Integrated Electrolysis System for Formic Acid Production
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Solution Overview
Problem
Conventional electrolysis methods typically produce only one high-value chemical product per electrode, generating byproducts like hydrochloric or sulfuric acid to convert formate into formic acid, which requires additional chemicals and increases electricity usage.
Innovation Solution
An electrolysis system with a diaphragm electrolytic bath producing peroxodisulfate at the anode and formate at the cathode, combined with a concentration-acidification unit using sulfuric acid to convert formate into formic acid, minimizing byproduct generation and chemical additions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electrolysis methods are used to produce one high-value chemical product, then the production efficiency is improved, but additional chemicals and electricity are required to convert byproducts into useful products
Solution Approach 1:
The patent combines the anode chamber and cathode chamber into a single integrated electrolysis system where the byproduct from one electrode serves as the reactant for the other electrode. Specifically, the formate produced at the cathode is directly converted to formic acid using the sulfuric acid byproduct from the anode, eliminating the need for separate chemical addition steps and reducing overall electricity consumption.
Solution Approach 2:
The patent converts harmful byproducts (formate and sulfuric acid) into valuable products (formic acid) by utilizing the electrochemical reactions within the integrated system. The sulfuric acid generated at the anode is used to acidify the formate from the cathode, transforming waste streams into the desired final product.
2Device complexity
If conventional electrolysis methods are used to produce one high-value chemical product, then the production process is simplified, but byproduct treatment requires additional chemicals and increases system complexity
Solution Approach 1:
The electrolysis system is designed to be self-sufficient by internally recycling its own byproducts. The sulfuric acid produced at the anode automatically serves to acidify the formate at the cathode, and the sodium ions from the formate combine with sulfate ions to precipitate sodium sulfate, eliminating the need for external chemical additives for byproduct treatment.
Solution Approach 2:
The patent recovers valuable substances from what would otherwise be waste streams. Sodium sulfate is recovered from the reaction between sodium ions and sulfate ions, and formic acid is recovered through the acidification of formate using sulfuric acid. This transforms waste disposal into a resource recovery process.
3Productivity
If additional chemicals are added to convert formate into formic acid, then the production of formic acid is improved, but the cost and environmental impact increase
Solution Approach 1:
The patent converts the harmful sulfuric acid byproduct into a useful reagent for formic acid production. Instead of treating sulfuric acid as waste that needs neutralization, the system utilizes it to acidify formate, thereby producing formic acid while eliminating the need for additional chemical additives and reducing chemical waste.
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
Simultaneously produces two high-value chemical products, reduces electricity consumption, minimizes byproduct treatment, and decreases the need for additional chemical materials, while reusing byproducts and reducing greenhouse gas emissions.
Implementation Method 1
supplying an electrolyte solution containing sulfuric acid ions to an anode chamber of a diaphragm electrolytic bath to generate peroxodisulfate through an anodic reaction
Implementation Method 2
supplying a carbon dioxide gas or an electrolyte solution containing the gas dissolved therein to the cathode chamber to generate formate through a cathodic reaction
Implementation Method 3
the formate is reacted with hydrogen ions supplied from the outside or supplied using self-generation to thus be converted into formic acid
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The present invention relates to an electrolysis system and an electrolysis method using the same. The electrolysis system includes a diaphragm electrolytic bath, including an anode chamber, which receives sulfuric acid ions supplied from an electrolyte solution to thus generate sulfur peroxide through an anodic reaction, and a cathode chamber, which receives a carbon dioxide gas or an electrolyte solution containing the gas dissolved therein to thus generate formate, and a concentration-acidification unit for converting the formate, generated in the diaphragm electrolytic bath, into formic acid.