CO2 to Methanol via Formic Acid Intermediates

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for producing methanol are energy-intensive and rely on fossil fuels, with limitations in efficiency and the need for synthesis gas, while also contributing to greenhouse gas emissions due to the use of carbon dioxide from industrial sources.

Innovation Solution

A method for reductive conversion of carbon dioxide to methanol, utilizing photochemical or electrochemical reduction to produce formic acid and formaldehyde, followed by catalytic conversion to methanol, with optional hydrogenation of methyl formate to enhance yield, using carbon dioxide from industrial exhausts or the atmosphere as a renewable carbon source.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional methods using synthesis gas from fossil fuels are used to produce methanol, then methanol production is achieved, but energy consumption is high and greenhouse gas emissions increase

Engineering Contradiction:

Improvemethanol production efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent changes the fundamental reaction parameters by using CO2 directly as feedstock instead of synthesis gas, employing photochemical or electrochemical reduction conditions rather than conventional high-temperature catalytic processes, and utilizing formic acid and formaldehyde as intermediate species to achieve methanol synthesis under milder conditions with lower energy input

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the harmful greenhouse gas CO2 into valuable methanol product, transforming an environmental liability into an economic asset. The CO2 that would otherwise contribute to global warming is now the primary feedstock for methanol production, simultaneously addressing climate change and energy needs

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If synthesis gas is used as intermediate to produce methanol, then methanol can be produced, but the process becomes complex and requires multiple steps

Engineering Contradiction:

Improvemethanol productionVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the methanol synthesis pathway into distinct photochemical/electrochemical reduction steps producing formic acid and formaldehyde, followed by their conversion to methanol, allowing each step to be optimized independently and simplifying the overall process design compared to conventional synthesis gas routes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces formic acid and formaldehyde as intermediary species in the conversion pathway from CO2 to methanol. These intermediates serve as stable, easily manageable compounds that facilitate the transformation process and can be isolated or converted as needed, simplifying the overall synthesis route

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If CO2 from industrial sources is utilized, then greenhouse gas emissions are reduced, but the source of CO2 is limited

Engineering Contradiction:

Improvegreenhouse gas emissionsVSAvoidavailability of CO2

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The patent makes the methanol synthesis process universally applicable to any CO2 source by designing a system that can process CO2 from diverse origins including atmospheric CO2, industrial exhausts, and natural sources. The photochemical and electrochemical reduction methods are agnostic to the specific CO2 source, enabling flexible deployment anywhere CO2 is available

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach provides an efficient, environmentally friendly method for producing methanol, reducing greenhouse gas emissions and mitigating global warming by utilizing abundant atmospheric carbon dioxide, offering a renewable energy storage and transportation solution.

Implementation Method 1

reducing the carbon dioxide by photochemical or electrochemical reduction

Methodology Applied

Scientific EffectPhotochemical reduction: Photosynthesis

Implementation Method 2

reducing the carbon dioxide by photochemical or electrochemical reduction

Methodology Applied

Scientific EffectElectrochemical reduction: Electrolysis

Implementation Method 3

followed, without separation of the reaction mixture, by a treatment step conducted under conditions sufficient to convert the formaldehyde to formic acid and methanol

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 4

with optional hydrogenation of methyl formate to enhance yield

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Data Source

PatentUS7605293B2Efficient and selective conversion of carbon dioxide to methanol, dimethyl ether and derived products

Publication Date: 2009.10.20 UNIV OF SOUTHERN CALIFORNIA

AI summary

An environmentally beneficial method of producing methanol from varied sources of carbon dioxide including flue gases of fossil fuel burning powerplants, industrial exhaust gases or the atmosphere itself. Converting carbon dioxide by electrochemical reduction produces formic acid acid and some formaldehyde and methanol mixtures. The formic acid can be used as source of carbon as well as hydrogen to produce methanol, dimethyl ether and other products.