Process and high surface area electrodes for the electrochemical reduction of carbon dioxide

• US 8,858,777 B2
• Filed: 12/21/2012
• Issued: 10/14/2014
• Est. Priority Date: 07/26/2012
• Status: Active Grant

• Current Assignee: Avantium Knowledge Centre B.V. (Avantium NV)
• Original Assignee: Liquid Light, Inc. (Avantium NV)
• Inventors: Kaczur, Jerry J., Kramer, Theodore J., Keyshar, Kunttal, Majsztrik, Paul, Twardowski, Zbigniew
• Primary Examiner(s): Wong, Edna
• Application Number:
  US13/724,885
• Publication Number:
  US 20130180863A1
• Time in Patent Office: 662 Days
• Field of Search: 205/413, 205/440, 205/349, 205/464, 205/555
• US Class Current: 205/349
• CPC Class Codes: C25B 11/091 consisting of at least one catalytic element and at least one catalytic compound; consisting of two or more catalytic elements or catalytic compounds
• CPC Class Codes: C25B 15/00 Operating or servicing cells
• CPC Class Codes: C25B 15/08 Supplying or removing reactants or electrolytes; Regeneration of electrolytes
• CPC Class Codes: C25B 3/25 Reduction
• CPC Class Codes: C25B 9/19 with diaphragms
• CPC Class Codes: C25B 9/23 comprising ion-exchange membranes in or on which electrode material is embedded

Abstract

Methods and systems for electrochemical conversion of carbon dioxide to organic products including formate and formic acid are provided. A method may include, but is not limited to, steps (A) to (C). Step (A) may introduce an acidic anolyte to a first compartment of an electrochemical cell. The first compartment may include an anode. Step (B) may introduce a bicarbonate-based catholyte saturated with carbon dioxide to a second compartment of the electrochemical cell. The second compartment may include a high surface area cathode including indium and having a void volume of between about 30% to 98%. At least a portion of the bicarbonate-based catholyte is recycled. Step (C) may apply an electrical potential between the anode and the cathode sufficient to reduce the carbon dioxide to at least one of a single-carbon based product or a multi-carbon based product.

Claims

1. A method for electrochemical reduction of carbon dioxide into products, comprising:

(A) introducing an acidic anolyte to a first compartment of an electrochemical cell, the first compartment including an anode;

(B) introducing an alkali metal bicarbonate-based catholyte saturated with carbon dioxide to a second compartment of the electrochemical cell, the second compartment including a high surface area cathode, the high surface area cathode including a conductive base electrode structure and at least two electrocatalysts on the conductive base electrode structure, a first electrocatalyst of the at least two electrocatalysts including a metal, the first electrocatalyst is a layer covering the conductive base electrode structure, a second electrocatalyst of the at least two electrocatalysts is another layer on the first electrocatalyst, the high surface area cathode having a void volume of between about 30% to 98%, at least a portion of the alkali metal bicarbonate-based catholyte being recycled; and

(C) applying an electrical potential between the anode and the high surface area cathode sufficient to reduce the carbon dioxide to at least one of a single-carbon based product or a multi-carbon based product.

2. The method of claim 1, wherein applying an electrical potential between the anode and the cathode sufficient to reduce the carbon dioxide to at least one of a single-carbon based product or a multi-carbon based product comprises:

applying the electrical potential between the anode and the high surface area cathode sufficient to reduce the carbon dioxide to the single-carbon based product, the single carbon-based product including an alkali metal formate.

3. The method of claim 1, wherein the second compartment further includes a homogenous heterocyclic amine catalyst.

4. The method of claim 3, wherein the homogenous heterocyclic amine catalyst is selected from the group consisting of 4-hydroxy pyridine, adenine, a heterocyclic amine containing sulfur, a heterocyclic amine containing oxygen, an azole, a benzimidazole, a bipyridine, a furan, an imidazole, an imidazole related species with at least one five-member ring, an indole, a lutidine, a methylimidazole, an oxazole, a phenanthroline, a pterin, a pteridine, pyridine, a pyridine related species with at least one six-member ring, a pyrrole, a quinoline, and a thiazole.

5. The method of claim 1, wherein the anode comprises an electrocatalytic coating including at least one of ruthenium oxide, iridium oxide, a platinum oxide, gold, and a gold oxide.

6. The method of claim 1, wherein the electrochemical cell includes a membrane configured to selectively control a flow of ions between the first compartment and the second compartment.

7. The method of claim 1, wherein the high surface area cathode has a surface area of 2 to 2000 cm²/cm³.

8. The method of claim 1, wherein the first electrocatalyst is tin foil and the second electrocatalyst is an indium composition.

9. The method of claim 1, wherein the conductive base electrode structure includes copper.

10. The method of claim 1, wherein the high surface area cathode has structure which has a specific surface area which varies in a horizontal or vertical direction.

11. The method of claim 1, wherein the second electrocatalyst of the at least two electrocatalysts is applied as a coating on the first electrocatalyst.

12. A method for electrochemical reduction of carbon dioxide into products, comprising:

(A) introducing an acidic anolyte to a first compartment of an electrochemical cell, the first compartment including an anode;

(B) introducing an alkali metal bicarbonate-based catholyte saturated with carbon dioxide to a second compartment of the electrochemical cell, the second compartment including a high surface area cathode, the high surface area cathode including a conductive base electrode and at least two electrocatalysts on the conductive base electrode, a first electrocatalyst of the at least two electrocatalysts including a metal, the first electrocatalyst is a layer covering the conductive base electrode structure, a second electrocatalyst of the at least two electrocatalysts is another layer on the first electrocatalyst, the second electrocatalyst of the at least two electrocatalysts is applied as a coating on the first electrocatalyst, the high surface area cathode having a void volume of between about 30% to 98%, at least a portion of the alkali metal bicarbonate-based catholyte being recycled; and

(C) applying an electrical potential between the anode and the high surface area cathode sufficient to reduce the carbon dioxide to a multi-carbon based product.

13. The method of claim 12, wherein the second compartment further includes a homogenous heterocyclic amine catalyst.

14. The method of claim 13, wherein the homogenous heterocyclic amine catalyst is selected from the group consisting of 4-hydroxy pyridine, adenine, a heterocyclic amine containing sulfur, a heterocyclic amine containing oxygen, an azole, a benzimidazole, a bipyridine, a furan, an imidazole, an imidazole related species with at least one five-member ring, an indole, a lutidine, a methylimidazole, an oxazole, a phenanthroline, a pterin, a pteridine, pyridine, a pyridine related species with at least one six-member ring, a pyrrole, a quinoline, and a thiazole.

15. The method of claim 12, wherein the anode comprises an electrocatalytic coating including at least one of ruthenium oxide, iridium oxide, a platinum oxide, gold, and a gold oxide.

16. The method of claim 12, wherein the electrochemical cell includes a membrane configured to selectively control a flow of ions between the first compartment and the second compartment.

17. The method of claim 12, wherein the high surface area cathode has a surface area of 2 to 2000 cm²/cm³.

18. The method of claim 12, wherein the first electrocatalyst is tin foil.

19. The method of claim 18, wherein the second electrocatalyst is an indium composition.

20. The method of claim 19, wherein the indium composition covers a range of 5% to 100% of the tin foil.

21. The method of claim 12, wherein the conductive base electrode structure includes copper.

22. The method of claim 12, wherein the high surface area cathode has structure which has a specific surface area which varies in a horizontal or vertical direction.