Electrochemical production of an alkaline solution using CO2

• US 7,993,511 B2
• Filed: 11/12/2009
• Issued: 08/09/2011
• Est. Priority Date: 07/15/2009
• Status: Active Grant

• Current Assignee: Eleryc Incorporated
• Original Assignee: Calera Corporation
• Inventors: Knott, Nigel Antony, Kostowskyj, Michael, Decker, Valentin, Gilliam, Ryan J., Boggs, Bryan
• Primary Examiner(s): Phasge; Arun S
• Application Number:
  US12/617,005
• Publication Number:
  US 20100084280A1
• Time in Patent Office: 635 Days
• Field of Search: 205/510, 205/514, 205/517, 204/252, 204/263
• US Class Current: 205/510
• CPC Class Codes: C01B 32/60 Preparation of carbonates or bicarbonates in general of percarbonates C01B15/10; of specific carbonates or bicarbonates according to the cation C01B-C01G
• CPC Class Codes: C25B 1/14 Alkali metal compounds

Abstract

An electrochemical system comprising a cathode electrolyte comprising added carbon dioxide and contacting a cathode; and a first cation exchange membrane separating the cathode electrolyte from an anode electrolyte contacting an anode; and an electrochemical method comprising adding carbon dioxide into a cathode electrolyte separated from an anode electrolyte by a first cation exchange membrane; and producing an alkaline solution in the cathode electrolyte and an acid.

Claims

1. An electrochemical system comprising:

a cathode electrolyte comprising added carbon dioxide and in contact with a cathode in a cathode compartment;

a first cation exchange membrane separating the cathode electrolyte from an anode electrolyte wherein the anode electrolyte is in contact with an anode in an anode compartment and comprises a salt and an acid;

a mineral dissolution system operatively connected to the anode compartment and wherein the mineral dissolution system is configured to dissolve a mineral with the acid in the anode electrolyte and produce a mineral solution comprising divalent cations, un-reacted acid and the salt; and

a nano-filtration system operatively connected to the mineral dissolution system and wherein the nano-filtration system is configured to receive the mineral solution and produce a first mineral solution comprising the salt and un-reacted acid, and a second mineral solution comprising divalent cations.

2. The electrochemical system of claim 1, comprising a second cation exchange membrane in contact with the anode and wherein the second cation exchange membrane is configured to separate the anode from the anode electrolyte.

3. The electrochemical system of claim 1, wherein the carbon dioxide added to the cathode electrolyte is contained in a waste gas from an industrial operation comprising an electrical power generating plant, a cement plant, an ore processing facility or a fermentation system.

4. The electrochemical system of claim 3, wherein the cathode electrolyte is configured to prevent atmospheric carbon dioxide from entering into the cathode electrolyte.

5. The electrochemical system of claim 4, wherein the cathode electrolyte is operatively connected to the industrial facility to receive the waste gas comprising carbon dioxide.

6. The electrochemical system of claim 5, wherein water is reduced to hydroxide ions and hydrogen gas at the cathode with an applied voltage across the anode and cathode, and wherein hydroxide ions at the cathode are migrated into the cathode electrolyte to produce the cathode electrolyte comprising hydroxide ions and/or bicarbonate ions and/or carbonate ions.

7. The electrochemical system of claim 6, wherein hydrogen gas is oxidized to hydrogen ions at the anode and wherein the hydrogen ions are migrated into the anode electrolyte to form the acid in the anode electrolyte.

8. The electrochemical system of claim 7, wherein the anode is configured to oxidize hydrogen gas to hydrogen ions and the cathode is configured to produce hydroxide ions and hydrogen gas with less than 1V applied across the anode and cathode, without producing a gas at the anode.

14. The electrochemical system of claim 8, further comprising a reverse osmosis system operatively connected to the nano-filtration system and wherein the reverse osmosis system is configured to concentrate the salt and un-reacted acid in the first mineral solution to produce the anode electrolyte.

15. The electrochemical system of claim 14, wherein the reverse osmosis system is operatively connected to the anode compartment and wherein the reverse osmosis system is configured to replenish the anode electrolyte in the anode compartment.

16. The electrochemical system of claim 15, wherein the second mineral solution comprises calcium and/or magnesium ions.

17. The electrochemical system of claim 16, further comprising a carbonate precipitation system operatively connected to the nano-filtration system and to the cathode compartment, and wherein

the carbonate precipitation system is configured to receive cathode electrolyte from the cathode compartment and the second mineral solution from the nano-filtration system, and produce a carbonate and/or bicarbonate by mixing the waste gas with the cathode electrolyte and the second mineral solution.

18. The electrochemical system of claim 17, wherein the carbonate ad/or bicarbonate comprises calcium carbonate, calcium bicarbonate, magnesium carbonate and/or magnesium bicarbonate or a mixture thereof.

19. The electrochemical system of claim 18, further comprising a salt concentrator operatively connected to the anode compartment and configured to receive the anode electrolyte and concentrate the salt therein.

20. The electrochemical system of claim 19, wherein the anode comprises a gas diffusion anode.

9. An method comprising:

adding carbon dioxide into a cathode electrolyte in contact with a cathode in a cathode compartment of an electrochemical system wherein the cathode electrolyte is separated from an anode electrolyte by a first cation exchange membrane and wherein the anode electrolyte is in contact with an anode in an anode compartment;

producing an alkaline solution in the cathode electrolyte without producing a gas at the anode in contact with the anode electrolyte by applying a voltage across the anode and cathode to reduce water to hydroxide ions and hydrogen gas at the cathode, migrate the hydroxide ions into the cathode electrolyte, and migrate cations from a salt in the anode electrolyte into the cathode electrolyte through the first cation exchange membrane;

producing an acid in the anode electrolyte by reducing hydrogen at the anode to hydrogen ions and migrating the hydrogen ions into the anode electrolyte;

dissolving a mineral using the anode electrolyte in a mineral dissolution system operatively connected to the anode compartment to produce a mineral solution comprising divalent cations, un-reacted acid and the salt; and

separating the salt and un-reacted acid from the mineral solution in a first mineral solution, and separating the divalent cations from the mineral solution in a second mineral solution using a nano-filtration system.

10. The method of claim 9 comprising producing hydroxide ions and/or bicarbonate ions and/or carbonate ions in the cathode electrolyte.

11. The method of claim 10, wherein the carbon dioxide added to the cathode electrolyte is contained in a waste gas from an industrial operation comprising an electrical power generating plant, a cement plant, an ore processing facility or a fermentation system.

12. The method of claim 11, wherein carbon dioxide in ambient air is excluded from the cathode electrolyte.

13. The method of claim 12, comprising maintaining a pH of between 8 and 11 in the cathode electrolyte.

21. The method of claim 13, comprising isolating the anode from the anode electrolyte using a second cation exchange membrane and migrating the hydrogen ions from through the second cation exchange membrane into the anode electrolyte.

22. The method of claim 21, comprising concentrating the first mineral solution by reverse osmosis to produce a concentrated first mineral solution and using the concentrated first mineral solution as the anode electrolyte.

23. The method of claim 22, comprising mixing the cathode electrolyte with the waste gas and the second mineral solution to produce a carbonate and/or bicarbonate comprising calcium and/or magnesium.

24. The method of claim 23, comprising withdrawing a portion of the anode electrolyte from the anode compartment, concentrating the withdrawn anode electrolyte by removing water, and returning the concentrated anode electrolyte to the anode compartment.