Molten Carbonate Cathode Product Separation via High-Temperature Press Filtration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current processes for separating electrolyte from solid carbon nanomaterials produced during molten carbonate electrolysis are inefficient, wasteful, and environmentally detrimental, often requiring extensive acid usage and generating unnecessary CO2 emissions.
Innovation Solution
The implementation of High-Temperature Press Filtration (HTPF) method for scalable and sustainable separation and purification of carbon products from molten salts, which involves applying a force to a solid carbon/molten electrolyte mixed product to remove the electrolyte, and then optionally isolating the solid carbon product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If aqueous washing methodologies are used to separate carbon from carbonate electrolyte, then separation is achieved, but large amounts of water and additives are consumed and heat is lost
Solution Approach 1:
The patent applies extraction by removing the electrolyte from the carbon product through filtration and washing with minimal water. The solid carbon product is separated from the molten carbonate electrolyte by passing it through a filter, and the filter cake is washed with small amounts of water to remove residual electrolyte, achieving separation without consuming large quantities of water or additives.
Solution Approach 2:
The patent replaces the chemical washing process (aqueous washing with additives) with a mechanical filtration system. A filter press or similar mechanical filtration device is used to physically separate the solid carbon product from the molten electrolyte, eliminating the need for chemical additives and reducing water consumption significantly.
2Loss of substance
If firebrick is used to draw molten electrolyte through chemical reaction, then electrolyte separation is achieved, but firebrick materials are consumed
Solution Approach 1:
The patent extracts the electrolyte from the carbon product through physical filtration rather than chemical reaction. The filtered carbon product retains minimal electrolyte, and the separated electrolyte can be reused in the electrolysis process, eliminating the need for consumable firebrick materials.
Solution Approach 2:
The patent recovers the molten carbonate electrolyte after separation through filtration. The electrolyte is collected and can be reused in subsequent electrolysis cycles, preventing waste and eliminating the need for continuous consumption of separation materials like firebrick.
3Loss of substance
If acid is added to dissolve carbonate for separation, then electrolyte removal is achieved, but CO2 emissions increase and material waste occurs
Solution Approach 1:
The patent extracts carbonate electrolyte from the carbon product through physical filtration and minimal water washing, avoiding acid treatment entirely. This eliminates CO2 emissions from acid-carbonate reactions while effectively removing electrolyte from the product.
Solution Approach 2:
The patent converts the potentially harmful acid treatment process into a benign physical filtration process. By using mechanical separation instead of chemical reaction, the process eliminates harmful CO2 emissions and avoids the need for acid handling and neutralization steps.
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
HTPF effectively extracts over 95% of the electrolyte from the cathode product, allowing for the recycling of high-temperature electrolyte and reducing material waste, while preserving the structure and stability of the solid carbon nanomaterials.
Implementation Method 1
applying a force to a solid carbon/molten electrolyte mixed product to remove the electrolyte
Data Source
AI summary
A process for the separation of electrolyte from the carbon in a solid carbon/electrolyte cathode product formed at the cathode during molten carbonate electrolysis. The processes allow for easy separation of the solid carbon product from the electrolyte without any observed detrimental effect on the structure and/or stability of the resulting solid carbon nanomaterial.