Systems and methods for producing synthetic fuels and platform chemicals from carbon-based fuel combustion sources - Patents.com

Abstract

A system for producing synthetic fuels from carbon-based fuel combustion flue gas is provided. A system for producing platform chemicals from carbon-based fuel combustion flue gas is also provided. A method for producing platform chemicals from carbon-based fuel combustion flue gas is also provided.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 305,199, entitled “CO2 Separation from Combustion Streams and Conversion of CO2 Separation from Combustion Streams,” filed January 31, 2022, which is incorporated by reference in its entirety.

[0002] The present disclosure relates to the separation of CO2 from combustion streams and the purification and conversion of CO2 to synthetic fuels and / or platform chemicals. The systems and processes of the present disclosure also provide for the use of synthetic fuels and / or platform chemicals as or from CO2 sequestration materials. [Background technology]

[0003] CO2 is typically produced in significant quantities as a product of combustion of air with carbonaceous fuels. The combustion products are not pure CO2, but rather a mixture of other compounds. These other compounds may include global warming compounds, but are not present at the levels of concentration of CO2. Separating CO2 from these other compounds, sequestering the separated CO2, and / or using CO2 to form other compounds present significant challenges. Increasing reliance on fossil fuels for energy has led to an alarming rise in atmospheric CO2 concentrations, which currently exceed 406 PPM. The International Energy Agency reports that anthropogenic emissions of CO2 from the burning of fossil fuels account for the largest portion of overall emissions. Growing concerns about climate change have motivated international efforts to implement regulations to combat global warming, as agreed at the 2015 Paris Climate Change Conference. The consensus is to reduce CO2 emissions to less than 1000 GT, which corresponds to an atmospheric temperature increase of less than 2°C. This challenging goal can only be achieved by transitioning to greener and more efficient technologies, including the large-scale incorporation of renewable energy sources. Moreover, carbon capture (CCS) and sequestration is now a proven technology that could contribute nearly 12% of the Paris target. The present disclosure provides systems and methods that overcome some of these challenges. Summary of the Invention

[0004] A system for producing synthetic fuel from carbon-based fuel combustion flue gas is provided. The system may include a carbon-based fuel combustion source, one or more components configured to receive the flue gas from the carbon-based fuel combustion source and configured to dry, separate N2 from CO2, and purify the CO2 to produce purified CO2, and a synthetic fuel production component configured to produce synthetic fuel from the purified CO2.

[0005] A system for generating platform chemicals from carbon-based fuel combustion flue gas is also provided. The system can include a carbon-based fuel combustion source, one or more components configured to receive the flue gas from the carbon-based fuel combustion source and configured to dry, separate N2 from CO2, and purify the CO2 to generate purified CO2, and a platform generation component configured to generate at least one platform chemical from the purified CO2.

[0006] A method for producing platform chemicals from carbon-based fuel combustion flue gas is provided, the method including receiving at least a portion of the flue gas from a carbon-based fuel combustion source, one or more of drying, separating N2 from CO2, and / or purifying the flue gas source to provide purified CO2, and producing at least one platform chemical from the purified CO2. [Brief description of the drawings]

[0007] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings.

[0008] [Figure 1] FIG. 1 illustrates a system and process for producing synthetic fuels according to one embodiment of the present disclosure. [Diagram 2] FIG. 1 illustrates a CO2 electrolysis cell according to one embodiment of the present disclosure. [Diagram 3] FIG. 1 illustrates an electrolysis system and process for producing and purifying CO according to one embodiment of the present disclosure. [Figure 4] FIG. 1 illustrates an electrolysis system and downstream process for forming synthetic fuel from CO2 according to one embodiment of the present disclosure. [Diagram 5] FIG. 1 illustrates a CO2 electrolysis cell according to one embodiment of the present disclosure. [Figure 6] FIG. 1 illustrates a CO2 electrolysis cell according to one embodiment of the present disclosure. [Figure 7]FIG. 1 illustrates a CO2 electrolysis cell according to one embodiment of the present disclosure. [Figure 8] FIG. 1 illustrates a system and process for forming platform molecules from CO 2 according to one embodiment of the present disclosure. [Figure 9] FIG. 1 illustrates a system and process for forming synthetic fuel from CO2 according to one embodiment of the present disclosure. [Figure 10] FIG. 1 illustrates a system and process for forming an exemplary synthetic fuel from CO2 according to one embodiment of the present disclosure. [Figure 11] FIG. 1 illustrates a system and process for forming another exemplary synthetic fuel from CO2 according to an embodiment of the present disclosure. [Figure 12] FIG. 1 illustrates a system and process for forming another exemplary synthetic fuel from CO2 according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Electrolysis of CO2 can be used to provide synthetic fuels and product starting materials, eliminating reliance on traditional fossil fuels while simultaneously removing significant global warming molecules from the atmosphere. Carbon monoxide from the electrolysis of CO2 captured from combustion, along with hydrogen (which can be provided renewable), can be processed to provide synthetic fuels and high value chemicals consistent with global goals in sustainability.

[0010] Separating, purifying, liquefying, and / or storing CO2 from building flue gases is disclosed in U.S. Patent Application Serial No. 16 / 862,006, entitled "Building Emission Processing and / or Sequestration Systems and Methods," U.S. Patent Application Publication No. 2020 / 0340665, published October 29, 2020. These systems and processes can be improved to include methods of CO2 conversion for downstream processing purposes into starting materials such as value-added synthetic fuels and platform chemicals. This can include direct conversion of CO2 and renewable hydrogen to liquid or gaseous products, or indirect conversion of CO2 to CO and blending with renewable hydrogen, known as "renewable syngas" (xCO+yH2).

[0011] An embodiment of the disclosed system and method is described with reference to Figures 1-12. Referring initially to Figure 1, an overall schematic synthetic fuel production process 10 is shown, which incorporates portions of U.S. Patent Application Serial No. 16 / 862,006, entitled "Building Emission Processing and / or Sequestration Systems and Methods," U.S. Patent Application Publication No. 2020 / 0340665, published October 29, 2020. According to an exemplary embodiment, the combustion may be from a residential, commercial, or industrial process, and flue gas during combustion is produced. The flue gas may be processed according to the above-referenced patent application to form a stream 12 of CO2. This stream 12 may have a specific CO2 concentration minimum and a specific water maximum. The CO2 may be reacted with H2 to form a synthetic fuel 14.

[0012] Synthetic fuels can be any form of fuel derived from captured CO2 and renewable H2 and can be utilized to generate energy. These synthetic fuels can typically be processed from syngas (carbon monoxide and hydrogen) to produce both oxygenated and non-oxygenated carbon compounds.

[0013] Referring now to Figure 2, a detailed diagram of solid oxide electrolysis is shown. Utilizing DC electrical energy and a solid electrolyte, CO2 can be chemically reduced to CO and O2 in a solid oxide electrolysis cell.

[0014] The SOEC cell and method of Figure 2 has a Technology Readiness Level (TRL) of 8, while other cells and methods described herein range from TRL=1 to TRL=4. Figure 2 shows a high temperature solid oxide electrochemical cell (SOEC) for the dry conversion of carbon dioxide to carbon monoxide and oxygen. The SOEC converts oxygen ions (O -- The ceramic electrolyte used transports ionic conductivity, which generally increases exponentially with temperature.

[0015] Commonly used electrolytes include, but are not limited to, stabilized zirconia (including yttria and scandia) and / or doped ceria (including gadolinia and samaria). Two electrodes, the anode and the cathode, are in contact with the solid electrolyte. The electrodes are usually a composite of nickel, which provides both electrical conductivity and catalytic activity. This particular cell can be operated endothermally and maintained at a suitable temperature. The faradaic efficiency of CO production in this cell can approach 100%. 750 mA / cm 2 Current densities above 1000 kcal / s are common. The electrochemical equation for electrolysis is: anode 1 / 2 O2 -- >> 1 / 2 O2+2e - Cathode CO2+2e - >>CO+ 1 / 2 O2 --

[0016] The electrons may be provided by an external power source, preferably a renewable power source.

[0017] The enthalpy of formation of carbon monoxide under standard conditions is -110 kJ / mol. In the above overall reaction, CO2>>CO+ 1 / 2 O2. Therefore the enthalpy applied is -393 >> -110 -0, or delta H to the right, is 283 kj / mol, which is the total energy required to produce 1 mole of carbon monoxide.

[0018] If the CO2 is converted completely to electricity, this electrolysis energy can be expressed in units of kWhr per cubic foot of CO and in units of kWhr per standard cubic meter of CO, as shown below: 283kj / mol CO=0.0786kWhr / mol CO=0.0994kWhr / cu ft.CO=3.39kWhr / Nm 3 CO(IDEAL)

[0019] Therefore, at an estimated electrolysis efficiency of 60% (realistic), 5.65kWhr of electrical energy would be required to produce a standard cubic meter of CO. (1Nm 3 of gas is equivalent to 34 standard cubic feet.)

[0020] However, the total energy delta H can be made up of a combination of both heat and electricity, if desired.

[0021] The thermal energy required to heat the incoming gas is different from the heat of reaction mentioned above. The disclosed system and process desirably transfers heat from the output gas to the input gas to increase the overall efficiency of the electrolysis. This design also utilizes Joule heating from ionic conduction through the electrolyte.

[0022] The electrochemical cell shown in FIG. 2 typically operates at temperatures in the range of 500°C to 1000°C.

[0023] From Figure 2, it can be seen that the output stream may contain some small percentage of unconverted CO2. Therefore, in a practical design, a purification section is added to separate the CO2 for feedback to the process, producing a high purity output CO stream. According to Figure 3, the SOEC electrolysis products of CO and CO2 can be further purified to high purity CO while feeding the CO2 back to the SOEC cell input. Thus, the CO2 is not released into the atmosphere.

[0024] 4, an exemplary system and process for converting CO2 to CO and syngas, and then generally forming a synthetic fuel, is shown. As shown, in electrolysis component 30, CO can be produced. In component 32, H2 can be added to the CO to form syngas.

[0025] According to Figure 4, CO2 can be fed from the process of Figure 1 in, for example, two or more streams, but at least the CO2 can be fed to the solid oxide electrochemical cell in substantially pure form. Electricity can be provided to the cell, and the CO2 can be reduced to concentrated CO with a small amount of CO2, which is provided to final CO gas purification to form a CO product, which can be treated with hydrogen to make synthetic fuels. Excess CO2 separated during CO purification can be recycled to the solid oxide electrochemical cell input.

[0026] In addition to those shown in Figure 2, some additional CO2 to CO2 electrolysis cells are shown in Figures 5-7. These are as follows: Figure 5 shows molten carbonate electrolysis, Figure 6 shows low-temperature electrolysis, and Figure 7 shows low-temperature electrolysis with gas diffusion. These electrolysis components may share some functional elements, such as two separate electrodes in contact with an electrolyte (solid or liquid). These electrolytes are associated with the ions they conduct, e.g., protons, hydroxide ions, oxide ions, carbonate ions, and bicarbonate ions. With applied electricity, reduction occurs at the negative potential cathode and oxidation occurs at the positive potential anode.

[0027] Referring now to FIG. 5, an electrochemical cell and method is shown in which the electrolyte is a carbonate melt similar to that of a Molten Carbonate Electrolysis Cell (MCEC) operating at 500°C-800°C. The components of the MCEC can include a Li2O / LiCO3 molten electrolyte in combination with a titanium cathode and a graphite anode. The Li2CO3 can be electrochemically converted to Li2O at the cathode, thus increasing the oxide melt ratio to incorporate more CO2 concentrated on top of the melt into the mix. The MCEC can provide a high purity CO output and / or utilize a CO2 stream diluted with some water vapor. The faradaic efficiency of CO production in this cell can approach 100%. 3A / cm 2 Current densities as high as 1000 Å have been demonstrated in polarization measurements.

[0028] Referring now to FIG. 6, the electrochemical cell and method are shown as a low-temperature electrochemical cell (low-temperature electrolysis H-cell) in which reduction and oxidation occur in liquid electrolyte solutions, catholyte and anolyte, respectively. The electrolyte can include a solid membrane partition, such as a proton exchange membrane (PEM) or an anion exchange membrane (AEM), and an aqueous solution of KHCO3, or a combination. Most low-temperature electrolysis cells operate under alkaline conditions. Each cell uses an H-cell configuration, whereby both electrodes are immersed in the respective electrolyte solutions (anolyte and catholyte). FIG. 6 shows the configuration with an anion exchange membrane (AEM) partition. The anode catalyst is typically IrO2, and the cathode catalyst is gold and silver nanoparticles with appropriate support materials for selectivity and stability (i.e., carbon nanotubes).

[0029] Referring now to FIG. 7, an electrochemical cell and method is shown as a low-temperature electrochemical cell with gas diffusion where reduction occurs in an aqueous solution. This cell differs from the H-cell of FIG. 6 by adding a gas diffusion electrode to overcome the mass balance limitations. These cells may have beneficial applications in direct CO2 to chemical production such as formic acid, ethylene, ethanol, etc. Additionally, CO pathways to important chemicals may also be relevant to low-temperature electrolysis cells. None of these pathways are possible with high-temperature electrochemical cells.

[0030] 8-12, systems and processes are provided for utilizing CO2 separated and purified from combustion sources as a carbon source for synthetic fuels as well as many other carbon-based materials such as platform chemicals and application-specific chemical reagents. FIG. 8 shows a general system and process for preparing platform molecules and / or mixtures from CO2. For example, CO2 obtained from flue gas can be processed according to the techniques referenced herein to form CH3OH, low molecular weight hydrocarbons, formic acid, and / or synthesis gas.

[0031] FIG. 9 is just one example providing the selective hydrogenation of CO to form methanol, a general platform chemical, which can be converted into many other application specific reagents including synthetic fuels and polymer precursors.

[0032] FIG. 10 provides an exemplary system and process for the direct conversion of CO2 to low molecular weight hydrocarbons via biosynthesis, which can form the starting material for a myriad of industrial compounds traditionally provided by the petroleum industry.

[0033] FIG. 11 provides an exemplary system and process for converting CO2 via electrochemical reduction to formate ions and finally to formic acid, another valuable oxygenated hydrocarbon and sustainable green platform chemical that is also used as a hydrogen carrier.

[0034] Additionally, FIG. 12 provides an exemplary system and process for converting CO2 to synthesis gas via dry reforming using hydrogen resulting in the excess production of methane (CH4) or water.

[0035] Beyond sequestration, there is a need to produce future "sustainable" fuels from captured CO2 and green hydrogen. These synthetic fuels can be carbon neutral and can significantly reduce the need for traditional fossil fuels, fossil fuel processing, and / or fossil fuel by-products. In addition to synthetic fuels, high-value platform chemicals (low molecular weight hydrocarbons, methanol, and / or formic acid) can also be produced from captured CO2, green hydrogen, and in certain cases, formic acid.

[0036] As described herein, electrochemical and direct catalytic reactions can be used to form these synthetic fuels and platform chemicals. Energy is required, so renewable energy sources such as solar, wind, tidal, and geothermal are preferred. Candidate processes therefore include electrolysis, electroreduction, photocatalysis, selective hydrogenation, and biocatalytic conversion of CO2. Since syngas (xCO+yH2) can be used as a reagent to produce high molecular weight (C4-C16) fuels via the demonstrated Fischer Tropsch process, electrolysis of CO2 to produce CO would therefore be the preferred CO2 front-end conversion method. Highly efficient CO2 conversion methods require novel combinations of processes and materials.

[0037] Additionally, a relatively new branch of materials science called lytic chemistry has been shown to produce robust molecular framework materials with enormous surface areas (up to 10,000 square meters / gram) with large amounts of uniform pore sites, greatly exceeding the capacity of natural and synthetic silicate materials common today. The design of these framework materials offers enormous possibilities for chemistry for nodes, linkers, and interconnects. Furthermore, these materials can be geometrically optimized and / or specifically functionalized before or after synthesis to impart desired properties, including improved catalytic properties.

[0038] Framework materials are envisioned to revolutionize solid adsorption gas separation and / or future conversion processes. The desirable properties of candidate molecular framework materials for CO2 separation from flue gas are selectivity, capacity, durability, scalability, hydrophobicity, physisorption, and stable cyclic operation at temperatures up to 150 °C and pressures from 10 mbar to 7 bar. Furthermore, pores within the framework materials can be configured for catalytic, enzymatic, and ion transport functions. Framework materials can also be included in structured mixed matrix membranes (MMMs). From these perspectives, engineered molecular framework materials become essential for highly efficient CO2 separation and conversion processes.

Claims

1. 1. A system for producing synthetic fuel from carbon-based fuel combustion flue gas, comprising: a carbon-based fuel combustion source; One or more components configured to receive flue gas from the carbon-based fuel combustion source, the one or more components configured to dry and ２ From N ２ and CO ２ is purified to produce purified CO ２ one or more components configured to generate The purified CO ２ a synthetic fuel production component configured to produce a synthetic fuel from the A system comprising:

2. The system of claim 1 , wherein the synthetic fuel production component comprises a solid oxide electrochemical cell.

3. The system of claim 2 , wherein the solid oxide electrochemical cell comprises a solid electrolyte.

4. The system of claim 2 , wherein the solid oxide electrochemical cell comprises a molten electrolyte.

5. The system of claim 2 , wherein the synthetic fuel production component further comprises a CO refinery component.

6. The system of claim 2 , wherein the synthetic fuel production component further comprises a syngas production component.

7. 1. A system for producing platform chemicals from carbon-based fuel combustion flue gas, comprising: a carbon-based fuel combustion source; One or more components configured to receive flue gas from the carbon-based fuel combustion source, the one or more components configured to dry and ２ From N ２ and CO ２ is purified to produce purified CO ２ one or more components configured to generate The purified CO ２ a platform generation component configured to generate at least one platform chemical from A system comprising:

8. The platform chemicals are syngas, CH ３ 8. The system of claim 7, wherein the OH, LMWHC, and / or formic acid are one or more of:

9. The system of claim 8 , wherein the platform generation component is a reduction cell.

10. The platform chemicals are ３ 10. The system of claim 9, wherein the acid is one or both of OH or formic acid.

11. The system of claim 8 , wherein the platform production component is a biosynthetic cell and the platform chemical is a LMWHC.

12. The system of claim 7 , wherein the platform generation component is configured as a dry reforming component and the platform chemical is syngas.

13. 1. A method for producing platform chemicals from carbon-based fuel combustion flue gas, comprising: receiving at least a portion of the flue gas from a carbon-based fuel combustion source; Purified CO ２ drying to provide N ２ CO ２ and / or purifying said flue gas source; The purified CO ２ generating at least one platform chemical from A method comprising:

14. The method of claim 13 , wherein the platform chemical is a synthetic fuel.

15. 15. The method of claim 14, wherein the generating comprises electrolysis using one or more of a solid electrolyte, a molten electrolyte, low temperature electrolysis, and / or low temperature electrolysis with gas diffusion electrodes.

16. 16. The method of claim 15, wherein the electrolysis produces CO.

17. The CO is converted into H ２ 20. The method of claim 16, further comprising mixing with a gas to form a synthesis gas.

18. The step of generating at least one platform chemical comprises: ２ is reduced to CH ３ The method of claim 13 comprising forming OH.

19. The step of generating at least one platform chemical comprises: ２ The method of claim 13, comprising forming the LMWHC from the biosynthesis of

20. The step of generating at least one platform chemical comprises: ２ to form formic acid.

21. The step of generating at least one platform chemical comprises: ２ The method of claim 13, comprising dry modifying the

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