Bimetallic Copper Catalyst Composition for Stable C2+ CO2 Electrolysis
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Solution Overview
Problem
Existing copper-based electrocatalysts for converting CO2 into C2+ products, such as ethylene, suffer from low selectivity and stability, requiring complex manufacturing processes.
Innovation Solution
A catalyst comprising copper and specific metals like yttrium, zinc, lanthanum, or gadolinium, with a molar ratio of 100:1 to 100:10, is used to enhance CO2 conversion to ethylene by maintaining strong CO binding while allowing dimerization, achieved through a simple co-precipitation method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If copper catalysts are used for CO2 reduction to C2+ products, then catalytic activity is achieved, but selectivity and stability are low
Solution Approach 1:
The patent applies composite materials by combining copper with specific metals (Zn, Ga, In, Al) to create bimetallic catalysts. This composite approach allows the catalyst to benefit from both copper's inherent CO2 reduction activity and the stabilizing effects of the alloying metals, thereby improving both selectivity for C2+ products and long-term stability under electrochemical conditions.
Solution Approach 2:
The patent employs local quality by creating specific metal distributions within the catalyst structure through controlled co-precipitation processes. The alloying metals are strategically positioned within the copper matrix to locally enhance stability and selectivity properties, rather than uniformly distributing all catalyst properties throughout the material.
2Productivity
If copper catalysts are used for CO2 reduction, then CO2 conversion occurs, but selectivity for desired C2+ products is low
Solution Approach 1:
The patent uses local quality by creating specific metal distributions within the catalyst structure through controlled co-precipitation processes. The alloying metals are strategically positioned within the copper matrix to locally enhance stability and selectivity properties, rather than uniformly distributing all catalyst properties throughout the material.
Solution Approach 2:
The patent applies parameter changes by systematically varying the composition ratios of copper to alloying metals (Zn, Ga, In, Al) and controlling co-precipitation parameters such as pH, temperature, and mixing conditions. These parameter adjustments optimize the catalyst's selectivity for C2+ products while maintaining high CO2 conversion rates.
3Reliability
If complex manufacturing processes are used to improve catalyst performance, then selectivity and stability improve, but ease of manufacture decreases
Solution Approach 1:
The patent applies preliminary action by performing co-precipitation of the bimetallic catalyst particles before final catalyst formation and electrode fabrication. This preliminary synthesis step creates the stable bimetallic structure in advance, simplifying subsequent manufacturing steps and eliminating the need for complex post-processing treatments to achieve catalyst stability.
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
The modified copper catalysts demonstrate high selectivity and stability for ethylene production, with Faradaic efficiencies up to 55.7% under electrochemical conditions.
Implementation Method 1
Copper catalysts for the electrochemical conversion of carbon dioxide or carbon monoxide to C2+ products
Implementation Method 2
An electrolyser which uses electricity to drive chemical reactions by supplying electrons to the substrate directly
Data Source
AI summary
A catalyst for the electrochemical conversion of carbon dioxide or carbon monoxide to a C2+ product. The catalyst comprises copper and a metal (M) selected from the group consisting of: yttrium (Y), zinc (Zn), lanthanum (La) and gadolinium (Gd); wherein the molar ratio of Cu:M is from 100:1 to 100:10. The catalyst has particular use in a gas diffusion electrode, a catalyst coated membrane of an electrolyser.