Electrosynthesis Catalyst Restoration via Hydrogen Reduction
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Solution Overview
Problem
In electrosynthesis systems, the deposition of carbon on catalysts leads to decreased efficiency in hydrocarbon gas synthesis, and attempts to remove deposited carbon through heating with air result in catalyst oxidation, further reducing efficiency.
Innovation Solution
An electrosynthesis system with an electrolysis device generating carbon monoxide and hydrogen gases, a synthesizing device using a catalyst to produce hydrocarbon gas, and a control device that adjusts water vapor and carbon dioxide flow rates, supplying hydrogen gas to the synthesizing device when carbon dioxide concentration falls below a threshold, allowing reduction of oxidized catalysts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If air is supplied to the synthesizing device to remove deposited carbon from the catalyst, then carbon removal efficiency is improved, but catalyst oxidation occurs leading to decreased synthesis efficiency
Solution Approach 1:
Hydrogen gas is introduced as an intermediary substance to mediate between the carbon deposition problem and catalyst oxidation issue. The hydrogen gas reduces oxidized catalyst components (such as NiO) back to their active metallic state (Ni) through chemical reaction, thereby restoring catalyst activity without requiring high-temperature air treatment that would cause oxidation. This intermediary approach allows carbon removal while preserving catalyst integrity and synthesis efficiency.
Solution Approach 2:
The invention changes the chemical environment parameters within the synthesizing device by controlling the composition of gas supplied (specifically introducing hydrogen gas) and adjusting operational parameters such as gas flow rates and temperature. By modifying these parameters, the system transitions from an oxidizing atmosphere (air) to a reducing atmosphere (hydrogen-rich), enabling catalyst restoration while preventing oxidation and maintaining high synthesis efficiency throughout the carbon removal process.
2Loss of substance
If the catalyst is heated at high temperature to remove deposited carbon, then carbon removal is achieved, but the catalyst becomes oxidized and synthesis efficiency decreases
Solution Approach 1:
The invention changes the chemical environment parameters within the synthesizing device by controlling the composition of gas supplied (specifically introducing hydrogen gas) and adjusting operational parameters such as gas flow rates and temperature. By modifying these parameters, the system transitions from an oxidizing atmosphere (air) to a reducing atmosphere (hydrogen-rich), enabling catalyst restoration while preventing oxidation and maintaining high synthesis efficiency throughout the carbon removal process.
Solution Approach 2:
Hydrogen gas is introduced as an intermediary substance to mediate between the carbon deposition problem and catalyst oxidation issue. The hydrogen gas reduces oxidized catalyst components (such as NiO) back to their active metallic state (Ni) through chemical reaction, thereby restoring catalyst activity without requiring high-temperature air treatment that would cause oxidation. This intermediary approach allows carbon removal while preserving catalyst integrity and synthesis efficiency.
3Productivity
If hydrogen gas is supplied to reduce oxidized catalyst, then catalyst activity is restored, but additional gas supply equipment and control are required
Solution Approach 1:
The electrolysis device serves multiple functions: it generates hydrogen gas for catalyst reduction, produces carbon monoxide for hydrocarbon synthesis, and provides thermal energy through the electrolysis process itself. By integrating these functions into a single device, the system eliminates the need for separate hydrogen generation equipment and reduces overall system complexity despite the added control requirements for gas composition monitoring.
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 suppresses the decrease in hydrocarbon gas synthesis efficiency by reducing oxidized catalysts through hydrogen gas reactions, maintaining system performance without the need for additional heating sources.
Implementation Method 1
an electrolysis device configured to subject carbon dioxide gas and water vapor to electrolysis and thereby generate carbon monoxide gas and hydrogen gas
Implementation Method 2
a synthesizing device configured to use a catalyst to synthesize hydrocarbon gas from the carbon monoxide gas and the hydrogen gas
Implementation Method 3
the catalyst, which has been oxidized by the combustion of carbon deposited on the catalyst, can be reduced by a reaction with the hydrogen gas
Implementation Method 4
a water vapor amount adjustment valve configured to adjust a flow rate of the water vapor supplied to the electrolysis device, a carbon dioxide amount adjustment valve configured to adjust a flow rate of the carbon dioxide gas supplied to the electrolysis device
Data Source
AI summary
In the case that the concentration of carbon dioxide gas within an exhaust gas has fallen below a predetermined carbon dioxide concentration threshold value in a state in which oxygen gas is being supplied to a synthesizing device, an electrosynthesis system opens a water vapor amount adjustment valve without opening a carbon dioxide amount adjustment valve, and thereby supplies hydrogen gas to the synthesizing device via an electrolysis device.