CO and Chlor-Alkali Electrolyzer Integration for Energy Reduction
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Solution Overview
Problem
Carbon dioxide (CO2) capture and conversion technologies face challenges in industrial chemical production, including high energy costs and inefficiencies in separating valuable organic species from basic electrolyte streams in CO electrolyzers.
Innovation Solution
The integration of CO electrolyzers with chlor-alkali electrolyzers to create novel process chains for valorizing oxocarbons into hydrochloric acid, vinyl chloride, vinyl acetate, ethylene oxide, and other chemicals, while optimizing the operation of both electrolyzers to enhance efficiency and reduce energy demand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If basic electrolyte streams are used in CO electrolyzers to ensure effective conversion of CO into useful chemicals, then conversion efficiency is improved, but separation of valuable organic species from the basic stream becomes difficult and energy-intensive
Solution Approach 1:
The patent extracts the valuable organic species (carboxylates, alcohols, organic acids) from the basic electrolyte stream using a separate extraction unit. This allows the CO electrolyzer to maintain its basic electrolyte for high conversion efficiency while the extraction unit recovers the products, avoiding direct mixing and reducing subsequent separation energy requirements.
Solution Approach 2:
The patent introduces an intermediary extraction solvent or membrane system that facilitates the transfer of organic species from the basic electrolyte stream to a separate phase or compartment. This intermediary mechanism enables product recovery without requiring direct neutralization or evaporation of the entire basic stream, thereby reducing energy consumption.
2Productivity
If CO electrolyzers operate with basic electrolyte streams, then CO conversion into useful chemicals is effective, but additional energy is required to neutralize or evaporate the products from the stream
Solution Approach 1:
The patent extracts valuable organic species (carboxylates, alcohols, organic acids) from the basic electrolyte stream using a separate extraction unit. This allows the CO electrolyzer to maintain its basic electrolyte for high conversion efficiency while the extraction unit recovers the products, avoiding direct mixing and reducing subsequent separation energy requirements.
Solution Approach 2:
The patent changes the physical or chemical parameters of the electrolyte stream, such as pH adjustment or temperature control, to optimize the extraction efficiency of organic species. By modifying these parameters, the system minimizes the energy required for neutralization and evaporation while maintaining high chemical production rates.
3Productivity
If CO electrolyzers consume hydroxide in the electrolyte, then carboxylate and alcohol production increases, but electrolyte pH decreases leading to reduced electrolyzer performance
Solution Approach 1:
The patent implements a feedback mechanism where the electrolyte pH is continuously monitored, and base is automatically added to maintain the optimal pH range. This feedback control ensures that hydroxide consumption during carboxylate and alcohol production does not lead to pH depletion, thereby maintaining consistent electrolyzer performance and reliability.
Solution Approach 2:
The patent dynamically adjusts electrolyte composition parameters, particularly pH and hydroxide concentration, to optimize both product formation and electrolyzer performance. By maintaining the electrolyte in a strongly alkaline state through controlled base addition, the system ensures high energy efficiency of the anode and stable operation over time.
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 integration reduces the energy demand for producing valuable chemicals, addresses issues like hydroxide consumption and separation challenges, and provides a cost-effective means to valorize CO2, thereby enhancing the economic viability and environmental sustainability of the process.
Implementation Method 1
generating a volume of chlorine gas using a chlor-alkali electrolyzer, generating a volume of dihydrogen using a carbon monoxide electrolyzer
Implementation Method 2
CO electrolyzers offer numerous opportunities to valorize oxocarbons by either directly valorizing CO or by indirectly valorizing CO2 or other oxocarbons that are first converted into CO
Implementation Method 3
separating the volume of dihydrogen from an output stream of the carbon monoxide electrolyzer
Implementation Method 4
generating a volume of hydrochloric acid using a hydrochloric acid reactor, the volume of dihydrogen, and the volume of chlorine gas
Data Source
AI summary
Integrations of carbon monoxide electrolyzers and chlor-alkali electrolyzers are disclosed herein. The disclosed integrations include novel process chains for the valorization of oxocarbons into hydrochloric acid, vinyl chloride, vinyl acetate, ethylene oxide, and other useful chemicals. The disclosed integrations further include novel ways to operate the electrolyzers in tandem to increase the efficiency of both reactors. This disclosure also includes novel ways to balance the operation of both electrolyzers to assure they are operating at an optimal level to take advantage of the benefits of the disclosed integrations.