Removing carbon dioxide from waste streams through co-generation of carbonate and/or bicarbonate minerals

• US 8,741,244 B2
• Filed: 05/28/2010
• Issued: 06/03/2014
• Est. Priority Date: 09/23/2004
• Status: Active Grant

• Current Assignee: Carbonfree Chemicals Holdings, LLC
• Original Assignee: Skyonic Corp.
• Inventors: Jones, Joe David
• Primary Examiner(s): Mayes, Melvin C
• Assistant Examiner(s): DAVIS, SHENG HAN
• Application Number:
  US12/790,121
• Publication Number:
  US 20100260653A1
• Time in Patent Office: 1,467 Days
• Field of Search: 205/349, 205/508, 205/510, 205/516, 205/615, 205/618, 205/620, 204/194, 423/234, 423/419.1, 423/421, 423/422, 423/432, 423/481, 423/487
• US Class Current: 423/220
• CPC Class Codes: B01D 2251/304 of sodium
• CPC Class Codes: B01D 2251/604 Hydroxides
• CPC Class Codes: B01D 2258/0283 Flue gases
• CPC Class Codes: B01D 53/1418 Recovery of products
• CPC Class Codes: B01D 53/1475 Removing carbon dioxide
• CPC Class Codes: B01D 53/62 Carbon oxides
• CPC Class Codes: B01D 53/73 After-treatment of removed components
• CPC Class Codes: B01D 53/965 including an electrochemical process step
• 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: C01D 7/07 Preparation from the hydroxides
• CPC Class Codes: C01D 7/14 Preparation of sesquicarbonates
• CPC Class Codes: C01F 1/00 Methods of preparing compounds of the metals beryllium, magnesium, aluminium, calcium, strontium, barium, radium, thorium, or the rare earths, in general
• CPC Class Codes: Y02C 20/40 of CO2
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 20/129 Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
• CPC Class Codes: Y02P 20/133 Renewable energy sources, e.g. sunlight
• CPC Class Codes: Y02P 20/151 Reduction of greenhouse gas [GHG] emissions, e.g. CO2

Abstract

Methods for removing carbon dioxide and other pollutants from a gas stream are provided. The methods include obtaining hydroxide in an aqueous mixture, mixing the hydroxide with the gas stream to produce bicarbonate products or a combination of carbonate and bicarbonate products in an admixture, separating the products from the admixture, and using the products to perform ion-exchanges with one or more group-1 or group-2 salts to precipitate carbonates, wherein obtaining the hydroxide comprises obtaining a group-1 or group-2 salt; mixing the salt with acid and water, acid and steam, or acid, water, and steam to produce a protonated brine solution; and electrolyzing the protonated brine solution to produce a hydroxide; and wherein mixing the hydroxide with the gas stream comprises altering the product equilibrium to favor the production of bicarbonate products.

Claims

1. A method of sequestering carbon dioxide produced by a source and contained in a gas stream, comprising the steps of:

(a) obtaining a hydroxide in an aqueous mixture;

(b) admixing the hydroxide with carbon dioxide produced by the source to produce bicarbonate products or a combination of carbonate and bicarbonate products in an admixture;

(c) separating said products from the admixture, thereby sequestering the carbon dioxide in a mineral product form; and

(d) using said products to perform ion-exchanges with one or more group-1 or group-2 salts to precipitate carbonates;

wherein obtaining the hydroxide comprises;

obtaining a group-1 or group-2 salt;

admixing the salt with acid and water, acid and steam, or acid, water, and steam to produce a protonated brine solution; and

electrolyzing the protonated brine solution to produce a hydroxide;

wherein step (b) comprises altering the product equilibrium to favor the production of bicarbonate products.

2. The method of claim 1, wherein an amount of carbon dioxide is generated in performing steps (a)-(c), and that amount of carbon dioxide is less than the amount of carbon dioxide sequestered in performing steps (a)-(c).

3. The method of claim 1, wherein the admixing occurs in two separate chambers, with one chamber being used to produce carbonate products and the other chamber being used to produce bicarbonate products.

4. The method of claim 1, wherein the admixing occurs in a bubble column or series of bubble columns.

5. The method of claim 1, wherein step (c) involves a heated-precipitation separation process.

6. The method of claim 5, wherein the heat for the separation process is derived from heat exchange with incoming flue-gases.

7. The method of claim 1, further comprising:

transporting the products to a remote sequestration site;

combining the products with acid in a neutralization reaction to generate pure carbon dioxide; and

injecting the carbon dioxide into a carbon bank.

8. The method of claim 1, wherein other components of the gas stream are neutralized and/or captured in performing steps (a)-(c).

9. The method of claim 1, wherein electrolyzing the protonated brine comprises combusting a carbon-based fuel source to produce DC electricity.

10. The method of claim 1, wherein the amount of acid admixed with the salt is based on a determination of the optimum protonation rate that achieves the lowest energy to produce reactants and the highest energy to recover from products.

11. The method of claim 1, wherein:

the protonated brine solution is electrolyzed in an electrochemical cell having a catholyte side and an anolyte side; and

the products are recycled to the catholyte side of the electrochemical cell.

12. The method of claim 1, wherein the energy required by the method is supplemented with waste-heat recovered from the gas stream.

13. The method of claim 1, wherein the salt is sodium chloride, the acid is hydrochloric acid, and the hydroxide produced by electrolyzing the protonated brine solution is sodium hydroxide.

14. The method of claim 1, wherein the gas stream is an exhaust stream from a plant.

15. The method of claim 14, wherein the plant is a power plant that employs a carbon-based fuel source.

16. The method of claim 13, wherein electrolyzing the protonated brine solution also produces chlorine gas and hydrogen gas.

17. The method of claim 16, wherein the chlorine gas and hydrogen gas are combusted to form hydrochloric acid.

18. The method of claim 16, wherein the hydrogen gas is used to produce energy.

19. The method of claim 17, wherein the hydrochloric acid formed from the chlorine gas and hydrogen gas is used in obtaining additional hydroxide.

20. The method of claim 16, wherein the hydrogen gas is combusted with atmospheric oxygen or oxygen from stock chemicals to produce water.

21. The method of claim 18, wherein step (c) involves a heated-precipitation separation process in which the heat for the separation process is derived from the energy produced by the hydrogen gas.

22. The method of claim 18, wherein the hydrogen gas is co-burned with coal to improve coal-fired emissions.

23. The method of claim 18, wherein the hydrogen gas is used in a combustion process for fuel-cell recovery of DC electricity.

24. A method of sequestering carbon dioxide produced by a source and contained in a gas stream, comprising the steps of:

(a) obtaining a hydroxide in an aqueous mixture;

(b) admixing the hydroxide with carbon dioxide produced by the source to produce bicarbonate products or a combination of carbonate and bicarbonate products in an admixture; and

(c) separating said products from the admixture, thereby sequestering the carbon dioxide in a mineral product form;

wherein obtaining the hydroxide comprises;

obtaining a group-1 or group-2 salt;

admixing the salt with acid and water, acid and steam, or acid, water, and steam to produce a protonated brine solution; and

electrolyzing the protonated brine solution to produce a hydroxide using diaphragm, mercury, or membrane cells;

wherein step (b) comprises altering the product equilibrium to favor the production of bicarbonate products.

25. A method of sequestering carbon dioxide produced by a source and contained in a gas stream, comprising the steps of:

(a) obtaining a hydroxide in an aqueous mixture;

(b) admixing the hydroxide with carbon dioxide produced by the source to produce bicarbonate products or a combination of carbonate and bicarbonate products in an admixture; and

(c) separating said products from the admixture, thereby sequestering the carbon dioxide in a mineral product form;

wherein obtaining the hydroxide comprises;

obtaining a group-1 or group-2 salt;

admixing the salt with acid and water, acid and steam, or acid, water, and steam to produce a protonated brine solution; and

electrolyzing the protonated brine solution to produce a hydroxide and hydrogen gas;

wherein step (b) comprises altering the product equilibrium to favor the production of bicarbonate products;

wherein the hydrogen gas is traded or sold.

26. A method of sequestering carbon dioxide produced by a source and contained in a gas stream, comprising the steps of:

(a) obtaining a hydroxide in an aqueous mixture;

(b) admixing the hydroxide with carbon dioxide produced by the source to produce bicarbonate products or a combination of carbonate and bicarbonate products in an admixture; and

(c) separating said products from the admixture, thereby sequestering the carbon dioxide in a mineral product form;

wherein obtaining the hydroxide comprises;

obtaining a group-1 or group-2 salt;

admixing the salt with acid and water, acid and steam, or acid, water, and steam to produce a protonated brine solution; and

electrolyzing the protonated brine solution to produce a hydroxide;

wherein step (b) comprises altering the product equilibrium to favor the production of bicarbonate products;

wherein a quantity of power is required to perform steps (a)-(c), and that power is produced by one or more non-greenhouse-gas emitting power sources.

27. The method of claim 26, wherein the non-greenhouse-gas emitting power sources are selected from wind-power, hydro-electric power, solar power, and nuclear power.