Alkyl Formate Decomposition for Low-Temperature Carbon Monoxide Production
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Solution Overview
Problem
Current methods for producing carbon monoxide (CO) are inefficient, require high temperatures and pressures, and rely on costly or toxic catalysts, limiting their economic and environmental viability, especially in achieving high CO conversion rates and selectivity.
Innovation Solution
A method using an alkyl formate of formula H—COOR, where R is an alkyl with 1 to 12 carbon atoms, in contact with a catalyst such as alcoholates or nitrogenous bases with high pKa values, in a mixture of polar and aprotic solvents at temperatures below 35°C, facilitating efficient CO production without the need for expensive or toxic metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional methods (partial oxidation of hydrocarbons or gasification) are used to produce CO, then CO can be produced on industrial scale, but high temperatures (1100-1500°C) and high pressures (60-80 bar) are required, leading to multiple secondary reactions and requiring purification
Solution Approach 1:
The invention changes the key parameters of the reaction system by using formic acid derivatives as reactants instead of hydrocarbons, enabling CO production at mild temperatures (20-100°C) and atmospheric pressure, thus eliminating the need for high temperature and pressure conditions while maintaining industrial scalability
Solution Approach 2:
The invention extracts the carbon monoxide production function from the complex high-temperature hydrocarbon oxidation process and isolates it into a simpler formic acid derivative decomposition reaction, separating the CO generation step from the problematic secondary reactions that occur at high temperatures
2Productivity
If reverse water gas shift reaction is used to produce CO, then CO can be produced from CO2 and H2, but the reaction is thermodynamically unfavourable with low equilibrium constant, requiring high temperatures (750°C) or complex recycling systems
Solution Approach 1:
Instead of using the thermodynamically unfavourable reverse water gas shift reaction (CO2 + H2 → CO), the invention inverts the approach by using formic acid derivatives that naturally decompose to release CO under mild conditions, avoiding the need for high temperatures or hydrogen recycling systems
Solution Approach 2:
The invention uses formic acid derivatives as disposable reactants that decompose completely to release CO, eliminating the need for catalyst recycling or complex equilibrium management required in the reverse water gas shift process
3Temperature
If electrochemical reduction of CO2 is used to produce CO, then CO can be produced at ambient temperature, but slow reaction kinetics lead to overvoltage >1.0 V, considerably increasing energy cost
Solution Approach 1:
The invention replaces the electrochemical reduction process with a chemical decomposition process of formic acid derivatives, substituting electrical energy input with chemical energy stored in the formic acid bonds, thereby eliminating overvoltage losses and reducing energy costs while maintaining ambient temperature operation
4Productivity
If metal catalysts (copper, nickel, zinc) are used to produce CO from formic acid, then CO production can be catalysed, but the catalysts are toxic and the process requires temperatures above 100°C
Solution Approach 1:
The invention uses organic catalysts based on readily available compounds like quaternary ammonium salts and phosphines, replacing toxic heavy metal catalysts. These organic catalysts are less toxic, more environmentally friendly, and enable CO production at lower temperatures without the harmful effects of metal contamination
5Ease of manufacture
If formic acid is used directly to produce CO, then CO can be produced from a simple reactant, but the conversion efficiency is low and additional catalysts are required
Solution Approach 1:
The invention uses composite organic catalyst systems combining quaternary ammonium salts with phosphines or other organic compounds, creating synergistic catalytic effects that dramatically improve formic acid derivative decomposition efficiency and CO conversion rates while maintaining simplicity of reactant handling
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves high CO conversion rates with a catalyst that is inexpensive and low in toxicity, producing CO with a percentage of 46.7% in the molecule, surpassing existing methods, and allows for mild reaction conditions, reducing energy costs and environmental impact.
Implementation Method 1
making use of a derivative of formic acid, in particular an alkyl formate... in contact with a catalyst such as alcoholates or nitrogenous bases
Data Source
AI summary
The present invention concerns a method of production for carbon monoxide using a derivative of formic acid, in particular an alkyl formate.It also concerns a method chosen from among, the method of production of methanol, the method of production of acetic acid (Monsanto and Cativa methods), the method of hydroformylation of olefins (oxo and aldox method, the method of production of hydrocarbons (Fischer-Tropsch method), or the method of carbonylation of nickel (Mond method), comprising a step of production of carbon monoxide using an alkyl formate of formula (I) by the method according to the invention.It further concerns a “CO pump” or “CO liquid storage” method comprising a step of production of carbon monoxide using an alkyl formate of formula (I) according to the method of the invention.