chemical or fuel per day, or an industrial-scale production of thousands of kilograms or more of a chemical or fuel per day.

[0127] Chemical conversion systems can utilize one or more microstructures or nanostructured membranes to perform electrochemical reduction of carbon dioxide. Chemical conversion systems can include one or more microstructures or nanostructured membranes to separate carbon dioxide from a gas stream and provide carbon dioxide to a chemical reactor. Chemical conversion systems can include one or more microstructures or nanostructured membranes to separate chemical mixtures produced by the unit operations of chemical conversion systems. Chemical conversion systems can include one or more microstructures or nanostructured membranes to perform catalytic electrochemical reduction of carbon dioxide to another chemical substance (e.g., formate, methanol, ethanol). Chemical conversion systems can include one or more microstructures or nanostructured membranes to perform one or more catalytic conversion reactions of one or more substances, which are formed by electrochemical reduction of carbon dioxide (e.g., further reducing CO or CO2 reduction products, such as formate reduction to methanol or ethanol, methanol and ethanol reduction to propanol, ethanol reduction to butanol, etc.; ethanol dehydration to ethylene).

[0128] The chemical conversion system may include one or more unit operations to separate chemical substances using a membrane comprising a microstructure or nanostructure material. The chemical conversion system may include one or more unit operations to react one or more chemical substances using a membrane comprising a microstructure or nanostructure material. In some cases, the chemical conversion system may utilize a membrane unit operation of a microstructure or nanostructure to perform different operations, such as the reaction of one or more chemical substances or the separation of one or more chemical substances. In some cases, the chemical conversion system may utilize a membrane unit operation of a single microstructure or nanostructure to perform multiple operations, such as the simultaneous reaction and separation of one or more chemical substances. In some cases, the chemical conversion system may include multiple unit operations, and the multiple unit operations include a membrane comprising a microstructure or nanostructure material. In some cases, multiple unit operations may work redundantly on a specific process, such as multiple CO or CO2 to formate chemical reactors. In other cases, multiple unit operations may be performed in a series of processes, such as chemical reactors customized to produce hydrocarbons with different molecular weight ranges.

[0129] Any unit operation in a chemical conversion system can be designed to operate in intermittent, semi-intermittent or continuous mode. Any unit operation in a chemical conversion system can have one or more feed streams. Any unit operation in a chemical conversion system can have one or more product streams. The unit operation in a chemical conversion system can utilize one or more circulations or purge streams to control its function. In some cases, the unit operation that can carry out multiple processes (e.g., reaction and separation) can be operated continuously. In some cases, the unit operation that can carry out multiple processes can be operated cyclically between operating modes.

[0130] In addition to the membrane-based unit operations, the chemical conversion system of the present invention may include any number of additional operations. The chemical conversion system may include one or more unit operations for separation. The operation of the separation unit may include a distillation column, a reactive distillation column, a gas absorption column, a stripping column, other catalytic operations, such as using a catalyst-filled column, a flash tank, a humidifier, a leaching unit, a liquid-liquid extraction unit, a dryer, an adsorption system, an ion exchange column, a membrane separation unit, a filtration unit, a sedimentation unit, and a crystallization unit. The chemical conversion system may include one or more unit operations for heat transfer. The heat transfer unit operation may include a hood heater, a cartridge heater, a belt heater, a pad heater, a resistive heater, a radiant heater, a fan heater, a shell and tube heat exchanger, a plate heat exchanger, a surface widening heat exchanger, a scraped surface heat exchanger, a condenser, a vaporizer, and an evaporator. The chemical conversion system may include one or more unit operations for fluid transport. The fluid transport device may include pipes, piping, fittings, valves, pumps, fans, blowers, compressors, stirrers, agitators, and mixers. The pumping equipment may be operated at a pressure above atmospheric pressure or used to draw a vacuum. The chemical conversion system may include one or more chemical reaction units in addition to the electrochemical reduction reactor. The chemical reaction units may include plug flow reactors, continuous stirred tank reactors, packed bed columns, fluidized bed reactors, and batch reactors. Chemical reactors may be used for a variety of upgrading and conversions including dehydrogenation, hydrogenation, cracking, dehydration, decarboxylation, carboxylation, amination, deamination, alkylation, dealkylation, oxidation, reduction, polymerization, and depolymerization.

[0131] The chemical conversion system may have one or more devices for process control or process safety. The chemical conversion system may include one or more thermocouples, temperature gauges, pressure gauges, rotor flow meters, mass flow controllers, pH probes, chemical analyzers, speedometers, infrared sensors, flow sensors, PID control devices, PLC control devices, exhaust valves, purge lines, and circulation lines. The chemical conversion system may be controlled by the operation of one or more computers or computer systems.

[0132] Any unit operation within a chemical conversion system, including a central electrochemical reduction unit, may have at least one feed or input stream. Any unit operation within a chemical conversion system, including a central electrochemical reduction unit, may have at least one product or outlet stream. Any feed or input stream and product or outlet stream may include one or more online unit operations for processes such as fluid transfer, heat transfer, mass transfer, chemical reaction, or process control.

[0133] The chemical conversion system including one or more microstructures or nanostructured membranes can reduce or eliminate the energy consumption associated with one or more unit operations. For example, a gas separator including one or more microstructures or nanostructured membranes can eliminate the need for a distillation tower or a separation adsorption system to separate CO or CO from air. In some cases, a unit operation comprising a microstructure or nanostructured membrane can remove one or more pumps, compressors, heat exchangers, separators or reactors from an electrochemical reduction system. The energy consumption of a processing step or processing assembly can be reduced by at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 99% or more using one or more microstructured or nanostructured membranes.

[0134] The chemical conversion system may include one or more energy generation devices. The energy generation device may include a renewable or clean energy generation device, such as a photovoltaic cell, a solar collector, a wind turbine, a hydro turbine, a biomass combustion system, and a biomass gasifier. The chemical conversion system may be directly electrically connected to an energy source such as a nuclear power source or a geothermal power source. Renewable or clean energy can provide the necessary electrical energy for electrochemical reduction of CO or CO2 to other chemicals. Renewable or clean energy can provide the necessary electrical energy for any other unit operation necessary for performing the production of chemical products. Renewable or clean energy can include solar power sources (e.g., photovoltaic cells), geothermal power sources, hydroelectric power sources, nuclear power sources, tidal power sources, wind power sources, biomass power sources, or any combination thereof. In some cases, the chemical conversion system can be completely self-sustaining, i.e., no external power supply is required. In other cases, compared with conventional production methods, the chemical conversion system can reduce the external power demand of the chemical production process. In some cases, a power generation system can be used to utilize non-target byproducts, such as utilizing a fuel cell to convert hydrogen, methane, or CO with oxygen to generate electrical energy, which can be used in an electrochemical process.

[0135] The chemical conversion system can reduce the external power demand of the chemical process by at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99% or more. In some cases, the chemical conversion system can produce a fuel having an energy content greater than the total external energy consumed to produce the fuel. The chemical conversion system can reduce the carbon footprint used to produce one or more chemicals.

[0136] Chemical conversion system can reduce the net carbon emission in chemical production process.The total carbon emission in chemical production process can reduce at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99% or more.In some cases, chemical production process can be net carbon negative, i.e., the carbon chelated in the product is more than the carbon released by the production product.Chemical conversion system can be used to reduce the net carbon emission of another chemical process.In some cases, chemical conversion system can be coupled with waste gas source (e.g., power plant flue gas stream) to minimize the total carbon dioxide released from the waste gas source. A chemical conversion system can reduce the total carbon emissions of another system or source by at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99% or more.

[0137] Chemical reduction system and method

[0138] The present disclosure provides a chemical conversion system that converts CO or CO2 into other chemicals (e.g., C1+ products) by an electrochemical reduction system. In some cases, the electrochemical conversion system can produce hydrocarbons in the liquid phase by electrochemically reducing bicarbonate ions, and bicarbonate ions are generated by CO or CO2 reacting with water. The electrochemical reduction system can produce bicarbonate ions by capturing CO or CO2 from various sources, and these sources include carbon dioxide in the atmosphere and waste gas from industrial or chemical processes. In some cases, the chemical reduction system can reduce the energy consumption of CO or CO2 reduction process by at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, 99% or more. In some cases, CO or CO2 reduction system can utilize a feed stream comprising carbon dioxide without further purification. In some cases, the CO or CO2 reduction system can utilize a feed stream containing CO or CO2 without an additional separation process to enrich the CO or CO2 component of the feed stream. The feed stream of the electrochemical reduction system can contain about 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.2%, 0.5%, 1%, 5%, 10%, 20%, 50%, 90%, 95% or more carbon dioxide on a molar basis. The feed stream of the electrochemical reduction system may contain at least about 0.01%, 0.02%, 0.03%, 0.04%, 0.05%, 0.06%, 0.07%, 0.08%, 0.09%, 0.1%, 0.2%, 0.5%, 1%, 5%, 10%, 20%, 50%, 90%, 95% or more carbon dioxide based on moles. The feed stream of the electrochemical reduction system may contain no more than about 95%, 90%, 50%, 20%, 10%, 5%, 1%, 0.5%, 0.2%, 0.1%, 0.09%, 0.08%, 0.07%, 0.06%, 0.05%, 0.04%, 0.03%, 0.02% or 0.01% or less carbon dioxide based on moles.

[0139] The electrochemical reduction system can produce hydrocarbons at a specific rate based on the available surface area for electrochemical reduction. The electrochemical reduction system can produce hydrocarbons at a rate of about 10 kg / m2 / hour (kg / m 2 / hr)、20kg / m 2 / hr、30kg / m 2 / hr、40kg / m 2 / hr、50kg / m 2 / hr、60kg / m 2 / hr、70kg / m2 / hr、80kg / m 2 / hr、90kg / m 2 / hr、100kg / m 2 / hr、150kg / m 2 / hr or about 200kg / m 2 / hr. The electrochemical reduction system can produce hydrocarbons at a rate of about 10kg / m 2 / hr、20kg / m 2 / hr、30kg / m 2 / hr、40kg / m 2 / hr、50kg / m 2 / hr、60kg / m 2 / hr、70kg / m 2 / hr、80kg / m 2 / hr、90kg / m 2 / hr、100kg / m 2 / hr、150kg / m 2 / hr or about 200kg / m 2 / hr or greater. The electrochemical reduction system may produce hydrocarbons at a rate of no more than about 200 kg / m 2 / hr、150kg / m 2 / hr、100kg / m 2 / hr、90kg / m 2 / hr、80kg / m 2 / hr、70kg / m 2 / hr、60kg / m 2 / hr、50kg / m 2 / hr、40kg / m 2 / hr、30kg / m 2 / hr、20kg / m 2 / hr or 10kg / m 2 Hydrocarbons are produced at a rate of / hr or less.

[0140] The electrochemical reduction system may have the selectivity of converting CO or CO2 into one or more chemical substances (e.g., C1+ products). In some cases, selectivity may be defined as the percentage of carbon atoms that are converted into product substances entering the reactor, system or unit. For example, a selectivity of 50% may indicate that 50% of the CO or CO2 molecules entering are converted into hydrocarbon substances in the reactor, system or unit. In some cases, selectivity may be defined as the percentage of carbon atoms that are converted into chemical substances within a specific category, weight range, carbon number range or other characteristics entering the reactor, system or unit. For example, a selectivity of 50% C1-C4 may indicate that 50% of the CO or CO2 molecules entering are converted into hydrocarbon products from C1 to C4. Selectivity may be a single-pass selectivity. Single-pass selectivity may be defined as the percentage of carbon atoms that are converted into hydrocarbon products when entering a reactor, system or unit through a single pass through the reactor, system or unit. Selectivity may be a recycle selectivity. Cycle selectivity may be defined as the percentage of carbon atoms that are converted into hydrocarbon products when entering a reactor, system or unit through two or more passes through the reactor, system or unit.

[0141] The electrochemical reduction system may have a selectivity of about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or about 99%. The electrochemical reduction system may have a selectivity of at least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95% or about 99% or more. The electrochemical reduction system may have a selectivity of no more than 99%, 95%, 90%, 80%, 70%, 60%, 50%, 40%, 30%, 20% or 10% or less.

[0142] The electrochemical reduction system for converting CO or CO2 into other chemicals may include various components that may be necessary for reducing CO or CO2. The components may include cathodes, anodes, contactors, extractors, pumps, gas-liquid separators, and ion exchange membranes. In some cases, according to a preferred embodiment of the device, certain components may be included in or excluded from the chemical reduction system. In some cases, the chemical reduction system may be a single, independent, or fully integrated system that performs all processes in the electrochemical reduction of CO or CO2. In other cases, the electrochemical reduction system may include at least two or more operably connected unit operations that jointly perform the necessary processes in the electrochemical reduction of CO or CO2.

[0143] The electrochemical reduction system may include a housing. The housing may provide various functions for the electrochemical reduction system, including, but not limited to, fixing components (e.g., membranes), physically containing fluids, separating different fluids within a single unit, maintaining temperature or pressure, and / or providing insulation. The housing may include any suitable material, including metals, ceramics, refractory materials, insulating materials, plastics, and glass. The housing may include one unit (e.g., a cathode) of the electrochemical reduction system. The housing may include two or more units (e.g., a cathode and an anode) of the electrochemical reduction system. A complete electrochemical reduction system may be contained in a single housing.

[0144] The housing may include one or more walls. The housing may include one or more compartments or chambers. The housing may have a cross-section that is circular, triangular, square, rectangular, pentagonal, hexagonal, or a partial shape thereof, or a combination of shapes thereof. The housing may be a single piece or formed of multiple pieces (e.g., pieces welded together). The housing may include a coating on its interior. Such a coating may prevent reaction with a surface on the interior of the housing, such as corrosion or oxidation / reduction reaction with the surface.

[0145] The electrochemical reduction system may include a cathode, an anode, and an electrolyte solution, which together provide the components required to reduce carbon dioxide to other chemicals. The electrolyte may include a salt water solution having an optimal ionic strength and pH for electrochemical reduction of CO or CO2. The electrolyte may include a salt water solution containing bicarbonate ions. In some cases, the electrolyte may include an aqueous solution of sodium bicarbonate or potassium bicarbonate. In some cases, the bicarbonate ions may dissociate in the presence of one or more catalysts to produce CO or CO2 molecules for the reduction reaction. The dissolution of CO or CO2 in the electrolyte solution may regenerate or maintain an optimal concentration of bicarbonate ions.

[0146] The electrochemical reduction system can be configured to operate at an optimal processing temperature. The operating temperature of the electrochemical reduction system or any component thereof may be about -30°C, -20°C, -10°C, 0°C, 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 50°C, 60°C, 70°C, or about 80°C. The operating temperature of the electrochemical reduction system or any component thereof may be at least about -30°C, -20°C, -10°C, 0°C, 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 50°C, 60°C, 70°C, or about 80°C or higher. The operating temperature of the electrochemical reduction system or any component thereof may not exceed about 80°C, 75°C, 70°C, 65°C, 60°C, 55°C, 50°C, 45°C, 40°C, 35°C, 30°C, 25°C, 20°C, 15°C, 10°C, 5°C, 0°C, -5°C, -10°C, -20°C, or about -30°C or less.

[0147] The electrochemical reduction system can be configured to operate at an optimal voltage for reducing CO or CO2 to a reduction product. The electrochemical reduction system can be arranged in a stacked or series configuration to adjust the system voltage to an optimal value. The electrochemical reduction system can have an operating voltage of about 0.1 volt (V), 0.2V, 0.3V, 0.4V, 0.5V, 0.75V, 1.0V, 2.0V, 3.0V, 4.0V, 5.0V, 10V, 15V or about 20V. The electrochemical reduction system can have an operating voltage of at least about 0.1 volt (V), 0.2V, 0.3V, 0.4V, 0.5V, 0.75V, 1.0V, 2.0V, 3.0V, 4.0V, 5.0V, 10V, 15V or about 20V or higher. The electrochemical reduction system may have an operating voltage of no more than about 20V, 15V, 10V, 5.0V, 4.0V, 3.0V, 2.0V, 1.0V, 0.75V, 0.5V, 0.4V, 0.3V, 0.2V, or about 0.1V or less.

[0148] The electrochemical reduction system can have an optimal cathode current density. In some cases, the cathode current density can determine the rate of CO or CO2 reduction at the cathode. The cathode can be characterized by overall electrochemical efficiency. Overall electrochemical efficiency can be defined as the percentage of electrical energy converted into chemical energy. The cathode can have an optimal cathode current density of about 10 mA / cm2. 2 )、50mA / cm 2 , 100mA / cm 2 , 150mA / cm 2 , 200mA / cm 2 , 250mA / cm 2 、300mA / cm 2 、350mA / cm 2 , 400mA / cm 2 , 450mA / cm 2 , 500mA / cm 2 、600mA / cm 2 , 700mA / cm 2 、800mA / cm 2 , 900mA / cm 2 or about 1000mA / cm 2 The cathode may have a cathode current density of at least about 10 mA / cm 2 , 50mA / cm 2 , 100mA / cm 2 , 150mA / cm 2 , 200mA / cm 2 , 250mA / cm 2 、300mA / cm 2、350mA / cm 2 , 400mA / cm 2 , 450mA / cm 2 , 500mA / cm 2 、600mA / cm 2 , 700mA / cm 2 、800mA / cm 2 , 900mA / cm 2 or about 1000mA / cm 2 The cathode may have a current density of no more than about 1000 mA / cm 2 , 900mA / cm 2 、800mA / cm 2 , 700mA / cm 2 、600mA / cm 2 , 500mA / cm 2 , 450mA / cm 2 , 400mA / cm 2 、350mA / cm 2 、300mA / cm 2 , 250mA / cm 2 , 200mA / cm 2 , 150mA / cm 2 , 100mA / cm 2 , 50mA / cm 2 , 10mA / cm 2 or lower cathode current density.

[0149] The cathode in the electrochemical reduction system may have an overall electrochemical efficiency. The cathode may have an overall electrochemical efficiency of about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% or more. The cathode may have an overall electrochemical efficiency of at least about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% or more. The cathode may have an overall electrochemical efficiency of no more than about 95%, 90%, 85%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, or less.

[0150] The electrolyte may comprise a solution having a particular ionic strength or molarity. The electrolyte may have an ionic strength of about 0.01 mol / L (M), 0.05 M, 0.1 M, 0.2 M, 0.3 M, 0.4 M, 0.5 M, 0.6 M, 0.7 M, 0.8 M, 0.9 M, 1.0 M, 1.1 M, 1.2 M, 1.3 M, 1.4 M, 1.5 M, 2.0 M, 2.5 M, or about 3.0 M. The electrolyte may have an ionic strength of at least about 0.01 M, 0.05 M, 0.1 M, 0.2 M, 0.3 M, 0.4 M, 0.5 M, 0.6 M, 0.7 M, 0.8 M, 0.9 M, 1.0 M, 1.1 M, 1.2 M, 1.3 M, 1.4 M, 1.5 M, 2.0 M, 2.5 M, or at least about 3.0 M or more. The electrolyte may have an ionic strength of no more than about 3.0 M, 2.5 M, 2.0 M, 1.5 M, 1.4 M, 1.3 M, 1.2 M, 1.1 M, 1.0 M, 0.9 M, 0.8 M, 0.7 M, 0.6 M, 0.5 M, 0.4 M, 0.3 M, 0.2 M, 0.1 M, 0.05 M, or no more than about 0.01 M or less. The salt in the electrolyte may have a molar concentration of about 0.01 moles / liter (M), 0.05 M, 0.1 M, 0.2 M, 0.3 M, 0.4 M, 0.5 M, 0.6 M, 0.7 M, 0.8 M, 0.9 M, 1.0 M, 1.1 M, 1.2 M, 1.3 M, 1.4 M, 1.5 M, 2.0 M, 2.5 M, or about 3.0 M. The salt in the electrolyte can have a molar concentration of at least about 0.01 M, 0.05 M, 0.1 M, 0.2 M, 0.3 M, 0.4 M, 0.5 M, 0.6 M, 0.7 M, 0.8 M, 0.9 M, 1.0 M, 1.1 M, 1.2 M, 1.3 M, 1.4 M, 1.5 M, 2.0 M, 2.5 M, or at least about 3.0 M or more. The salt in the electrolyte can have a molar concentration of no more than about 3.0 M, 2.5 M, 2.0 M, 1.5 M, 1.4 M, 1.3 M, 1.2 M, 1.1 M, 1.0 M, 0.9 M, 0.8 M, 0.7 M, 0.6 M, 0.5 M, 0.4 M, 0.3 M, 0.2 M, 0.1 M, 0.05 M, or no more than about 0.01 M or less. The salt in the electrolyte can have a molar concentration in the range of about 0.01 M to about 0.1 M, about 0.01 M to about 0.2 M, about 0.01 M to about 0.5 M, about 0.01 M to about 1.0 M, about 0.01 M to about 3.0 M, about 0.1 M to about 0.2 M, about 0.1 M to about 0.5 M, about 0.1 M to about 1.0 M, about 0.1 M to about 3.0 M, about 0.2 M to about 0.5 M, about 0.2 M to about 1.0 M, about 0.2 M to about 3.0 M, about 0.5 M to about 1.0 M, about 0.5 M to about 3.0 M, or about 1.0 M to about 3.0 M.

[0151] The electrolyte may have an optimal pH for electrochemical reduction of CO2. The electrolyte may have a pH of about 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, or about 14. The electrolyte may have a pH of at least about 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or more. The electrolyte may have a pH of no more than about 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0, or less. The electrolyte can have a pH in the range of about 0 to about 2, about 0 to about 3, about 0 to about 4, about 0 to about 5, about 0 to about 7, about 0 to about 10, about 0 to about 14, about 2 to about 3, about 2 to about 4, about 2 to about 5, about 2 to about 7, about 2 to about 10, about 2 to about 14, about 3 to about 4, about 3 to about 5, about 3 to about 7, about 3 to about 10, about 3 to about 14, about 4 to about 5, about 4 to about 7, about 4 to about 10, about 4 to about 14, about 5 to about 7, about 5 to about 10, about 5 to about 14, about 7 to about 10, about 7 to about 14, or about 10 to about 14.

[0152] The electrolyte in the electrochemical reduction system may be a non-aqueous electrolyte. In some cases, the electrolyte may include an ionic liquid with a dissolved salt. The ionic liquid may include, but is not limited to, a 34-imidazolium-based fluoride anion ionic liquid, 34-imidazolium acetate, 34-imidazolium fluoroacetate, a pyrrolidinium ionic liquid, or any combination thereof.

[0153] The anode may comprise a single metal, such as nickel, tin or gold. The anode may comprise a wire mesh, a metal foam or other permeable structure of the selected anode material. The anode material may be in operative contact with an anion exchange membrane material or another physical separator that prevents contact with the cathode.

[0154] The cathode may comprise any suitable material. In some cases, the cathode may comprise copper nanoparticles and / or N-doped carbon nanomaterials. In some cases, the cathode may comprise a microstructured or nanostructured membrane material. In some cases, the cathode may comprise one or more catalysts for electrochemical reduction of CO or CO2 or other chemical reactions. The cathode material may be in effective contact with an anion exchange membrane material or another physical partition that prevents contact with the cathode. In some cases, the distance between the cathode and the anode may be minimized to reduce resistance. In some cases, forced convection of the electrolyte between the electrodes may further reduce resistance and / or may allow a greater distance between the electrodes. In some cases, the electrodes may be located in different housings. In some cases, there may be a minimum distance between the anode and the cathode, with an ion selective membrane therebetween. In some cases, an ion selective membrane may not be used.

[0155] The electrochemical reduction system may include one or more extractor units. The extractor unit may include any unit operation or separation unit that selectively separates one or more chemical substances from a feed stream. In some cases, the extractor may include a membrane separator. In some cases, the extractor may include a microstructured or nanostructured membrane. In some cases, the extractor may extract one or more chemical substances derived from carbon dioxide reduction. In some cases, the extractor may extract one or more chemical substances derived from CO or CO2 reduction from an electrolyte solution. In other cases, the extractor may separate one or more chemical substances derived from subsequent reactions of the products of the electrochemical reduction of carbon dioxide.

[0156] The electrochemical reduction system may include one or more contactor units. The contactor unit may include any unit operation or separation unit that selectively separates one or more chemical substances from a feed stream. In some cases, the contactor may include a gas adsorption tower. In other cases, the contactor may include a filler for increasing the surface area of ​​the liquid solution and a fan for increasing the gas passing through the liquid interface. Such a contactor may share design features with a cooling tower. In other cases, the extractor may include a membrane separator. In some cases, the extractor may include a microstructure or nanostructured membrane. In some cases, the contactor may extract one or more chemical substances from the feed stream. In some cases, the contactor may extract carbon dioxide from the feed stream. In some cases, the contactor may separate CO or CO2 from the feed stream and dissolve CO or CO2 in an electrolyte solution. In some cases, the feed stream may be air. In some cases, the feed stream may be filtered before use. In some cases, this filtration may remove particulate matter and / or volatile organic materials and / or various undesirable materials. The absorption of CO or CO2 in the gas contactor may be enhanced by the presence of hydroxide ions produced in the electrochemical reduction system.

[0157] The electrochemical reduction system may include one or more ion exchange membranes. The ion exchange membrane may include a cation exchange membrane, an anion exchange membrane or a bipolar membrane. The ion exchange membrane may be in effective contact with the cathode, the anode or both the cathode and the anode. In some cases, the electrochemical reduction system may not include an ion exchange membrane. In some cases, the ion exchange membrane may be configured to minimize the distance between the anode and the cathode. The thickness of the ion exchange membrane may be about 1 μm, 5 μm, 10 μm, 25 μm, 50 μm, 100 μm, 125 μm, 150 μm, 200 μm, 250 μm, 300 μm, 400 μm, 500 μm, 750 μm, 1 mm or greater than 1 mm. The thickness of the ion exchange membrane may be at least about 1 μm, 5 μm, 10 μm, 25 μm, 50 μm, 100 μm, 125 μm, 150 μm, 200 μm, 250 μm, 300 μm, 400 μm, 500 μm, 750 μm, 1 millimeter (mm) or more. The thickness of the ion exchange membrane may not exceed about 1 mm, 750 μm, 500 μm, 400 μm, 300 μm, 250 μm, 200 μm, 150 μm, 125 μm, 100 μm, 50 μm, 25 μm, 10 μm, 5 μm, 1 μm or less.

[0158] The electrochemical reduction system may include one or more compartments or chambers. A compartment or chamber may be defined as an enclosed volume within the electrochemical reduction system where mass transfer occurs. For example, the electrochemical reduction system may include a first compartment or chamber in which a C1+ product is produced, and a second compartment or chamber in which the C1+ product is extracted, separated, or otherwise transferred from the first compartment. Figure 16A-16C Various exemplary configurations of compartments or chambers that are within the scope of the present invention are shown. Fig.16A A schematic diagram of an electrochemical reduction system 1000 is depicted, wherein a first compartment or chamber 100 includes a cathode 140 and a second compartment or chamber 200 includes an anode 160, wherein the anode 140 and the cathode 160 are electrically coupled via a voltage source 130. The first compartment or chamber 100 is separated from the second compartment or chamber 200 by a microstructured or nanostructured membrane 150 that controls the transfer of C1+ products from the first compartment or chamber 100 to the second compartment or chamber 200. Fig. 16B A schematic diagram of an electrochemical reduction system 1000 is depicted that includes a cathode unit 210 and an anode unit 220. The cathode unit 210 includes a first compartment or chamber 100 that includes a cathode 140 that is electrically coupled to an anode 160 in the anode unit 220 via a voltage source 130. The first compartment or chamber 100 is separated from a second compartment or chamber 200 by a microstructured or nanostructured membrane 150 that controls the transfer of C1+ products from the first compartment 100 to the second compartment or chamber 200 in the cathode unit 210. Fig. 16C A schematic diagram of an electrochemical reduction system 1000 is depicted that includes a cathode unit 210, an anode unit 220, and an extractor 230. The cathode unit includes a cathode 140 and a first compartment 100. The cathode 140 is electrically coupled to an anode 160 in the anode unit 220 via a voltage source 130. A C1+ product is produced in the first compartment or chamber of the cathode unit 210 and is transferred to the extractor by a stream C1+, which includes a second compartment or chamber 200. The C1+ product is transferred from the stream C1+ to the second compartment or chamber 200 by flowing through a microstructured or nanostructured membrane 150.

[0159] Various embodiments of chemical reduction systems utilizing microstructured or nanostructured membranes can be envisioned. Figure 6In the described embodiments, an electrolyte solution (1) having an optimal pH can be introduced into a chemical reduction unit (2), wherein CO2 is introduced into the electrolyte and reduced to a useful reduced carbon product (RCP) by a catalyst. In some cases, CO2 is captured in a separate unit operation and introduced into the chemical reduction unit in gaseous form. In some cases, CO2 is captured in a separate unit operation and introduced as a component of the electrolyte. In some cases, the chemical reduction unit can be composed of various housings, tanks, pumps, or other elements for running the unit. In some cases, separate cathode electrolyte and anolyte reservoirs can be used. In some cases, a pump can be used to circulate the cathode electrolyte and anolyte to the electrolytic stack. In some cases, the cathode electrolyte reservoir can also be a gas-liquid separator. In some cases, a heat exchanger and a cooling or heating system can be used to maintain the desired temperature in various reservoirs, stacks, or other unit elements. In some cases, the chemical reduction unit (2) can include a microstructured or nanostructured membrane. The microstructured or nanostructured membrane can contain one or more catalysts. In other cases, the catalytic process may include a conventional electrochemical "stack" comprising an anode and a cathode within the same housing. In some cases, an ion exchange membrane may be used. In some cases, a variety of catalytic membranes may be used, or the desired CO2 reduction may be achieved by other reduction methods. Oxygen or other oxidizing species may also be produced by this method and released into the atmosphere or used for beneficial purposes. A stream (3) containing RCP is introduced into an extractor (4) where the RCP is extracted. In some cases, the RCP stream is a liquid electrolyte. In some cases, the RCP stream is a vapor. In some cases, the RCP stream is a vapor collected from a gas space above the electrolyte. In some cases, the gas space is an integral part of the chemical reduction unit. In some cases, the gas space is part of a gas-liquid separator, which may be located in a separate housing. In some cases, the gas-liquid separator may also be a cathode electrolyte reservoir. In some cases, the extractor may include a membrane extractor. The membrane extractor may include a microstructured or nanostructured membrane material. Due to a pressure or chemical potential difference (e.g., created by a vacuum downstream of the membrane cavity or on the back side of the membrane), RCP can be extracted through the pores or channels of the microstructured or nanostructured membrane, thereby producing an RCP product stream (5) which is condensed or otherwise collected by a collector unit. The collector unit may include a condenser. In some cases, the collector unit may include a heat exchange condenser, an adsorption unit, or other capture process. In other cases, the collector system may be understood to refer to any of a variety of product capture and / or further processing steps, which may include, but are not limited to, condensation, adsorption, repressurization, further reaction (such as for polymerization or further catalysis of other formations of long-chain hydrocarbons, etc.).The collected RCP can be directed to further processing or used in stream (7). Any non-condensable, non-collectible or intentionally uncollected gas stream (8) can be recompressed by a vacuum pump (9) and discharged to the environment or collected for further use in a product stream (10). In some cases, the uncollected gas may include reducing substances, such as H2, CO, CH4 or other gases, including alcohols. In some cases, the uncollected gas can be used beneficially. In some cases, the beneficial use may include power generation in a fuel cell or other unit operation, which may use the O2 produced by the chemical reduction process. In some cases, the uncollected gas can be used before the vacuum pump. In some cases, the uncollected gas can be sold or used to produce secondary products. After RCP extraction, the stream containing RCP is returned to the chemical reduction unit as a feed stream (1), which may be substantially depleted of RCP or may have a baseline recycle concentration of RCP (as may be required to optimize various features or operations of the process, such as extraction).

[0160] In another embodiment, Figure 7As shown, the electrolyte solution (1) can be directed to a chemical reduction unit (2), in which CO or CO2 is reduced to RCP. The electrolyte solution (3) containing RCP is directed to an extractor (4), in which the RCP is extracted. In some cases, the extractor can use a gas-liquid separator so that the RCP can be extracted from the vapor flow above the electrolyte. In some cases, the extractor may include a membrane extractor. The membrane extractor may include a microstructured or nanostructured membrane material. Due to a pressure or chemical potential difference (for example, caused by a vacuum downstream of the membrane cavity or on the back side of the membrane), the RCP can be extracted through the pores or channels of the microstructured or nanostructured membrane, thereby producing an RCP product stream (5), which is condensed or otherwise collected by a collector unit. The collector unit may include a condenser. In some cases, the collector unit may include a heat exchange condenser, an adsorption unit, or other capture process. In other cases, the collector system may be understood to refer to any of a variety of product capture and / or further processing steps, which may include, but are not limited to, condensation, adsorption, repressurization, further reaction (such as for polymerization of long chain hydrocarbons or further catalysis of other formations, etc.). The collected RCP may be directed to further processing or used in stream (7). Any non-condensable or non-collectible gas stream (8) may be recompressed by a vacuum pump (9) and discharged to the environment or collected for further use in the product stream (10). An electrolyte stream that consumes a large amount of RCP or has a certain recycle concentration may be directed to a contactor (12). The contactor may include a membrane for separating one or more gases from a gas feed stream, or using any other method to contact the gas with the electrolyte stream. The contactor membrane may include a microstructured or nanostructured membrane. The gas feed stream may contain air, exhaust gas, or any other gas stream containing CO or CO2 (13). In some cases, the hydroxide formed in the electrolyte in the chemical reduction unit may be the primary adsorbent in the electrolyte for capturing CO or CO2. In some cases, the pH of the electrolyte stream in the contactor can be controlled by adding hydroxides, such as sodium hydroxide or potassium hydroxide, for optimal CO or CO2 adsorption. The air stream depleted of CO or CO2 can be directed to an atmospheric purge for other uses. The electrolyte solution with the desired pH and carbonate species concentration can be returned as a feed stream (1) for reuse in the chemical reduction system.

[0161] In another embodiment, Figure 8As described, the electrolyte flow is directed to the cathode unit. In some cases, the cathode unit may include a microstructured or nanostructured membrane. In some cases, the cathode unit may include a microstructured or nanostructured membrane comprising a nitrogen-doped carbon nanomaterial with copper nanoparticles (which may include further depositing the NCM onto the membrane surface during or after its manufacture to promote improved conductivity or other properties). At the cathode unit, CO or CO2 can be reduced to RCP. The RCP can be extracted through the membrane (2) (through the membrane to the back layer or cavity), producing an RCP product stream (3), which is collected in a condenser (4) and produced as an RCP product stream (5). Any non-condensable gas (6) can be recompressed by a vacuum pump (7) to maintain the system vacuum or otherwise processed and then discharged into the environment or subsequently used for some other purpose (8). The cathode electrolyte outlet stream (9) is directed to a contactor (10), which can contact the electrolyte solution with air, exhaust gas or any other gas stream (11) containing CO or CO2 to allow the electrolyte to adsorb CO or CO2. Air depleted of CO or CO2 is directed to an outlet stream (12). An electrolyte stream (13) containing adsorbed CO or CO2 is directed to an anode unit (14). In some cases, the anode unit is located in the same housing as the cathode unit. In some cases, the distance between the cathode and the anode is minimized. In some cases, an ion exchange membrane is used between the cathode and the anode. The anode may include a membrane. In some cases, the anode may include a material that may be any type of microstructure or nanostructure, such as a membrane containing a carbon nanomaterial with reduced nanoparticle platinum or a similar catalyst (such as nickel, indium oxide, or other materials with similar performance characteristics). The electrolyte solution may be directed from one side of the membrane to the other to increase mass transfer to the catalyst site. Oxygen and hydrogen (in the form of hydrated hydrogen, reduced pH) may be produced in the anode unit, thereby completing the electrocatalytic loop. The anode unit and the cathode may be electrically connected. In some cases, the anode unit and the cathode unit may be combined in a single chemical reduction unit. If there are any residual RCPs in the stream (13), they may be oxidized in the anode unit. In some cases, it may be optimal to have a certain amount of oxidizable RCP species in the post-anode electrolyte stream to optimize system cost or performance. The electrolyte solution (15) containing oxygen and any CO or CO2 that may be released by lowering the pH of the solution can be directed to a gas liquid separator unit (VLS) (16) where the gas is directed to stream (17) and the liquid is directed to stream (18). The liquid produced from the VLS unit can be directed back to the cathode unit for reuse. In this and other embodiments where an anode and a contactor are present, the relative order of these two operations is generally interchangeable as the contactor can be located before or after the anode as desired.If the contactor follows the anode, oxygen evolution and CO or CO2 capture may be achieved in the same unit operation.

[0162] In another embodiment, Fig. 9 As described, the electrolyte solution (1) is directed to the cathode unit (2). In some cases, the cathode unit may include a microstructured or nanostructured membrane. In some cases, the cathode unit may include a microstructured or nanostructured membrane, which includes a nitrogen-doped carbon nanomaterial with copper nanoparticles. The cathode unit membrane may have an external electric field applied axially to the water transport direction in the nanopores or channels, so that the RCP is substantially repelled by the membrane, so that the electrolyte that consumes a large amount of RCP is directed to the flow (3), and an electrolyte flow with an increased RCP concentration is generated as a flow (4). The RCP concentration of the flow (4) can increase with a longer cathode membrane feed channel (removing the electrolyte solution while retaining the RCP continuously generated on the membrane surface). The electrolyte flow (4) containing RCP can be directed to an extractor (5). In some cases, the extractor may include a membrane extractor. The membrane extractor may include a microstructured or nanostructured membrane material. Due to a pressure or chemical potential difference (e.g., created by a vacuum downstream of the membrane cavity or on the back side of the membrane), RCP can be extracted through the pores or channels of the microstructured or nanostructured membrane, thereby producing an RCP product stream (5), which is condensed or otherwise collected by a collector unit, thereby producing an RCP product stream (8). Any non-condensed gases (9) can be recompressed by a vacuum pump (10) to maintain the system vacuum, or subjected to any other treatment method, and then discharged to the environment or subsequently used for some beneficial purpose (11). The extractor electrolyte product stream (12) is directed to the anode (13), where oxygen generation and pH reduction can occur. In some cases, the anode unit is located in the same housing as the cathode unit. In some cases, the distance between the cathode and the anode is minimized. In some cases, an ion exchange membrane is used between the cathode and the anode. The oxygen-containing stream (14) can be directed to the VLS (15), producing a gas outlet stream (16) and a liquid outlet stream (17). The electrolyte stream (3) depleted of RCP can be directed to a contactor (18) where it is contacted with air and exhaust gas or any other gas stream (19) containing CO2, thereby causing the adsorption of CO or CO2 onto the electrolyte, the increase in pH occurring during the reduction of CO or CO2 promoting such adsorption. The air reduced in CO or CO2 or depleted in CO or CO2 can be directed to an outlet stream (20). The electrolyte solution (21) containing RCP and adsorbed CO or CO2 can be combined or mixed with stream (17) to form the electrolyte stream (1) for reuse in the cathode unit.

[0163] In another embodiment, Fig.10As shown, the electrolyte flow (1) is directed to a cathode unit (2) including a membrane. In some cases, the cathode may include a microstructured or nanostructured membrane. A gas feed stream (3) containing CO or CO2 is introduced into the electrolyte from the back of the membrane so that it can be easily utilized by the catalyst on the membrane surface. CO or CO2 can be substantially pure and can come from various sources, including capture from combustion sources, geothermal sources, direct air capture or other sources as needed. The electrolyte flow (4) containing RCP can be directed to an extractor (5), where the RCP (6) is extracted to a collector (7) and produced as a stream (8). Non-condensable gas (NCG) (9) is directed to a vacuum pump (10) and is directed to a stream (11). The electrolyte solution (12) after the extractor can be directed to the anode (13). In some cases, the anode unit is located in the same housing as the cathode unit. In some cases, the distance between the cathode and the anode is minimized. In some cases, an ion exchange membrane is used between the cathode and the anode. The oxygenated solution (14) produced at the anode may be directed to the VLS (15), producing an outlet gas stream (16) and an outlet liquid stream (17), which may be recycled to the cathode unit.

[0164] In another embodiment, Fig.11 As shown, the electrolyte solution (1) can be directed to the cathode unit including the membrane from the back side or the cavity side. In some cases, the cathode unit membrane can include a microstructured or nanostructured membrane. The electrolyte solution can flow to the active catalyst surface, on which CO or CO2 is reduced to RCP. By introducing the reactants at the ideal pH directly to the catalyst site in this way, efficient utilization of the catalyst can be expected. The electrolyte flow (3) containing RCP is directed to the extractor (4), where the RCP (5) is extracted to the collector (6) and produced as an RCP product stream (7). The non-condensable gas (NCG) (8) is directed to the vacuum pump (9) and is directed to the outlet flow (10). The electrolyte solution (11) after the extractor is directed to the anode unit (12). In some cases, the anode unit is located in the same housing as the cathode unit. In some cases, the distance between the cathode and the anode is minimized. In some cases, an ion exchange membrane is used between the cathode and the anode. The oxygenated solution that may be produced in the anode unit (13) is directed to the VLS (14), thereby producing a gas outlet stream (15) and a liquid outlet stream (16), which becomes the recycled feed stream (1) for reuse.

[0165] In another embodiment, Fig.12As shown, an electrolyte solution (1) containing CO or CO2 is directed to an extraction catalytic membrane (2) in which RCP can be produced. The electrolyte stream (3) containing RCP can be directed to a condenser (4) and produced as an RCP product stream (5). NCG (6) is directed to a vacuum pump (7) and becomes an outlet stream 8. The post-extractor electrolyte solution, which can consume a large amount of RCP or have a desired minimum RCP recirculation concentration, is directed to an ion exchange membrane (10) to allow the exchange of OH- anions (in the case of anion exchange membranes) or H+ ions (in the case of proton (or cation) exchange membranes) from stream (11) to balance the pH required for the catalytic loop to continue to operate and to protect the RCP in stream (9) from oxidation that is expected to occur when in contact with the anode or its immediate environment. The ion-exchanged electrolyte stream can be directed to an anode unit (17). In some cases, the anode unit is located in the same housing as the cathode unit. In some cases, the distance between the cathode and the anode is minimized. In some cases, an ion exchange membrane is used between the cathode and the anode. In some cases, the indicated stream is diffusive. In some cases, the indicated stream is a recirculating stream intended to help reduce the boundary layer and improve mass transfer. If desired, this configuration allows high circulating concentrations of RCP, which can improve RCP extraction and / or provide other benefits. The pH-balanced stream (13) is directed into a contactor (14), where CO or CO2 is adsorbed from air, exhaust gas or any other gas stream (15) containing CO or CO2 in the contactor (14). Air depleted of CO or CO2 can be directed to an outlet stream (16). The reconstructed electrolyte stream (1) can be directed for reuse in the cathode unit. In the anode system, oxygen can be produced and the pH can be reduced. The oxygen-containing solution (18) can be directed to a VLS (19), producing an outlet product gas (20) and an outlet liquid (21), which can be recycled as a stream (11) for reuse. In this and other embodiments using contactors and ion exchange membranes, the relative order of these operations can be altered, for example, having the contactor before the ion exchange or vice versa, which may be beneficial for system optimization.

[0166] In another embodiment, Fig.13As shown, the electrolyte solution (1) is directed to a cathode unit (2) that can produce RCP. In some cases, the cathode unit can include a microstructured or nanostructured membrane. In some cases, the cathode unit can include a catalyst that includes a nitrogen-doped carbon nanomaterial with copper nanoparticles. In some cases, the cathode unit can include a microstructured or nanostructured membrane that includes a nitrogen-doped carbon nanomaterial with copper nanoparticles. The electrolyte stream (3) containing RCP is directed to an extractor (4). The substantially purified RCP stream (5) is directed to a collector to produce a product stream (7). NCG or other uncollected substances (8) are directed to a subsequent separation unit or process (such as a vacuum pump (9)) to become an outlet stream (10). The post-extractor electrolyte solution (11) is directed to an ion exchange (IX) membrane (12), where the pH between stream (11) and stream (13) is balanced to produce an electrolyte stream (14) (cathode side) and an electrolyte stream (15) (anode side). Stream (15) is directed to an anode unit (16) which may produce an oxidant-rich stream (17) which is directed to a separator device (represented herein as VLS) (18) to separate the oxidant from an electrolyte stream (20) which is reused as stream (13). Stream (14) is directed to a contactor where it is contacted with a CO or CO2 source (22) to produce an outlet stream (23) depleted of CO or CO2 and an electrolyte stream (24) having desired properties for recirculation to the cathode unit. In some cases, the anode unit is located in the same housing as the cathode unit. In some cases, the distance between the cathode and anode is minimized. In some cases, an ion exchange membrane is used between the cathode and anode. In some cases, the indicated stream is diffusive. In some cases, the indicated stream is a recirculating stream intended to help reduce the boundary layer and improve mass transfer.

[0167] In another embodiment, Fig.14As shown, the electrolyte solution (1) is directed to a cathode unit (2) where RCP can be produced. In some cases, the cathode unit can include a microstructured or nanostructured membrane. In some cases, the cathode unit can include a microstructured or nanostructured membrane that includes a nitrogen-doped carbon nanomaterial with copper nanoparticles. The electrolyte stream (3) containing RCP can be directed to an extractor (4). The substantially purified RCP stream (5) can be directed to a collector (6) to produce an RCP product stream (7). NCG or other uncollected substances (8) can be directed to a subsequent separation unit or process (such as a vacuum pump (9)) to become an outlet stream (10). The post-extractor electrolyte stream (11) can be directed to an ion exchange (IX) membrane (12), where the pH between stream (11) and stream (13) can be balanced to produce stream (14) (cathode side) and stream (15) (anode side). Stream (15) can be directed to an anode unit (16) to produce an oxidant-rich stream (17), which can be directed to a separator device (represented herein as VLS) (18) to separate the oxidant from an electrolyte stream (20), which can be reused as stream (13). Stream (14) becomes an electrolyte stream (14) having desired properties for reuse. A source of CO or CO2 (21), which may be substantially pure, can be introduced into the cathode membrane so that it is introduced into the active catalytic sites from the back or cavity side of the membrane, which can result in high utilization of the reactants and efficient utilization at the catalyst sites. In some cases, the anode unit is located in the same housing as the cathode unit. In some cases, the distance between the cathode and the anode is minimized. In some cases, an ion exchange membrane is used between the cathode and the anode. In some cases, the indicated stream is diffusive. In some cases, the indicated stream is a recirculating stream intended to help reduce the boundary layer and improve mass transfer.

[0168] It should be understood that the systems and methods for any of the described embodiments of the chemical reduction system can be used in any other embodiment of the chemical reduction system. For example, when appropriate, a specific cathode, anode, collector, extractor, contactor, or gas-liquid system can be applied to any embodiment of the chemical reduction system. In some cases, the differences in the system configuration of each embodiment can facilitate the selection of different system components to produce optimal system performance and processing conditions.

[0169] Computer Systems

[0170] The present disclosure provides computer systems programmed to implement the methods of the present disclosure. Fig.15A computer control system 1501 is shown that is programmed or otherwise configured to control a chemical reduction system or a process within a chemical reduction system (e.g., controlling and balancing the pH of an electrolyte flow). The computer control system 1501 can regulate various aspects of the methods of the present disclosure, such as methods of producing reduced carbon products or monitoring potentially dangerous operating conditions. The computer system 1501 can be implemented on a user's electronic device or a computer system remotely located relative to the electronic device. The electronic device can be a mobile electronic device.

[0171] The computer system 1501 includes a central processing unit (CPU, also referred to herein as a "processor" and "computer processor") 1505, which may be a single-core or multi-core processor, or multiple processors for parallel processing. The computer control system 1501 also includes a memory or storage location 1510 (e.g., random access memory, read-only memory, flash memory), an electronic storage unit 1515 (e.g., a hard disk), a communication interface 1520 (e.g., a network adapter) for communicating with one or more other systems, and peripheral devices 1525, such as cache memory, other memory, data storage, and / or an electronic display adapter. The memory 1510, storage unit 1515, interface 1520, and peripheral devices 1525 communicate with the CPU 1505 via a communication bus (solid lines) such as a motherboard. The storage unit 1515 may be a data storage unit (or data repository) for storing data. The computer control system 1501 may be operably coupled to a computer network ("network") 1530 by means of the communication interface 1520. The network 1530 may be the Internet, the Internet and / or an extranet and / or an intranet and / or an extranet in communication with the Internet. In some cases, the network 1530 is a telecommunication and / or data network. The network 1530 may include one or more computer servers that may implement distributed computing, such as cloud computing. In some cases, with the aid of the computer system 1501, the network 1530 may implement a peer-to-peer network, which may enable devices coupled to the computer system 1501 to act as clients or servers.

[0172] The CPU 1505 may execute a series of machine-readable instructions, which may be embodied in a program or software. The instructions may be stored in a storage location, such as a memory 1510. The instructions may be directed to the CPU 1505, which may then program or otherwise configure the CPU 1505 to implement the methods of the present disclosure. Examples of operations performed by the CPU 1505 may include fetching, decoding, executing, and writing back.

[0173] CPU 1505 may be part of a circuit such as an integrated circuit. One or more other components of system 1501 may be included in the circuit. In some cases, the circuit is an application specific integrated circuit (ASIC).

[0174] Storage unit 1515 can store files, such as drivers, libraries, and saved programs. Storage unit 1515 can store user data, such as user preferences and user programs. In some cases, computer system 1501 may include one or more additional data storage units that are external to computer system 1501, such as located on a remote server that communicates with computer system 1501 via an intranet or the Internet.

[0175] Computer system 1501 can communicate with one or more remote computer systems via network 1530. For example, computer system 1501 can communicate with a remote computer system of a user (e.g., a user controlling the manufacture of a slurry-coated substrate). Examples of remote computer systems include personal computers (e.g., portable PCs), tablet or tablet-type PCs (e.g., iPad, Galaxy Tab), phones, smartphones (e.g. iPhone, Android-enabled devices, ) or a personal digital assistant. A user can access the computer system 1501 via the network 1530.

[0176] The methods described herein may be implemented by machine (e.g., computer processor) executable code stored in an electronic storage location of the computer system 1501 (e.g., in the memory 1510 or electronic storage unit 1515). The machine executable code or machine readable code may be provided in the form of software. During use, the code may be executed by the processor 1505. In some cases, the code may be retrieved from the storage unit 1515 and stored in the memory 1510 for access by the processor 1505. In some cases, the electronic storage unit 1515 may be excluded and the machine executable instructions may be stored in the memory 1510.

[0177] The code may be precompiled and configured for use with a machine having a processor suitable for executing the code, or may be compiled during runtime. The code may be provided in a programming language, which may be selected to enable the code to be executed in a precompiled or as-compiled manner.

[0178] Aspects of the systems and methods provided herein, such as computer system 401, may be embodied in programming. Aspects of the present technology may be considered as "products" or "articles of manufacture", which are generally in the form of machine (or processor) executable code and / or related data carried or embodied on a certain type of machine-readable medium. The machine executable code may be stored in an electronic storage unit such as a memory (e.g., read-only memory, random access memory, flash memory) or a hard disk. "Storage" type media may include any or all tangible memory, processor, etc. of a computer, or its related modules, such as various semiconductor memories, tape drives, disk drives, etc., which may provide non-temporary storage for software programming at any time. All or part of the software may sometimes communicate via the Internet or various other telecommunications networks. Such communication, for example, may enable software to be loaded from one computer or processor to another, for example, from a management server or host to a computer platform of an application server. Therefore, another type of medium that can carry software elements includes optical waves, radio waves, and electromagnetic waves, such as optical waves, radio waves, and electromagnetic waves used across physical interfaces between local devices, through wired and optical landline networks, and through various air links. Physical elements that carry such waves, such as wired or wireless links, optical links, etc., can also be considered to be media that carry software. As used herein, unless restricted to non-transitory tangible "storage" media, terms such as computer or machine "readable media" refer to any medium that participates in providing instructions to a processor for execution.

[0179] Thus, machine-readable media such as computer executable code may take many forms, including but not limited to tangible storage media, carrier media, or physical transmission media. Non-volatile storage media include, for example, optical or magnetic disks, such as any storage device in any computer, such as may be used to implement a database such as shown in the accompanying drawings. Volatile storage media include dynamic memory, such as the main memory of such a computer platform. Tangible transmission media include coaxial cables; copper wire and optical fiber, including the wires that make up a bus within a computer system. Carrier transmission media may take the form of electrical or electromagnetic signals, or acoustic or light waves, such as those generated during radio frequency (RF) and infrared (IR) data communications. Thus, common forms of computer readable media include, for example, a floppy disk, a flexible disk, a hard disk, a magnetic tape, any other magnetic medium, a CD-ROM, a DVD or DVD-ROM, any other optical medium, a punched card stock tape, any other physical storage medium having a pattern of holes, a RAM, a ROM, a PROM and an EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave that transmits data or instructions, a cable or link that transmits such a carrier wave, or any other medium from which a computer can read programming code and / or data. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.

[0180] The computer system 1501 may include or communicate with an electronic display 1535, which includes a user interface (UI) 1540 for providing, for example, parameters for producing reduced carbon products. Examples of UIs include, but are not limited to, graphical user interfaces (GUIs) and web-based user interfaces.

[0181] The methods and systems of the present disclosure may be implemented by one or more algorithms. The algorithms may be implemented by software when executed by the central processing unit 1505. The algorithm may, for example, adjust the flow rate of the gas stream containing CO2 through the contactor unit to optimize the pH or bicarbonate concentration of the electrolyte solution. As another example, the algorithm may adjust the electric field applied to the microstructured or nanostructured membrane to control the selectivity of the membrane to a particular chemical substance.

[0182] The present invention provides embodiments including but not limited to the following:

[0183] 1. A system for producing a carbon product (C1+ product) containing one or more carbon atoms, comprising:

[0184] First compartment;

[0185] A second compartment; and

[0186] a separation unit that separates the first compartment and the second compartment, wherein the separation unit comprises (i) an anode, (ii) a cathode, and (iii) a membrane comprising a plurality of pores, wherein the plurality of pores are configured to allow fluid communication between the first compartment and the second compartment,

[0187] wherein the cathode and the anode are configured to reduce the carbonaceous material to the C1+ product in the first compartment while a voltage is applied between the cathode and the anode, and

[0188] Wherein the plurality of pores are configured to direct the C1+ product from the first compartment to the second compartment.

[0189] 2. The system according to embodiment 1 further includes a gas contactor in fluid communication with the first compartment, wherein the gas contactor is configured to contact the carbonaceous material with water to produce a solution containing the carbonaceous material.

[0190] 3. The system of embodiment 1, wherein the membrane comprises one or more materials selected from the group consisting of carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene, and porous pyrolytic carbon.

[0191] 4. The system of embodiment 1, wherein the cathode further comprises a catalyst.

[0192] 5. The system of embodiment 4, wherein the catalyst comprises metal nanoparticles.

[0193] 6. The system of embodiment 5, wherein the metal nanoparticles comprise a metal selected from the group consisting of copper, nickel, platinum, iridium, ruthenium, palladium, tin, silver, and gold.

[0194] 7. The system of embodiment 4, wherein the catalyst is N-doped.

[0195] 8. The system according to embodiment 1 further comprises a voltage source configured to supply the voltage.

[0196] 9. The system of embodiment 8, wherein the voltage source comprises a renewable power source.

[0197] 10. A system according to embodiment 8, wherein the voltage source includes one or more members selected from photovoltaic power sources, wind power sources, geothermal power sources, hydroelectric power sources, tidal power sources and nuclear power sources.

[0198] 11. The system of embodiment 1 further comprising an ion exchange membrane between the cathode and the anode.

[0199] 12. The system of embodiment 1, wherein the system is configured to have a single pass selectivity for the C1+ product of at least about 70%.

[0200] 13. The system of embodiment 1, wherein a pore in the plurality of pores has a pore size less than or equal to about 5 microns.

[0201] 14. The system of embodiment 13, wherein the pore size is less than or equal to about 500 nanometers.

[0202] 15. The system of embodiment 14, wherein the pore size is less than or equal to about 100 nanometers.

[0203] 16. The system of embodiment 15, wherein the pore size is less than or equal to about 50 nanometers.

[0204] 17. A system according to embodiment 16, wherein the pore size is less than or equal to about 10 nanometers.

[0205] 18. A system according to embodiment 17, wherein the pore size is less than or equal to about 5 nanometers.

[0206] 19. The system of embodiment 1, wherein the C1+ product comprises one or more members selected from methanol, ethanol, propanol, and butanol.

[0207] 20. The system of embodiment 1, wherein the first compartment comprises the cathode and the second compartment comprises the anode.

[0208] 21. The system of embodiment 1, wherein the first compartment comprises the cathode and the membrane.

[0209] 22. The system of embodiment 1, wherein the separation further comprises an extractor.

[0210] 23. The system of embodiment 22, wherein the extractor comprises the second compartment and the membrane.

[0211] 24. A method of producing a carbon product (C1+ product) containing one or more carbon atoms using a carbonaceous material, the method comprising:

[0212] (a) providing an electrochemical system, the electrochemical system comprising: a first compartment; a second compartment; and a separation unit, the separation unit separating the first compartment and the second compartment, wherein the separation unit comprises (i) an anode, (ii) a cathode, and (iii) a membrane comprising a plurality of pores, wherein the plurality of pores allow fluid communication between the first compartment and the second compartment;

[0213] (b) introducing an electrolyte solution containing the carbonaceous material into the first compartment so that the electrolyte solution is in contact with the cathode, wherein the anode and the cathode are electrically connected to each other through the electrolyte solution;

[0214] (c) reducing the carbonaceous material in the electrolyte solution while applying a voltage between the cathode and the anode to produce the C1+ product, the C1+ product being directed to the second compartment through the plurality of pores; and

[0215] (d) recovering the C1+ product from the second compartment of the electrochemical system.

[0216] 25. The method of embodiment 24, wherein the cathode further comprises a catalyst.

[0217] 26. A method according to embodiment 25, wherein the catalyst is used to reduce the carbonaceous material in the electrolyte.

[0218] 27. A method according to embodiment 24, wherein the carbon-containing material includes carbon monoxide (CO) and / or carbon dioxide (CO2).

[0219] 28. The method of embodiment 24, wherein the electrolyte solution comprises aqueous species produced by the interaction of the carbonaceous material with water.

[0220] 29. The method of embodiment 28, wherein the aqueous substance comprises one or more members selected from bicarbonate ions, carbonate ions, and formate ions.

[0221] 30. The method of embodiment 24 further comprises, prior to (b), introducing the carbonaceous material into water using a gas contactor.

[0222] 31. The method of embodiment 24, wherein the membrane comprises one or more materials selected from the group consisting of carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene, and porous pyrolytic carbon.

[0223] 32. The method of embodiment 24, wherein the membrane further comprises a catalyst.

[0224] 33. A method according to embodiment 32, wherein the catalyst comprises metal nanoparticles.

[0225] 34. The method of embodiment 33, wherein the metal nanoparticles comprise a metal selected from the group consisting of copper, nickel, platinum, iridium, ruthenium, palladium, tin, silver, and gold.

[0226] 35. The method of embodiment 32, wherein the catalyst is N-doped.

[0227] 36. The method of embodiment 24, wherein the voltage is applied by a power source comprising a renewable power source.

[0228] 37. A method according to embodiment 36, wherein the renewable power source includes one or more members selected from photovoltaic power generation, wind power generation, geothermal power generation, hydroelectric power generation, tidal power generation and nuclear power generation.

[0229] 38. The method of embodiment 24 further comprises introducing the carbonaceous material into the electrochemical system by using an electrochemically generated hydroxide.

[0230] 39. The method of embodiment 24, wherein the cathode operates at a temperature of about 10° Celsius (C) to 40°C.

[0231] 40. The method of embodiment 24, wherein the C1+ product is recovered from the electrochemical reduction system in the absence of a distillation unit.

[0232] 41. The method of embodiment 24, wherein the electrochemical system further comprises an ion exchange membrane.

[0233] 42. A method according to embodiment 24, wherein the C1+ product is recovered from the electrochemical reduction system with a single-pass selectivity of at least about 70%.

[0234] 43. A method according to embodiment 24, wherein the cathode comprises pores having a pore size no greater than about 5 microns.

[0235] 44. A method according to embodiment 24, wherein the C1+ product comprises one or more members selected from methanol, ethanol, propanol and butanol.

[0236] 45. A method according to embodiment 24, wherein the average cross-sectional dimension of the pores does not exceed about 5 microns.

[0237] 46. ​​A method according to embodiment 45, wherein the average cross-sectional dimension is no more than about 500 nanometers.

[0238] 47. A method according to embodiment 46, wherein the average cross-sectional dimension is no more than about 100 nanometers.

[0239] 48. A method according to embodiment 47, wherein the average cross-sectional dimension does not exceed about 50 nanometers.

[0240] 49. A method according to embodiment 48, wherein the average cross-sectional dimension does not exceed about 10 nanometers.

[0241] 50. A method according to embodiment 49, wherein the average cross-sectional dimension does not exceed about 5 nanometers.

[0242] 51. A method of producing a carbon product (C1+ product) containing one or more carbon atoms using a carbonaceous material, the method comprising:

[0243] (a) providing an electrochemical system, the electrochemical system comprising: a first compartment; a second compartment, and a separation unit, the separation unit comprising (i) an anode, (ii) a cathode, and (iii) a membrane having a microstructure or a nanostructure including pores, wherein the cathode comprises a catalyst, wherein the separation unit separates the first compartment and the second compartment, and wherein the first compartment is in fluid communication with the second compartment through the pores;

[0244] (b) introducing an electrolyte solution containing the carbonaceous material into the first compartment so that the electrolyte solution is in contact with the cathode, wherein the anode and the cathode are electrically connected to each other through the electrolyte solution;

[0245] (c) reducing the carbonaceous material in the electrolyte solution using the catalyst while applying a voltage between the cathode and the anode to produce the C1+ product, which is directed to the second compartment through the pores; and

[0246] (d) recovering the C1+ product from the second compartment of the electrochemical system.

[0247] 52. A method according to embodiment 51, wherein the carbon-containing material includes carbon monoxide (CO) and / or carbon dioxide (CO2).

[0248] 53. A method according to embodiment 51, wherein the anode comprises a catalyst.

[0249] 54. The method of embodiment 51, wherein the electrolyte solution comprises aqueous species produced by the interaction of the carbonaceous material with water.

[0250] 55. The method of embodiment 54, wherein the aqueous substance comprises one or more members selected from bicarbonate ions, carbonate ions, and formate ions.

[0251] 56. The method of embodiment 51 further comprises, prior to (b), introducing the carbonaceous material into water using a gas contactor.

[0252] 57. A method according to embodiment 56, wherein the gas contactor comprises a membrane.

[0253] 58. The method of embodiment 57, wherein the membrane comprises one or more nanomaterials selected from carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene, and porous pyrolytic carbon.

[0254] 59. A method according to embodiment 51, wherein the microstructured or nanostructured film comprises one or more materials selected from carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene and porous pyrolytic carbon.

[0255] 60. The method of embodiment 59, wherein the microstructured or nanostructured film further comprises a catalyst.

[0256] 61. The method of embodiment 60, wherein the catalyst comprises metal nanoparticles.

[0257] 62. The method of embodiment 61, wherein the metal nanoparticles comprise a metal selected from the group consisting of copper, nickel, platinum, iridium, ruthenium, palladium, tin, silver, and gold.

[0258] 63. The method of embodiment 51, wherein the catalyst is N-doped.

[0259] 64. A method according to embodiment 51, wherein the voltage is applied by a power source including a renewable power source.

[0260] 65. A method according to embodiment 64, wherein the renewable power source includes one or more members selected from photovoltaic power generation, wind power generation, geothermal power generation, hydroelectric power generation, tidal power generation and nuclear power generation.

[0261] 66. The method of embodiment 51 further comprises introducing the carbonaceous material into the electrochemical system by using an electrochemically generated hydroxide.

[0262] 67. A method according to embodiment 51, wherein the cathode operates at a temperature of about 10° Celsius (C) to 40°C.

[0263] 68. A method according to embodiment 51, wherein the C1+ product is recovered from the electrochemical reduction system in the absence of a distillation unit.

[0264] 69. The method of embodiment 51, wherein the electrochemical system further comprises an ion exchange membrane configured to minimize a distance between the cathode and the anode.

[0265] 70. The method of embodiment 51, wherein the C1+ product is recovered from the electrochemical reduction system with a single-pass selectivity of at least about 70%.

[0266] 71. The method of embodiment 51, wherein the cathode comprises pores having a pore size no greater than about 5 microns.

[0267] 72. A method according to embodiment 51, wherein the C1+ product comprises one or more members selected from methanol, ethanol, propanol and butanol.

[0268] 73. A method according to embodiment 51, wherein the average cross-sectional dimension of the pores does not exceed about 5 microns.

[0269] 74. A method according to embodiment 73, wherein the average cross-sectional dimension does not exceed about 500 nanometers.

[0270] 75. A method according to embodiment 74, wherein the average cross-sectional dimension of the pores is no more than about 100 nanometers.

[0271] 76. A method according to embodiment 75, wherein the average cross-sectional dimension of the pores does not exceed about 50 nanometers.

[0272] 77. A method according to embodiment 76, wherein the average cross-sectional dimension of the pores does not exceed about 10 nanometers.

[0273] 78. A method according to embodiment 77, wherein the average cross-sectional dimension of the pores does not exceed about 5 nanometers.

[0274] Although preferred embodiments of the present invention have been shown and described herein, it will be apparent to those skilled in the art that these embodiments are provided by way of example only. This does not mean that the present invention is limited by the specific embodiments provided in this specification. Although the present invention has been described with reference to the foregoing description, the description and explanation of the embodiments herein are not intended to be interpreted as limiting. Those skilled in the art will now think of various changes, modifications and substitutions without departing from the present invention. In addition, it should be understood that all aspects of the present invention are not limited to the specific description, configuration or relative proportion proposed herein according to various conditions and variables. It should be understood that various alternatives to the embodiments of the present invention described herein can be adopted in the process of practicing the present invention. Therefore, it is expected that the present invention should also cover any such alternatives, modifications, changes or equivalents. The following claims are intended to define the scope of the present invention, thereby covering the methods and structures and their equivalents within the scope of these claims.

Claims

1. A system for producing a carbon product (C1+ product) containing one or more carbon atoms, comprising: First compartment; Second compartment; as well as a separation unit that separates the first compartment and the second compartment, wherein the separation unit comprises (i) an anode, (ii) a cathode, and (iii) a membrane comprising a plurality of pores, wherein the plurality of pores are configured to allow fluid communication between the first compartment and the second compartment, wherein the cathode and the anode are configured to reduce the carbonaceous material to the C1+ product in the first compartment while a voltage is applied between the cathode and the anode, and Wherein the plurality of pores are configured to direct the C1+ product from the first compartment to the second compartment.

2. The system of claim 1, further comprising a gas contactor in fluid communication with the first compartment, wherein the gas contactor is configured to contact the carbonaceous material with water to produce a solution comprising the carbonaceous material.

3. The system of claim 1, wherein the membrane comprises one or more materials selected from the group consisting of carbon nanotubes, carbon nanospheres, carbon nanoonions, graphene, and porous pyrolytic carbon.

4. The system of claim 1, wherein the cathode further comprises a catalyst.

5. The system of claim 4, wherein the catalyst comprises metal nanoparticles.

6. The system of claim 5, wherein the metal nanoparticles comprise a metal selected from the group consisting of copper, nickel, platinum, iridium, ruthenium, palladium, tin, silver, and gold.

7. The system of claim 4, wherein the catalyst is N-doped.

8. The system of claim 1, further comprising a voltage source configured to supply the voltage.

9. A method for producing a carbon product (C1+ product) containing one or more carbon atoms using a carbonaceous material, the method comprising: (a) providing an electrochemical system, the electrochemical system comprising: a first compartment; a second compartment; and a separation unit, the separation unit separating the first compartment and the second compartment, wherein the separation unit comprises (i) an anode, (ii) a cathode, and (iii) a membrane comprising a plurality of pores, wherein the plurality of pores allow fluid communication between the first compartment and the second compartment; (b) introducing an electrolyte solution containing the carbonaceous material into the first compartment so that the electrolyte solution is in contact with the cathode, wherein the anode and the cathode are electrically connected to each other through the electrolyte solution; (c) reducing the carbonaceous material in the electrolyte solution while applying a voltage between the cathode and the anode to produce the C1+ product, the C1+ product being directed to the second compartment through the plurality of pores; and (d) recovering the C1+ product from the second compartment of the electrochemical system.

10. A method for producing a carbon product (C1+ product) containing one or more carbon atoms using a carbonaceous material, the method comprising: (a) providing an electrochemical system, the electrochemical system comprising: a first compartment; a second compartment, and a separation unit, the separation unit comprising (i) an anode, (ii) a cathode, and (iii) a membrane having a microstructure or a nanostructure including pores, wherein the cathode comprises a catalyst, wherein the separation unit separates the first compartment and the second compartment, and wherein the first compartment is in fluid communication with the second compartment through the pores; (b) introducing an electrolyte solution containing the carbonaceous material into the first compartment so that the electrolyte solution is in contact with the cathode, wherein the anode and the cathode are electrically connected to each other through the electrolyte solution; (c) reducing the carbonaceous material in the electrolyte solution using the catalyst while applying a voltage between the cathode and the anode to produce the C1+ product, which is directed to the second compartment through the pores; and (d) recovering the C1+ product from the second compartment of the electrochemical system.

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