Single-Atom Ni-Mn Catalyst for Low-Overpotential CO2-to-CO Conversion

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Solution Overview

Problem

Current electrochemical carbon dioxide reduction processes face limitations due to low reaction rates, low selectivity, and high energy requirements, particularly in using noble metal catalysts, which are costly and difficult to stabilize at the single atom level.

Innovation Solution

A nitrogen-doped carbon nanostructure loaded with indirectly linked nickel (Ni) and manganese (Mn) single atoms as a bimetallic catalyst, which enhances carbon dioxide conversion activity and selectivity for carbon monoxide at lower overpotential.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If noble metal catalysts (Au, Ag) are used for carbon dioxide reduction, then carbon monoxide selectivity and current density are improved, but cost and economic feasibility deteriorate

Engineering Contradiction:

Improvecarbon monoxide selectivityVSAvoidcost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive noble metals with inexpensive transition metals (Fe, Co, Ni, Cu, Zn, Mn, Cr, Mo) to create single atom catalysts that achieve comparable catalytic performance at much lower cost, directly addressing the economic feasibility issue while maintaining carbon monoxide selectivity

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent changes the fundamental parameter of metal type from noble metals to transition metals, and optimizes the coordination environment (M-Nx moieties with different nitrogen coordination numbers) to achieve high selectivity and activity with cheaper materials

Inventive Principle:

Principle #35Parameter changes

2Productivity

If metals are dispersed at single atom size to maximize conversion activity, then catalytic efficiency is improved, but stability deteriorates due to atom aggregation

Engineering Contradiction:

Improvecarbon dioxide conversion activityVSAvoidsingle atom stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent introduces nitrogen-doped carbon nanostructures as intermediary support materials that coordinate with transition metal atoms to form stable M-Nx moieties, preventing atom aggregation while maintaining single atom dispersion and high catalytic activity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates composite materials combining transition metals with nitrogen-doped carbon nanostructures, where the carbon-nitrogen matrix provides structural stability and prevents metal atom aggregation, while the single atom metal sites maintain high catalytic efficiency

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If complex synthesis processes are used to create stable single atom catalysts, then stability is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvesingle atom catalyst stabilityVSAvoidsynthesis process complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent segments the synthesis into simple, sequential steps: (1) preparing nitrogen-doped carbon nanostructure, (2) introducing transition metal precursors, (3) thermal treatment to form M-Nx moieties. This segmented approach simplifies the overall process while achieving stable single atom catalysts

Inventive Principle:

Principle #1Segmentation

4Productivity

If high overpotential is applied to achieve high reaction rates, then productivity is improved, but energy consumption increases

Engineering Contradiction:

Improvereaction rateVSAvoidoverpotential

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the electronic structure parameters of the catalyst by adjusting nitrogen coordination (M-N3 vs M-N4 moieties) and metal type, which optimizes the binding energy of reaction intermediates and enables high reaction rates at lower overpotentials, reducing energy consumption

Inventive Principle:

Principle #35Parameter changes

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 bimetallic catalyst achieves high carbon dioxide conversion activity and selectivity for carbon monoxide with reduced energy requirements, improving economic feasibility and stability compared to noble metal catalysts.

Implementation Method 1

a first transition metal (M1) and a second transition metal (M2) in the form of single atoms loaded in the nitrogen-doped carbon nanostructure... each bonded to a nitrogen atom of the nitrogen-doped carbon nanostructure

Methodology Applied

Scientific EffectCoordination bonding: Chemical Bonding

Implementation Method 2

electrochemical conversion... the carbon dioxide reduction reaction (CO2RR) of reacting thermodynamically stable carbon dioxide with water

Methodology Applied

Scientific EffectElectrochemical reduction: Electrolysis

Data Source

PatentUS20230383426A1Single atomic metal catalyst and carbon dioxide conversion system using the same

Publication Date: 2023.11.30 SK INNOVATION CO LTD

AI summary

An electrochemical hybrid catalyst has a structure in which a nitrogen-doped carbon nanostructure (N—C) composite is loaded or decorated with two single atom transition metals indirectly linked adjacent to each other, and thus exhibits high carbon monoxide selectivity and current density at a low overpotential during reduction reaction for converting carbon dioxide into carbon monoxide, and a carbon dioxide conversion system uses the same.