Boron-Doped Copper Catalyst for CO2 Reduction

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Solution Overview

Problem

Existing catalyst systems for the electrochemical reduction of carbon dioxide (CO2) to multi-carbon compounds, such as C2 hydrocarbons, suffer from low selectivity and stability due to the prone reduction of Cu+ species to Cu0 under high reducing potentials, leading to inefficient production of desired products like ethylene and ethanol.

Innovation Solution

A boron-doped copper catalytic material with a porous dendritic morphology and variable boron concentration is used, where boron is introduced through methods like incipient wetness impregnation or combination with sodium borohydride, maintaining a stable Cu+ oxidation state and enhancing selectivity towards multi-carbon hydrocarbon production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If copper oxide species are used to introduce Cu+ sites, then selectivity for C2 products is improved, but stability deteriorates due to reduction of Cu+ to Cu0 under high reducing potentials

Engineering Contradiction:

Improveselectivity for C2 productsVSAvoidstability of Cu+ oxidation state

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Boron acts as an intermediary element that mediates between the copper sites and the reducing environment. The boron dopant creates a protective electronic environment around Cu+ sites, preventing their reduction to Cu0 while maintaining their catalytic activity for C2 product formation. This intermediary boron layer allows the Cu+ sites to function selectively without being compromised by the harsh reducing conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the electronic and chemical parameters of the copper catalyst by introducing boron dopants. This doping modifies the oxidation state stability, electronic structure, and surface properties of copper, enabling Cu+ sites to maintain their selective C2-producing capability while resisting reduction. The boron concentration and distribution are carefully controlled to optimize both selectivity and stability parameters.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high reducing potentials are applied to electrosynthesize C2 compounds, then productivity is improved, but harmful effects increase due to reduction of Cu+ to Cu0

Engineering Contradiction:

Improverate of C2 compound productionVSAvoidreduction of Cu+ to Cu0

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The boron dopant provides preliminary protection against the harmful reduction effect before it can occur. By pre-modifying the copper catalyst with boron, the Cu+ sites are stabilized in advance, creating resistance to reduction even before high reducing potentials are applied. This preliminary anti-action prevents the loss of active sites while allowing high productivity to be achieved.

Inventive Principle:

Principle #9Preliminary anti-action

3Ease of manufacture

If conventional copper catalysts are used, then ease of manufacture is maintained, but selectivity for multi-carbon products deteriorates due to low selectivity

Engineering Contradiction:

Improvesimplicity of catalyst preparationVSAvoidselectivity for multi-carbon products

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention applies local quality modification by introducing boron dopants at specific locations and concentrations within the copper catalyst structure. Rather than uniformly changing the entire catalyst, boron is selectively incorporated to create localized regions with enhanced C2 selectivity. This allows the bulk copper structure to remain simple while specific active sites gain improved selectivity properties.

Inventive Principle:

Principle #3Local quality

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 boron-doped copper catalyst system achieves high Faradaic efficiency for C2 products, exceeding 80% with stability over 40 hours, significantly improving upon previous CO2 reduction technologies by maintaining a stable Cu+ oxidation state and reducing C1 and C3 species generation.

Implementation Method 1

Doping Cu with B leads to electron transfer from Cu to B, resulting in a stable Cuδ+ oxidation state that is resistant to further reduction.

Methodology Applied

Scientific EffectElectron transfer:

Implementation Method 2

The boron-doped copper catalyst system achieves high Faradaic efficiency for C2 products, exceeding 80% with stability over 40 hours, significantly improving upon previous CO2 reduction technologies

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

boron is introduced through methods like incipient wetness impregnation or combination with sodium borohydride

Methodology Applied

Scientific EffectImpregnation:

Data Source

PatentUS11390959B2Boron-doped copper catalysts for efficient conversion of CO2 to multi-carbon hydrocarbons and associated methods

Publication Date: 2022.07.19 TOTALENERGIES ONETECH

AI summary

The invention relates to a catalyst system for catalyzing conversion of carbon dioxide into multi-carbon compounds comprising a boron-doped copper catalytic material and associated methods.