Catalyst-Ionomer System for Gas-Phase Electrolysis
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Solution Overview
Problem
Gas-phase electrolysis for upgrading greenhouse gases like CO2 to valuable fuels and feedstocks is limited by gas diffusion through liquid electrolytes, restricting the volume where gas reactants, catalyst active sites, and electrolyte ions coexist, and operating at elevated current densities is challenging.
Innovation Solution
A catalyst system comprising a catalytic material, such as metals like Cu, Ag, or Pd, combined with ion-conducting polymer layers that include hydrophilic and hydrophobic groups, forming differentiated gas and ion transport routes, enhancing gas diffusion and ion conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gas-phase electrolysis is performed using liquid electrolyte, then electrochemical reactions can occur at catalyst surface, but gas diffusion through liquid electrolyte is limited restricting the volume where gas reactants, catalyst active sites, and electrolyte ions coexist
Solution Approach 1:
The patent employs a composite catalyst-ionomer system where a catalytic metal or carbon material is combined with an ion-conducting polymer layer. This composite structure enables simultaneous presence of gas reactants (through hydrophobic domains), catalyst active sites (on the catalytic material surface), and electrolyte ions (through hydrophilic domains of the ionomer), effectively expanding the reactive volume and enhancing productivity.
Solution Approach 2:
The ion-conducting polymer layer exhibits local quality differentiation with hydrophilic and hydrophobic domains. The hydrophobic regions facilitate gas diffusion to catalyst sites while hydrophilic regions conduct electrolyte ions, creating localized functional zones that optimize the coexistence of all three components (gas, catalyst, ions) at specific locations within the catalyst structure.
2Power
If conventional catalysts are used for gas-phase electrolysis, then electrochemical reactions can proceed, but operating at elevated current densities is challenging
Solution Approach 1:
The composite catalyst-ionomer system combines the electrocatalytic activity of metal/carbon materials with the ion-conducting and gas-transport capabilities of the polymer layer. This composite structure enables stable operation at elevated current densities by maintaining efficient mass transport and ion conduction even under high-power conditions.
Solution Approach 2:
The ion-conducting polymer layer contains hydrophobic domains that create porous-like pathways for gas diffusion. This porous structure allows continuous supply of gas reactants to catalyst active sites at high current densities, maintaining operational stability and preventing mass transport limitations that would otherwise constrain power levels.
3Quantity of substance
If gas diffusion through liquid electrolyte is the primary transport mechanism, then mass transport can occur, but it restricts the volume where gas reactants, catalyst active sites, and electrolyte ions coexist
Solution Approach 1:
The patent creates a composite catalyst-ionomer system where the ion-conducting polymer provides hydrophobic domains for gas diffusion and hydrophilic domains for ion conduction. This composite architecture expands the effective volume where gas reactants, catalyst active sites, and electrolyte ions can coexist, directly enhancing productivity by providing more reactive sites throughout the catalyst structure.
Solution Approach 2:
The ion-conducting polymer layer adds a new dimensional aspect to the catalyst structure, creating a three-dimensional network of hydrophobic and hydrophilic domains. This dimensional expansion allows gas, ions, and catalyst sites to coexist throughout the volume of the polymer layer rather than being constrained to a two-dimensional interface, increasing the effective reactive volume.
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 catalyst system enables efficient gas-phase electrolysis at elevated current densities, increasing the productivity of multi-carbon products and reducing byproduct generation, such as hydrogen, while maintaining high energy efficiency.
Implementation Method 1
gas diffusion through the liquid electrolyte to the surface of the catalyst
Implementation Method 2
one or more ion-conducting polymer layers provided on the catalytic material and comprising an ion-conducting polymer that includes hydrophilic and hydrophobic groups
Implementation Method 3
catalytic material being or comprising a catalytic metal and/or carbon
Implementation Method 4
electrochemical CO2 reduction
Data Source
AI summary
The disclosure provides in its first aspect a catalyst system for gas-phase electrolysis of a reactant gas to form a product in an aqueous medium, the catalyst system comprising a catalytic material; an ion-conducting polymer layer provided on the catalytic material and comprising an ion-conducting polymer that includes hydrophilic and hydrophobic groups. Said catalyst system is remarkable in that the ion-conducting polymer layer has a thickness of 2 nm to 50 nm measured by transmission-electron microscopy. In its second aspect, the disclosure provides a method of manufacturing a catalyst system for gas-phase electrolysis of reactant gas to produce a product in an aqueous medium preferably according to the first aspect. The use of the catalyst system in accordance with the first aspect in the electrochemical production of at least one multi-carbon compound from a carbon-containing gas or of at least one product from a reactant gas is also disclosed.