Iridium Oxide Electrocatalyst for Ethylene Halohydrin Synthesis
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Solution Overview
Problem
Current methods for producing oxiranes, such as thermocatalytic partial oxidation of ethylene, are energy-intensive and generate significant CO2 emissions, and existing electrochemical methods face challenges with high current densities and Faradaic efficiencies.
Innovation Solution
An electrochemical system using an iridium oxide-based electrocatalyst with a period-6 metal oxide loading on a titanium substrate in a halide ion-based electrolyte, facilitating selective anodic oxidation of olefins to produce ethylene halohydrin, which is then converted to oxirane, with the option of using a paired electrochemical system for CO2-to-ethylene conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermocatalytic partial oxidation of ethylene is used to produce oxirane, then high production volume is achieved, but high energy consumption and CO2 emissions occur
Solution Approach 1:
The patent replaces the thermocatalytic oxidation process with an electrochemical oxidation process. Instead of using high temperature and pressure thermal energy to drive the oxidation reaction, the invention uses electrical energy to drive the oxidation of ethylene to oxirane at ambient temperatures, thereby reducing energy consumption while maintaining productivity
Solution Approach 2:
The patent changes the operating parameters from high temperature (200-300°C) and high pressure (1-3 MPa) to ambient temperature and pressure conditions. By altering these thermodynamic parameters, the process achieves lower energy consumption while maintaining acceptable production rates through electrochemical driving forces
2Productivity
If thermocatalytic partial oxidation of ethylene is used to produce oxirane, then high production volume is achieved, but significant CO2 emissions are generated
Solution Approach 1:
The patent replaces the thermocatalytic oxidation process with an electrochemical oxidation process that operates at ambient conditions. This substitution eliminates the need for high-temperature combustion or oxidation processes that generate CO2, thereby reducing harmful emissions while maintaining productivity
Solution Approach 2:
The patent converts the harmful effect of CO2 emissions into a beneficial process by using CO2 as a feedstock in the electrochemical cell. The CO2 is reduced to carbon monoxide during the electrochemical process, which then reacts with ethylene to form oxirane, thereby transforming the harmful emission into a useful intermediate product
3Use of energy by moving object
If existing electrochemical methods are used for oxirane production, then energy consumption is reduced, but Faradaic efficiency and current density performance are insufficient
Solution Approach 1:
The patent employs a composite catalyst system consisting of multiple metal oxides (including cobalt oxide, nickel oxide, copper oxide, and zinc oxide) combined with support materials. This composite structure enhances the catalytic activity and selectivity for oxirane formation, improving Faradaic efficiency while maintaining low energy consumption
Solution Approach 2:
The patent applies different metal oxide components with specific local functions within the catalyst structure. Each metal oxide component is selected for its specific catalytic properties, creating a localized functional distribution that optimizes both energy efficiency and Faradaic efficiency for the overall oxirane production process
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 achieves high Faradaic efficiencies and reduced energy costs, enabling the production of oxirane at industrially relevant current densities while minimizing CO2 emissions, and can integrate CO2 conversion into the process, potentially reducing the carbon footprint of oxirane production.
Implementation Method 1
an electrocatalyst for selective anodic oxidation of an olefin reactant to produce ethylene halohydrin in a halide ion based electrolyte
Implementation Method 2
iridium oxide loaded with a period-6 metal oxide and provided on a substrate
Data Source
AI summary
Electrosynthesis of oxirane can include contacting a halide electrolyte with an anode that includes an electrocatalyst comprising iridium oxide loaded with a period-6 metal oxide and provided on a metal substrate. The cathode can be operated under ORR conditions. The electrochemical system can also be provided as an integrated system that includes CO2 electroreduction to produce ethylene and formation of hypochlorous acid using the electrocatalyst, followed by contact of the ethylene and the hypochlorous acid to form ethylene chlorohydrin which is, in turn, contacted with OH− ions to produce oxirane.