Integrated CO2 Conversion Process Using Novel Solid Solution Catalysts
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Solution Overview
Problem
Current processes for converting carbon dioxide into useful fuels and chemicals are inefficient and economically unviable, lacking effective catalysts and systems to maximize carbon dioxide utilization.
Innovation Solution
A catalytic process that combines autothermal reforming, Reverse Water Gas Shift (RWGS) reactions, and hydrogenation catalysts to convert carbon dioxide and water into high-quality fuels and chemicals, using a novel solid solution catalyst and operating conditions that optimize syngas production and hydrocarbon synthesis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional processes are used to convert carbon dioxide into fuels and chemicals, then the process can operate with existing technology, but the conversion efficiency is low and the process is economically unviable
Solution Approach 1:
The patent combines multiple processes (electrolysis, autothermal reforming, reverse water gas shift, and hydrogenation) into an integrated system where the output of one process serves as the input for another. This merging of processes enables synergistic effects that improve overall conversion efficiency and economic viability compared to conventional separate processes.
Solution Approach 2:
The patent employs novel catalysts with specific compositional parameters (e.g., Cu-Zn-Al-O-Si-P-W-O system with controlled ratios) and operational parameters (temperature, pressure, gas flow rates) to optimize the conversion of carbon dioxide. These parameter changes enable higher conversion efficiency and product quality while maintaining economic feasibility.
2Productivity
If existing catalysts are used for carbon dioxide conversion, then the process can proceed with current materials, but the catalyst performance is insufficient to maximize carbon dioxide utilization
Solution Approach 1:
The patent uses composite catalyst materials with multiple components (Cu-Zn-Al-O-Si-P-W-O) that work synergistically to enhance carbon dioxide conversion. The composite structure provides both high activity for CO2 utilization and selectivity for desired products, overcoming the limitations of single-component catalysts.
Solution Approach 2:
The catalyst system exhibits different functional zones or active sites with specialized properties for specific reactions. The local composition and structure of the catalyst are optimized to provide high performance for particular transformation steps, such as CO2 methanation or hydrocarbon synthesis, thereby maximizing overall carbon dioxide utilization.
3Productivity
If the process operates at optimized conditions for syngas production, then conversion efficiency improves, but the system complexity increases
Solution Approach 1:
The patent divides the carbon dioxide conversion process into distinct operational stages or modules (electrolysis unit, reforming section, shift conversion zone, hydrogenation reactor). Each segment is optimized for specific functions and can be independently controlled or scaled, reducing overall system complexity while maintaining high syngas production efficiency.
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
Enhances conversion efficiency, reduces capital costs, and produces a majority of hydrocarbons in the C5-C24 range, achieving high carbon yields and minimizing greenhouse gas emissions.
Implementation Method 1
conversion of water to hydrogen in an efficient electrolysis unit that uses electricity, ideally renewable electricity, as its energy source
Implementation Method 2
Carbon dioxide and hydrogen are reacted to carbon monoxide and water in a Reverse Water Gas Shift (RWGS) reactor
Implementation Method 3
The catalyst used in the reactor is a novel solid solution catalyst
Implementation Method 4
carbon monoxide and additional hydrogen are reacted to fuels and chemicals in a liquid fuels production reactor
Implementation Method 5
an autothermal reforming (ATR) process that converts the tail gas (and potentially other hydrocarbon feedstocks) from the fuel/chemical production stage and oxygen from the electrolysis processes into additional syngas
Data Source
AI summary
The present invention describes a processes, systems, and catalysts for the conversion of carbon dioxide and water and electricity into low carbon or zero carbon high quality fuels and chemicals. In one aspect, the present invention provides an integrated process for the conversion of a feed stream comprising carbon dioxide to a product stream comprising hydrocarbons between 5 and 24 carbon atoms in length.