Tin-Based Cathodic Catalyst for CO2 Reduction
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Solution Overview
Problem
Existing electrochemical systems for the reduction of carbon dioxide to formate and formic acid face challenges in achieving high and stable current density and Faradaic Efficiency, particularly due to unpredictable catalyst activity and mechanical instability of tin-based cathodic catalysts.
Innovation Solution
The development of electrodes comprising nano-scale tin deposits on carbon supports, applied with a sulfonated tetrafluoroethylene-based fluoropolymer binder to a carbon fiber substrate, which are used in an electrochemical process to reduce carbon dioxide to formate and formic acid, with specific processes involving the mixing of tin chloride, ethylene glycol, and carbon black, followed by refluxing and drying to create a catalyst ink for coating on the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tin-based cathodic catalysts are used for electrochemical reduction of carbon dioxide, then selectivity to formate and formic acid is improved, but mechanical stability and current density stability deteriorate
Solution Approach 1:
The patent applies composite materials by combining tin-based catalyst particles with a porous substrate to create a hybrid cathode structure. The tin-based catalyst provides high selectivity for formate and formic acid production, while the porous substrate offers mechanical stability and structural support. This composite approach allows the system to maintain both the catalytic activity of tin and the mechanical robustness of the substrate, resolving the contradiction between selectivity and mechanical stability.
Solution Approach 2:
The patent utilizes porous materials by employing a porous substrate as the cathode structure. The porous nature of the substrate provides high surface area for catalyst dispersion, enhances mass transport of reactants and products, and maintains mechanical integrity. The porous structure allows the tin-based catalyst to be effectively distributed while the substrate framework ensures stability during operation, addressing both selectivity and mechanical stability requirements.
2Productivity
If high surface area catalyst is used to improve reaction efficiency, then Faradaic Efficiency is improved, but mechanical stability deteriorates
Solution Approach 1:
The patent employs porous materials by using a porous substrate with high surface area that serves as the cathode structure. This porous architecture provides extensive surface area for the tin-based catalyst to disperse and function, thereby achieving high Faradaic Efficiency for carbon dioxide reduction. Simultaneously, the porous substrate maintains mechanical stability through its structured framework, preventing the catalyst from detaching or degrading during operation.
Solution Approach 2:
The patent applies composite materials by creating a composite structure where tin-based catalyst particles are deposited on or integrated with a porous substrate. The high surface area of the porous substrate enables high catalyst loading and high Faradaic Efficiency, while the substrate's mechanical properties provide stability. This composite design allows the system to achieve high productivity without sacrificing mechanical reliability.
3Productivity
If tin-based catalyst is applied to substrate, then catalytic activity is improved, but adhesion and long-term stability worsen
Solution Approach 1:
The patent utilizes porous materials by employing a porous substrate that provides high surface area for catalyst application. The porous structure allows for better penetration and anchoring of the tin-based catalyst within the substrate matrix, improving adhesion. The high surface area also enhances catalytic activity by providing more active sites. The porous framework maintains structural integrity during operation, ensuring long-term stability.
Solution Approach 2:
The patent applies composite materials by creating a composite cathode where tin-based catalyst is integrated with a porous substrate. The composite structure ensures strong interfacial bonding between the catalyst and substrate, improving adhesion. The high surface area of the porous substrate maximizes catalyst utilization and catalytic activity, while the substrate's mechanical properties ensure long-term operational stability and resistance to catalyst detachment.
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
These electrodes provide stable high current density and high Faradaic Efficiency over time, with Faradaic Efficiency ranging from 55 to 95 percent over 100 hours, maintaining performance through improved adhesion and mechanical stability.
Implementation Method 1
carbon dioxide is reduced to formate and formic acid at the cathode
Implementation Method 2
depositing tin onto a carbon support such as carbon black using a solution of tin (II) chloride
Implementation Method 3
mixing catalyst powder, the catalyst powder comprising tin-carbon particles, an alcohol-based solvent, and polymeric binder, to form a catalyst ink
Data Source
AI summary
An electrochemical electrode comprising a tin-based catalyst, method of making, and method of use are provided. Catalyst particles are prepared which comprise tin deposits of about 0.1 nm to about 10 nm deposited onto carbon support. Preparing an ink comprising the catalyst particles and a binder enable an electrode to be prepared comprising the catalyst particles bound to an electrode substrate. The electrode may then be used in an apparatus and process to reduce carbon dioxide to products such as formate and formic acid at Faradaic Efficiencies up to 95 percent.