Microwave Catalyst for CO2 Reforming

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Solution Overview

Problem

Current carbon capture and storage (CCS) processes face challenges such as high energy intensity, high operation temperatures, catalyst deactivation due to carbon deposition, and pollutant emissions from calcium-based absorbents, limiting their efficiency and scalability in converting CO2 into useful products.

Innovation Solution

A cyclic process using a bifunctional catalyst-absorbent system with nickel or cobalt species supported on carbonate or alkaline earth metal oxides, exposed to microwave radiation for hydrocarbon reforming, which facilitates low-temperature CO2 capture and conversion, reducing energy consumption and extending catalyst life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional thermal methane dry reforming is used to convert CO2 into useful products, then CO2 conversion is achieved, but high operation temperature (820°C) and energy consumption are required

Engineering Contradiction:
ImproveCO2 conversion rateVSAvoidenergy consumption
Core Design Contradiction:
ProductivityVSUse of energy by stationary object

Solution Approach 1:

The patent replaces the traditional thermal field (heating system) with an electromagnetic field (microwave radiation system) to activate the catalyst and drive the reforming reaction. This substitution allows the reaction to proceed at lower temperatures while maintaining high CO2 conversion rates, directly resolving the contradiction between productivity and energy consumption.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical and chemical parameters of the catalyst system by using microwave irradiation to selectively heat the catalyst particles, creating localized high-energy zones that enable CO2 conversion at lower bulk temperatures. This parameter change allows the system to achieve high productivity without the high energy consumption associated with conventional thermal heating.

Inventive Principle:
Principle #35Parameter changes

2Productivity

If traditional thermal methane dry reforming is used, then CO2 conversion is achieved, but catalyst deactivation due to carbon deposition occurs

Engineering Contradiction:
ImproveCO2 conversion rateVSAvoidcatalyst stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

By replacing thermal heating with microwave irradiation, the patent achieves more uniform and controlled catalyst activation. The electromagnetic field selectively interacts with the catalyst material, providing energy exactly where needed without the thermal gradients that cause carbon deposition and catalyst deactivation, thus maintaining both high productivity and catalyst reliability.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs periodic microwave irradiation cycles that activate the catalyst in controlled intervals. This periodic action prevents continuous high-temperature exposure that leads to carbon buildup, allowing the catalyst to maintain its activity and stability over extended operation periods while sustaining high CO2 conversion rates.

Inventive Principle:
Principle #19Periodic action

3Quantity of substance

If calcium-based absorbents are used for CO2 capture, then CO2 uptake is achieved, but CO2 uptake capacity decreases quickly after several cycles due to blockage by CaCO3

Engineering Contradiction:
ImproveCO2 uptake capacityVSAvoidcycle stability
Core Design Contradiction:
Quantity of substanceVSDuration of action of stationary object

Solution Approach 1:

The patent merges the CO2 capture function and CO2 conversion function into a single integrated catalyst-absorbent system. The metal species on the catalyst surface simultaneously capture CO2 from the gas phase and activate it for reforming reactions. This merging eliminates the CaCO3 blockage problem because the captured CO2 is immediately converted to products rather than accumulating as blocking carbonate deposits, thereby maintaining both high uptake capacity and long cycle stability.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The catalyst-absorbent system performs multiple functions simultaneously: CO2 capture, CO2 activation, and catalytic conversion. This multi-functionality allows the system to maintain high CO2 uptake capacity over many cycles by continuously converting captured CO2 into useful products, preventing the capacity degradation that occurs in single-function calcium-based absorbent systems.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Quantity of substance

If calcium-based absorbents are used for CO2 capture, then CO2 uptake is achieved, but huge pollutant emissions occur during preparation and use

Engineering Contradiction:
ImproveCO2 uptake capacityVSAvoidpollutant emissions
Core Design Contradiction:
Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent combines CO2 capture and conversion in one system, eliminating the need for separate calcium-based absorbent preparation and regeneration steps that generate pollutant emissions. The integrated catalyst-absorbent system directly converts captured CO2 into useful chemical products, avoiding the formation and emission of harmful byproducts associated with traditional calcium-looping processes.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent converts the previously harmful CO2 byproduct into a valuable resource by using it as a reactant in the reforming process. The CO2 that would normally be emitted as pollution is instead transformed into useful chemicals and fuels, turning an environmental liability into an economic and environmental asset while eliminating pollutant emissions.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 enhances energy efficiency, minimizes CO2 uptake capacity losses, and allows for scalable CO2 capture and conversion into hydrogen-rich syngas, suitable for industrial applications and atmospheric CO2 absorption, while reducing environmental impact.

Implementation Method 1

exposing a gaseous hydrocarbon to microwave radiation in the presence of a solid catalyst

Methodology Applied
Scientific EffectMicrowave radiation absorption: Microwave Radiation

Implementation Method 2

Rapid and selective heating offer the potential of reforming hydrocarbon at relatively low catalyst bed temperatures

Methodology Applied
Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 3

subsequently allowing for the formation of a CO2 absorbent without generating much exhaust heat

Methodology Applied
Scientific EffectThermal decomposition: Decomposition (biological)

Implementation Method 4

the catalyst comprises at least one metal species on a support, wherein the metal species is at least one of a nickel species or a cobalt species

Methodology Applied
Scientific EffectCatalysis: Catalysis

Data Source

PatentUS20230131680A1Process and catalyst
Publication Date: 2023.04.27 OXFORD UNIVERSITY INNOVATION LTD
  • US20230131680A1 patent drawing
  • US20230131680A1 patent drawing
  • US20230131680A1 patent drawing

AI summary

A process for producing a gaseous product comprising hydrogen, said process comprising exposing a gaseous hydrocarbon to microwave radiation in the presence of a solid catalyst, wherein the catalyst comprises at least one metal species on a support, wherein the metal species is at least one a nickel species or a cobalt species; and a solid catalyst suitable for use in said process, and wherein the support comprises at least one of a carbonate or an alkaline earth metal oxide.