Fluororesin-Coated Copper Electrode Catalyst for Selective C2 Production
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Solution Overview
Problem
The existing electrode catalysts for reducing carbon dioxide and/or carbon monoxide generate both C2 and C1 compounds, necessitating an energy-consuming and costly separation process due to their inefficient generation efficiency.
Innovation Solution
An electrode catalyst comprising a gas diffusion layer with a catalyst layer containing a Cu element and a fluororesin coating layer, optimized in thickness and fluorine content, enhances the generation efficiency of C2 compounds while reducing the generation of C1 compounds and hydrogen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electrode catalysts are used for reducing carbon dioxide and/or carbon monoxide, then the reduction reaction can proceed, but C1 compounds and hydrogen are generated as by-products requiring energy-consuming separation processes
Solution Approach 1:
The patent applies local quality by creating a coating layer with specific fluororesin content (0.2-15.0 mass% fluorine) on the catalyst surface. This localized modification of the catalyst surface properties selectively suppresses C1 compound and hydrogen generation while maintaining C2 compound production, resolving the contradiction between productivity and harmful by-product generation
Solution Approach 2:
The patent uses composite materials by combining copper-containing catalyst particles with fluororesin coating materials. This composite structure creates a catalyst that simultaneously achieves high C2 compound generation efficiency and suppressed by-product formation, eliminating the need for energy-consuming separation processes
2Reliability
If copper-containing catalysts are used to promote reduction reaction, then the reaction efficiency improves, but separation processes are required due to by-product generation
Solution Approach 1:
The patent extracts the problematic by-product generation function from the copper catalyst system by adding a fluororesin coating layer. This coating selectively suppresses C1 compound and hydrogen formation while preserving the copper catalyst's ability to promote C2 compound production, thereby eliminating separation process requirements while maintaining catalyst reliability
Solution Approach 2:
The patent changes the surface parameters of the copper catalyst by controlling the fluorine content in the coating layer within 0.2-15.0 mass%. This parameter optimization achieves the dual goal of maintaining high catalyst reliability for reduction reactions while suppressing by-product generation that would require complex separation processes
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 catalyst achieves a significantly higher generation efficiency of C2 compounds, such as ethylene, by suppressing the generation of C1 compounds and hydrogen, as evidenced by a Faraday efficiency ratio of 3.0 or more for C2 compounds and 27.0% or less for hydrogen.
Implementation Method 1
a catalyst present on a surface of the gas diffusion layer... the catalyst contains a Cu element... capable of electrochemically reducing carbon dioxide and/or carbon monoxide
Data Source
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AI summary
An object of the present invention is to provide: an electrode catalyst capable of achieving a significantly higher generation efficiency of a C2 compound than that of a C1 compound; an electrochemical reaction apparatus including the electrode catalyst; and a method for producing the electrode catalyst, and the present invention provides: an electrode catalyst (10) for electrochemically reducing carbon dioxide and/or carbon monoxide, the electrode catalyst (10) including a gas diffusion layer (11), a catalyst (12) present on a surface of the gas diffusion layer (11), and a coating layer (13) covering at least part of a surface of the catalyst (12), wherein the catalyst (12) contains a Cu element, and wherein the coating layer (13) contains a fluororesin; an electrochemical reaction apparatus including the electrode catalyst; and a method for producing the electrode catalyst.