Dilute Copper Alloy Catalysts for CO2 Reduction Selectivity
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Solution Overview
Problem
Current power-to-gas technologies face challenges in developing low-cost electrocatalysts that facilitate energy-efficient production of methane or other hydrocarbons from CO2 with high selectivity and long-term stability, due to limitations in manipulating reactivity and selectivity using traditional transition metals or alloys.
Innovation Solution
Development of dilute copper-based alloy catalysts with a majority component of copper and minority components such as transition metals, main group metals, or lanthanides, which break scaling relationships between reaction intermediates, allowing for improved selectivity and energy efficiency in CO2 reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional transition metals or alloys are used for CO2 reduction, then catalyst cost is reduced, but selectivity and energy efficiency deteriorate due to scaling relationships limiting reactivity manipulation
Solution Approach 1:
The patent changes the compositional parameters of the catalyst by using dilute alloys with majority copper (greater than 90 atomic percent) and minority components (less than 10 atomic percent) from transition metals, main group metals, lanthanides, or semimetals. This parameter change breaks the scaling relationships that limit traditional alloys, enabling independent tuning of reaction intermediate stabilities to improve both selectivity and energy efficiency
Solution Approach 2:
The patent creates composite catalyst materials by combining copper with small amounts of other metal elements. These dilute alloy composites exhibit synergistic effects where the minority components modify the electronic structure and surface properties of copper, enabling breakthrough in overcoming the scaling relationships that constrain traditional single-metal or alloy catalysts
2Ease of manufacture
If traditional transition metal alloys are used, then manufacturing cost is reduced, but ability to manipulate reactivity and selectivity deteriorates due to scaling relationships
Solution Approach 1:
The patent employs parameter changes by precisely controlling the composition of dilute alloys with majority copper (greater than 90 atomic percent) and minority components (less than 10 atomic percent). This compositional parameter control enables independent manipulation of reactivity and selectivity, overcoming the scaling relationship constraints that limit traditional alloys while maintaining ease of manufacture through established alloying techniques
3Reliability
If copper-based catalysts are used for CO2 reduction, then production cost is reduced, but selectivity and energy efficiency are limited by scaling relationships between reaction intermediates
Solution Approach 1:
The patent applies parameter changes by using dilute copper-based alloys with majority copper (greater than 90 atomic percent) and minority components (less than 10 atomic percent) from transition metals, main group metals, lanthanides, or semimetals. This compositional modification breaks the scaling relationships between reaction intermediates, enabling simultaneous improvement of selectivity and energy efficiency in CO2 reduction to methane and hydrocarbons
Solution Approach 2:
The patent creates modified copper catalyst systems that copy and enhance the beneficial properties of pure copper while eliminating its limitations. The dilute alloy structure preserves copper's inherent CO2 reduction activity while the minority components copy and amplify selectivity control, overcoming the energy efficiency limitations of traditional copper catalysts
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 dilute copper-based alloy catalysts enhance the energy efficiency and selectivity of power-to-gas conversion by individually tuning the rates of CO2-to-CO reduction and hydrogen evolution, promoting CO dimerization and methane production while suppressing hydrogen evolution.
Implementation Method 1
A key obstacle for deployment of one-step electrochemical PtG technology and electrosynthesis in general is the development of low-cost electrocatalysts that facilitate energy-efficient production of methane or other hydrocarbons from CO2
Data Source
AI summary
A product includes a dilute alloy catalyst for carbon dioxide reduction. The catalyst has a majority component and at least one minority component. The majority component is present in a concentration of greater than 90 atomic percent of the catalyst. The majority component is copper, and each minority component is selected from the group consisting of: a transition metal, a main group metal, a lanthanide, and a semimetal. A method includes forming a product on a cathode. The product includes a dilute alloy catalyst for carbon dioxide reduction. The catalyst has a majority component and at least one minority component. The majority component is present in a concentration of greater than 90 atomic percent of the catalyst. The majority component is copper, and each minority component is selected from the group consisting of: a transition metal, a main group metal, a lanthanide, and a semimetal.