Electrolytic Carbon Conversion to Hydrocarbons

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for recycling and recovering carbon from waste streams produce micron-scaled, high surface area carbon that lacks economic value as a combustion product, necessitating a process to efficiently convert this carbon into valuable hydrocarbons like methane, methanol, and propane.

Innovation Solution

An electrolytic process utilizing specific catalysts and electrolyte salts to drive reactions from carbon to hydrocarbons, involving reactions at an anode and cathode, where carbon is reduced to produce hydrogen ions and electrons, which react with oxygen to form hydrocarbons, with varying cathode materials and conditions optimizing methane, methanol, ethanol, and propane production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If carbon is recovered from organic waste streams, then environmental benefits and carbon resource availability are improved, but the economic value of the recovered carbon remains low as a combustion product

Engineering Contradiction:

Improveenvironmental benefitsVSAvoideconomic value

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The patent transforms the chemical composition and molecular structure of carbon by changing parameters such as reaction conditions, catalysts, and processing methods to convert micron-scaled carbon into higher-value hydrocarbons with different molecular weights and energy densities

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses electrolytic processes with specific electrolyte salts and catalysts as intermediaries to facilitate the conversion of carbon to hydrocarbons, enabling the transformation through electrochemical reactions that add value to the recovered carbon

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If micron-scaled carbon is produced from waste streams, then carbon recovery efficiency is improved, but the product value is limited compared to traditional fuel sources

Engineering Contradiction:

Improvecarbon recovery efficiencyVSAvoidproduct value

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent performs preliminary carbon recovery from waste streams to obtain micron-scaled carbon, then subsequently transforms this recovered carbon into higher-value hydrocarbons through electrolytic processes, making the preliminary recovery action economically viable

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the molecular parameters and chemical structure of the recovered carbon through electrochemical reactions, catalysts, and controlled processing conditions to produce hydrocarbons with significantly higher market value than the original carbon product

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If carbon is converted to hydrocarbons through electrolytic processes, then economic value and fuel production are improved, but process complexity and energy requirements increase

Engineering Contradiction:

Improveeconomic valueVSAvoidprocess complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent divides the conversion process into distinct electrochemical reactions occurring at separate electrodes (anode and cathode), allowing independent optimization of each reaction step and simplifying the overall process control despite the complexity of multiple transformations

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If multiple hydrocarbons are produced from carbon, then product versatility and economic value are improved, but manufacturing precision and process control become more difficult

Engineering Contradiction:

Improveproduct versatilityVSAvoidprocess control

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent applies different catalysts and electrolyte conditions at different electrodes to selectively produce specific hydrocarbon products (methane at one electrode, methanol at another, ethanol at a third), allowing local optimization of each reaction to achieve desired product selectivity and quality

Inventive Principle:

Principle #3Local quality

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 process efficiently converts carbon into hydrocarbons, enhancing the economic value of waste recycling and recovery processes, achieving reliable and reproducible production of fuel sources with improved environmental benefits.

Implementation Method 1

carbon is reduced to produce hydrogen ions and electrons

Methodology Applied

Scientific EffectElectrochemical reduction: Electrolysis

Implementation Method 2

hydrogen ions and electrons react with oxygen to form hydrocarbons

Methodology Applied

Scientific EffectElectrochemical synthesis: Electrolysis

Data Source

PatentEP2123796B1Conversion of carbon to hydrocarbons

Publication Date: 2011.03.02 CATO RES CORP

AI summary

The invention provides methods of forming lower alkyls and alcohols from carbon sources thermally and/or electrolytically.