Systems and methods for preparation and separation of products

• US 9,957,623 B2
• Filed: 10/21/2015
• Issued: 05/01/2018
• Est. Priority Date: 05/19/2011
• Status: Active Grant

• Current Assignee: Calera Corporation
• Original Assignee: Calera Corporation
• Inventors: Gilliam, Ryan J, Boggs, Bryan, Self, Kyle, Leclerc, Margarete K, Gorer, Alexander, Weiss, Michael J, Miller, John H, Mohanta, Samaresh
• Primary Examiner(s): Thomas, Ciel P
• Application Number:
  US14/919,281
• Publication Number:
  US 20160060774A1
• Time in Patent Office: 923 Days
• 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 1/20 Hydroxides
• CPC Class Codes: C25B 11/031 Porous electrodes
• CPC Class Codes: C25B 11/073 characterised by the electrocatalyst material
• CPC Class Codes: C25B 15/08 Supplying or removing reactants or electrolytes; Regeneration of electrolytes
• CPC Class Codes: C25B 9/00 Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features

Abstract

There are provided methods and systems for an electrochemical cell including an anode and a cathode where the anode is contacted with a metal ion that converts the metal ion from a lower oxidation state to a higher oxidation state. The metal ion in the higher oxidation state is reacted with hydrogen gas, an unsaturated hydrocarbon, and/or a saturated hydrocarbon to form products.

Claims

1. A system, comprising:

an anode in contact with an anode electrolyte in an anode chamber of an electrochemical cell comprising metal halide and saltwater wherein the anode is configured to oxidize the metal halide from a lower oxidation state to a higher oxidation state;

a cathode in contact with a cathode electrolyte in a cathode chamber in the electrochemical cell;

a power source to apply a voltage to the anode and the cathode;

a reactor operably connected to the anode chamber and configured to react the anode electrolyte comprising the metal halide in the higher oxidation state with an unsaturated hydrocarbon or saturated hydrocarbon in an aqueous medium to form one or more organic compounds comprising halogenated hydrocarbon and the metal halide in the lower oxidation state in the aqueous medium, and

a separator comprising an adsorbent operably connected to the reactor and configured to separate the one or more organic compounds from the aqueous medium comprising the metal halide in the lower oxidation state.

2. The system of claim 1, wherein the adsorbent is selected from activated charcoal, alumina, activated silica, polymer, and combinations thereof.

3. The system of claim 1, wherein the adsorbent is a polyolefin selected from polyethylene, polypropylene, polystyrene, polymethylpentene, polybutene-1, polyolefin elastomers, polyisobutylene, ethylene propylene rubber, polymethylacrylate, poly(methylmethacrylate), poly(isobutylmethacrylate), and combinations thereof.

4. The system of claim 1, wherein the adsorbent is polystyrene.

5. The system of claim 1, wherein the adsorbent is in a shape of powder, plate, mesh, beads, cloth, fiber, pills, flakes, or blocks.

6. The system of claim 1, wherein the separator is one or more packed bed columns comprising polystyrene.

7. The system of claim 1, wherein the adsorbent is configured to adsorb more than 95% w/w of the one or more organic compounds.

8. The system of claim 1, wherein the separator further comprises a recirculating system operably connected to the anode chamber to recirculate the aqueous medium comprising metal halide in the lower oxidation state to the anode electrolyte.

9. The system of claim 1, wherein the anode is a diffusion enhancing anode.

10. The system of claim 1, wherein the cathode electrolyte comprises water and the cathode is an oxygen depolarizing cathode that is configured to reduce oxygen and water to hydroxide ions;

the cathode electrolyte comprises water and the cathode is a hydrogen gas producing cathode that is configured to reduce water to hydrogen gas and hydroxide ions;

the cathode electrolyte comprises hydrochloric acid and the cathode is a hydrogen gas producing cathode that is configured to reduce hydrochloric acid to hydrogen gas;

or the cathode electrolyte comprises hydrochloric acid and the cathode is an oxygen depolarizing cathode that is configured to react hydrochloric acid and oxygen gas to form water.

11. The system of claim 1, wherein and the cathode is an oxygen depolarizing cathode.

12. The system of claim 1, wherein metal ion in the metal halide is selected from the group consisting of iron, chromium, copper, tin, silver, cobalt, uranium, lead, mercury, vanadium, bismuth, titanium, ruthenium, osmium, europium, zinc, cadmium, gold, nickel, palladium, platinum, rhodium, iridium, manganese, technetium, rhenium, molybdenum, tungsten, niobium, tantalum, zirconium, hafnium, and combinations thereof.

13. The system of claim 1, wherein metal ion in the metal halide is copper that is converted from Cu⁺ to Cu²⁺, metal ion in the metal halide is iron that is converted from Fe²⁺ to Fe³⁺, metal ion in the metal halide is tin that is converted from Sn²⁺ to Sn⁴⁺, metal ion in the metal halide is chromium that is converted from Cr²⁺ to Cr³⁺, metal ion in the metal halide is platinum that is converted from Pt²⁺ to Pt⁴⁺, or combinations thereof.

14. The system of claim 1, wherein the unsaturated hydrocarbon is compound of formula I resulting in compound of formula II after halogenation:

15. The system of claim 1, wherein the unsaturated hydrocarbon is ethylene, propylene, or butylene and the halogenated hydrocarbon is ethylene dichloride, propylene dichloride or dichlorobutane, respectively.

16. The system of claim 1, wherein the one or more organic compounds comprise ethylene dichloride, chloroethanol, trichloroethane, chloral hydrate, 1,1-dichloroethene, trichloroethylene, tetrachloroethene, 1,1,2,2-tetrachloroethane, dichloroacetaldehyde, trichloroacetaldehyde, or combinations thereof.

17. The system of claim 1, wherein the saturated hydrocarbon is methane, ethane, or propane.

18. The system of claim 1, wherein the saltwater comprises water comprising more than 1 wt % chloride content.

19. The system of claim 1, wherein the saltwater comprises sodium chloride.

20. The system of claim 1, wherein the saltwater comprises more than 10 wt % of sodium chloride.