Dendritic Copper Catalyst for Ethylene Selectivity
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Solution Overview
Problem
Current electrolysis systems for CO2 and CO reduction face challenges in achieving high selectivity and efficiency for ethylene production due to carbonate formation, electrode instability, and high energy consumption, particularly in alkaline flow cells and single-step electroreduction processes.
Innovation Solution
The use of a dendritic copper oxide or copper catalyst in a zero-gap or two-gap electrolyser with an anion-exchange membrane, where the catalyst is prepared by electrodeposition from an acidic CuSO4 solution, and an input flow rich in CO is used to enhance selectivity and stability for ethylene production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If alkaline flow cells with gas-diffusion cathodes are used for CO2 electroreduction to ethylene, then high production rates and selectivities are achieved, but carbonate formation occurs causing electrolyte degradation and system instability
Solution Approach 1:
The patent changes the pH parameter of the electrolyte from alkaline to neutral, which prevents carbonate formation while maintaining high ethylene production rates. This parameter change resolves the contradiction by eliminating the harmful side reaction between OH- and CO2 that causes system instability.
Solution Approach 2:
The patent converts the harmful effect of CO2 loss to carbonate into a beneficial outcome by operating at neutral pH where carbonate formation is prevented. The CO2 that would have been lost to carbonate formation is now available for productive ethylene synthesis, improving both productivity and reliability.
2Productivity
If conventional CO2 electroreduction is performed in alkaline media, then C2 products formation is favored, but high carbonate formation consumes up to 72% of energy input unproductively
Solution Approach 1:
The patent changes the pH parameter from alkaline to neutral, which eliminates the energy-wasting carbonate formation pathway while preserving the selectivity to C2 products. This resolves the energy loss issue without sacrificing productivity.
Solution Approach 2:
The patent extracts and removes the harmful alkaline environment that causes carbonate formation, leaving only the beneficial neutral conditions that favor ethylene production. This extraction of the problematic component (high pH) eliminates the energy waste while maintaining product selectivity.
3Device complexity
If single-step CO2-to-ethylene electroreduction is performed, then direct production is achieved, but CO2 loss to carbonate consumes excessive energy and reduces efficiency
Solution Approach 1:
The patent changes the pH parameter to neutral, which prevents carbonate formation in the single-step process. This allows the simple single-step configuration to maintain high energy efficiency by eliminating the unproductive CO2 consumption pathway.
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 achieves a Faradaic Efficiency of up to 78% for ethylene production with H2 as the only byproduct, demonstrating improved stability and selectivity compared to previous systems, while minimizing carbonate formation and energy input.
Implementation Method 1
Electrochemical carbon dioxide reduction (CO2R) offers an attractive route to upgrade greenhouse gases such as CO2 to valuable fuels and feedstocks
Implementation Method 2
Cu is unique in activating CO2 for C—C coupling
Implementation Method 3
GDCs are designed to improve CO2 mass transport by maximizing the access of gaseous CO2 to the catalyst active sites in contact with the electrolyte
Implementation Method 4
preparing a cathode catalyst by electrodeposition of Cu on a Cu electrode from an acidic CuSO4 solution
Implementation Method 5
providing an electrolyser comprising a gas diffusion cathode, an anode and an ion-exchange membrane in between said gas diffusion cathode and said anode
Data Source
AI summary
The invention relates to a process for electrolysing carbon oxides selected from carbon monoxide and/or carbon dioxide into ethylene by means of an electrolyser comprising a cathode catalyst being a dendritic copper oxide catalyst or a dendritic copper catalyst.