Membrane Reactor Trickle Bed for CO2 Conversion Efficiency
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Solution Overview
Problem
Existing electrolytic cells for electrochemical reduction of CO2 have low conversion efficiencies and flux, limiting their commercialization potential.
Innovation Solution
A membrane reactor design featuring a porous conductive layer with a trickle bed structure, a solid electrolyte separator, and specific catalyst materials, which enhances proton and electron transfer rates, and includes a fuel cell for efficient electrochemical reduction of CO2 to form useful products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrolytic cells are used for electrochemical reduction of CO2, then the system is simple to fabricate and operates under mild conditions, but the conversion efficiency and flux are low
Solution Approach 1:
The reactor is divided into distinct cathode and anode chambers separated by a solid electrolyte membrane, with each chamber containing specific catalyst particles. This segmentation allows optimized electrochemical reactions in each zone while maintaining overall system simplicity.
Solution Approach 2:
The patent employs porous conductive layers and porous catalyst particles to increase the surface area for electrochemical reactions. The porous structure enhances flux and conversion efficiency by providing more active sites for CO2 reduction while maintaining mild operating conditions.
2Temperature
If traditional electrolytic cells are used, then the operation condition is mild, but the conversion efficiency and flux are low
Solution Approach 1:
The patent changes key parameters including using solid electrolyte membranes instead of liquid electrolytes, employing porous catalyst particles with specific size ranges (1-1000 micrometers), and using trickle bed reactor configurations. These parameter changes enhance conversion efficiency while maintaining mild temperature and pressure conditions.
Solution Approach 2:
The reactor uses composite structures combining porous conductive layers with catalyst particles, solid electrolyte membranes with porous supports, and multiple functional layers in the cathode and anode assemblies. These composite materials enable high conversion efficiency under mild operating conditions.
3Device complexity
If electrolytic cells are used, then the system is simple, but the flux is low
Solution Approach 1:
The patent introduces a trickle bed reactor configuration where electrolyte flows as liquid drops through porous catalyst particles, adding a dimensional aspect to the reaction interface. This enhances mass transfer and flux without significantly increasing system complexity.
Solution Approach 2:
Porous catalyst particles and porous conductive layers provide extensive internal surface areas for reactions, dramatically increasing flux. The porous structure allows efficient mass transfer of CO2 and electrolyte while maintaining a relatively simple reactor design.
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 membrane reactor achieves high conversion efficiency of CO2, with efficiencies reaching above 80% and the ability to convert over 100 tons of CO2 per day, while reducing catalyst damage and prolonging catalyst life.
Implementation Method 1
a solid electrolyte separator (260) disposed in the cavity (20)
Implementation Method 2
The plurality of cathode catalyst particles (2204) are used to electrochemically reduce the CO2 gas
Implementation Method 3
enhances proton and electron transfer rates
Implementation Method 4
includes a fuel cell for efficient electrochemical reduction of CO2
Data Source
AI summary
A membrane reactor used for electrochemically converting a carbon dioxide gas into an expected product includes a cavity, a solid electrolyte membrane separator, a cathode, an anode, and a power source. The solid electrolyte membrane separator is disposed in the cavity and divides the cavity into two chambers defined as a cathode chamber and an anode chamber. The cathode is disposed in the cathode chamber, and the anode is disposed in the anode chamber. The cathode is a trickle bed structure including a porous conductive layer and cathode particles disposed on the porous conductive layer. The power source is disposed outside the cavity to provide an electrolytic voltage.