Flow-Cell CO2 Electroreduction with Gas-Liquid Recirculation
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Solution Overview
Problem
Existing electrochemical carbon dioxide reduction systems face challenges in producing pure target products without the need for gas separation processes, as they often result in mixed gas and liquid phases with unconverted CO2, hydrogen, and carbon monoxide byproducts, limiting carbon conversion efficiency.
Innovation Solution
A system and process utilizing a flow-cell electrolyzer with recirculation systems for gases and liquids, including a gas diffusion electrode and an anion exchange membrane, allows for continuous conversion of CO2 to target products like formate without requiring separation processes by recirculating and adjusting CO2 concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gas separation processes are used to remove unconverted CO2 and byproducts, then product purity is improved, but device complexity and process steps increase
Solution Approach 1:
The patent extracts and removes gaseous byproducts (H2, CO, unconverted CO2) from the reaction system through a gas separation unit, obtaining pure liquid phase formate product while eliminating the need for complex gas-liquid separation processes
Solution Approach 2:
The patent introduces a membrane electrode assembly as an intermediary component that selectively allows formate ions to pass through while blocking gaseous byproducts, achieving product separation without complex mechanical separation equipment
2Device complexity
If single pass conversion is used to simplify the process, then device complexity is reduced, but carbon conversion efficiency decreases due to unconverted CO2 and byproduct accumulation
Solution Approach 1:
The patent implements a continuous recirculation system where unconverted CO2 and byproducts are continuously removed and fed back into the electrolyzer, maintaining continuous electrochemical conversion and achieving high carbon conversion efficiency without requiring complex batch processing
Solution Approach 2:
The patent changes the operational parameters by maintaining a continuous flow regime with optimized gas flow rates and electrolyte circulation, enabling high single-pass conversion while managing byproduct accumulation through controlled recirculation
3Manufacturing precision
If membrane separation and pressure swing adsorption are added to remove gaseous byproducts, then product purity is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent replaces mechanical separation systems (membrane separators, pressure swing adsorption units) with an electrochemically driven gas removal mechanism at the electrode surface, eliminating the need for additional energy-intensive separation equipment while maintaining product purity
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 system achieves substantially pure target products with high carbon conversion efficiency by continuously recycling gases and liquids, eliminating the need for additional separation steps and enhancing product purity.
Implementation Method 1
electrochemical CO2 conversion
Implementation Method 2
gas diffusion electrode
Implementation Method 3
anion exchange membrane
Implementation Method 4
gas-liquid recirculation
Data Source
AI summary
Systems and processes designed for gas and liquid recirculation for continuous carbon dioxide reduction to different target products are disclosed. The systems and processes include gas regeneration through the anodic oxidation of carbon monoxide and hydrogen gas. Advantageously, the target chemical products produced using said systems and processes are substantially pure without requiring any separation processes to remove unreacted reactants or unwanted byproducts.