CO;utilization in electrochemical systems

• US 8,894,830 B2
• Filed: 07/03/2012
• Issued: 11/25/2014
• Est. Priority Date: 07/16/2008
• Status: Active Grant

• Current Assignee: Eleryc Incorporated
• Original Assignee: Celera Corporation (Quest Diagnostics Incorporated)
• Inventors: Gilliam, Ryan J., Albrecht, Thomas A., Jalani, Nikhil, Knott, Nigel Antony, Decker, Valentin, Kostowskyj, Michael, Boggs, Bryan, Gorer, Alexander, Farsad, Kasra
• Primary Examiner(s): Smith, Nicholas A
• Application Number:
  US13/540,992
• Publication Number:
  US 20120312697A1
• Time in Patent Office: 875 Days
• Field of Search: 204/263, 205/637
• US Class Current: 204/263
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2313/08 Flow guidance means within the module or the apparatus
• CPC Class Codes: B01D 2313/16 Specific vents
• CPC Class Codes: B01D 2313/26 Specific gas distributors or gas intakes
• CPC Class Codes: B01D 53/326 in electrochemical cells
• CPC Class Codes: B01D 61/422 Electrodialysis
• CPC Class Codes: B01D 61/44 Ion-selective electrodialysis
• CPC Class Codes: B01D 61/46 Apparatus therefor
• CPC Class Codes: B01D 61/463 comprising the membrane sequence AC or CA, where C is a cation exchange membrane
• CPC Class Codes: C01B 7/01 Chlorine; Hydrogen chloride
• CPC Class Codes: C01D 1/40 by electrolysis
• CPC Class Codes: C01D 7/07 Preparation from the hydroxides
• CPC Class Codes: C01F 11/18 Carbonates
• CPC Class Codes: C01F 5/24 Magnesium carbonates
• CPC Class Codes: C02F 1/46109 Electrodes
• CPC Class Codes: C02F 1/68 by addition of specified substances, e.g. trace elements, for ameliorating potable water medicinal water A61K
• CPC Class Codes: C02F 2001/46166 Gas diffusion electrodes
• CPC Class Codes: C02F 2201/46115 Electrolytic cell with membranes or diaphragms
• CPC Class Codes: C02F 2201/4613 Inversing polarity
• CPC Class Codes: C02F 2201/46135 Voltage
• CPC Class Codes: C02F 2201/46185 : Recycling the cathodic or anodic feed
• CPC Class Codes: C02F 2209/06 : pH
• CPC Class Codes: C02F 2301/046 : Recirculation with an external loop
• CPC Class Codes: C25B 1/00 : Electrolytic production of inorganic compounds or non-metals
• CPC Class Codes: C25B 1/02 : Hydrogen or oxygen
• CPC Class Codes: C25B 1/04 : by electrolysis of water
• CPC Class Codes: C25B 1/14 : Alkali metal compounds
• CPC Class Codes: C25B 1/16 : Hydroxides by simultaneous production of alkali metal hydroxides and chlorine, oxyacids or salts of chlorine C25B1/34
• CPC Class Codes: C25B 1/20 : Hydroxides
• CPC Class Codes: C25B 1/26 : Chlorine; Compounds thereof by simultaneous production of alkali metal hydroxides and chlorine, oxyacids or salts of chlorine C25B1/34
• CPC Class Codes: C25B 15/08 : Supplying or removing reactants or electrolytes; Regeneration of electrolytes
• CPC Class Codes: Y02C 20/40 : of CO2
• CPC Class Codes: Y02E 60/36 : Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
• CPC Class Codes: Y02P 20/151 : Reduction of greenhouse gas [GHG] emissions, e.g. CO2

Abstract

A low-voltage, low-energy electrochemical system and method of removing protons and/or producing a base solution comprising hydroxide and carbonate/bicarbonate ions, utilizing carbon dioxide in a cathode compartment that is partitioned into a first cathode electrolyte compartment and a second cathode electrolyte compartment such that liquid flow between the cathode electrolyte compartments is possible, but wherein gaseous communication between the cathode electrolyte compartments is restricted. Carbon dioxide gas in one cathode electrolyte compartment is utilized with the cathode electrolyte in both compartments to produce the base solution with less that 3V applied across the electrodes.

Claims

1. An electrochemical method comprising:

contacting an anode electrolyte with an anode in an anode compartment;

contacting a cathode electrolyte with a cathode in a cathode compartment wherein the cathode produces hydroxide ions;

directing an industrial waste gas comprising carbon dioxide into the cathode electrolyte in the cathode compartment or directing carbon dioxide into the cathode electrolyte from a gas/liquid contactor that is in contact with an industrial waste gas;

converting bicarbonate ions to carbonate ions in the cathode electrolyte and producing a pH differential between the anode electrolyte and the cathode electrolyte of between 6-12; and

contacting the cathode electrolyte with a divalent cation solution to produce divalent cation carbonate and/or bicarbonate compounds, wherein the divalent carbonate and/or bicarbonate compounds comprise calcium, magnesium, or both calcium and magnesium.

2. The method of claim 1, further comprising using the divalent carbonate and/or bicarbonate compounds in making building materials.

3. The method of claim 1, further comprising disposing off the divalent carbonate and/or bicarbonate compounds.

4. The method of claim 1, comprising applying a voltage across the anode and the cathode of less than 0.8V.

5. The method of claim 1, comprising withdrawing and circulating the cathode electrolyte between the gas/liquid contactor and the cathode compartment.

6. The method of claim 1, further comprising producing hydrogen ions at the anode to form an acid in the anode electrolyte.

7. The method of claim 6, further comprising dissolving minerals or waste materials with the acid to form the divalent cation solution.

8. The method of claim 7, wherein the mineral comprises calcium and/or magnesium rich minerals and the waste material comprises fly ash or red mud.

9. The method of claim 1, wherein the liquid in the gas/liquid contactor comprises the cathode electrolyte.

10. The method of claim 1, wherein the industrial waste gas further comprises sulfur gas, nitrogen oxide gas, metal, particulates, or combination thereof.

11. The method of claim 1, further comprising separating the cathode electrolyte from a third electrolyte by a cation exchange membrane and separating the anode electrolyte from the third electrolyte by an anion exchange membrane.

12. The method of claim 11, wherein the third electrolyte comprises sodium ions and chloride ions.

13. An electrochemical system comprising:

(a) a cathode compartment comprising a cathode electrolyte in contact with a cathode wherein the cathode is configured to produce hydroxide ions, wherein the cathode compartment is operatively connected to a system selected from an industrial waste gas system that delivers carbon dioxide derived from combusting fossil fuels or cement plants to the cathode compartment;

a gas/liquid contactor operatively connected to the industrial waste gas system wherein the gas/liquid contactor contacts the cathode electrolyte with the carbon dioxide from the industrial waste gas system;

or combination thereof;

(b) an anode compartment comprising an anode electrolyte in contact with an anode;

(c) the cathode electrolyte comprising bicarbonate ions wherein the anode electrolyte and the cathode electrolyte have a pH differential of between 6-12; and

(d) a carbonate and/or bicarbonate precipitation system operably connected to the cathode compartment and a source of divalent cations and configured to produce divalent cation carbonates and/or divalent cation bicarbonate.

14. The system of claim 13, further comprising a cathode electrolyte circulating system operably connected to the cathode compartment and the gas/liquid contactor and configured to circulate the cathode electrolyte between the cathode compartment and the gas/liquid contactor.

15. The system of claim 13, wherein the anode is configured to form hydrogen ions.

16. The system of claim 15, further comprising a mineral dissolution system operably connected to the anode compartment and configured to dissolve minerals with the acid to form divalent cation solution.

17. The system of claim 13, further comprising at least one ion exchange membrane between the anode compartment and the cathode compartment.

18. The system of claim 17, wherein the at least one ion exchange membrane comprises a cation exchange membrane separating the cathode electrolyte from a third electrolyte and an anion exchange membrane separating the anode electrolyte from the third electrolyte.

19. The system of claim 18, wherein the third electrolyte comprises sodium ions and chloride ions and wherein the system is configured to migrate the sodium ions from the third electrolyte to the cathode electrolyte through the cation exchange membrane, and migrate the chloride ions from the third electrolyte to the anode electrolyte through the anion exchange membrane.

20. The system of claim 13, further comprising a carbonate and/or bicarbonate disposal system configured to dispose a slurry/suspension of the divalent cation carbonates and/or divalent cation bicarbonate in an ocean.