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Utah 2011 CO2 + H2O = Hydrocarbon Syngas

United States Patent: 8075746

A number of times during the course of our reportage over the last several years, we've documented for you the development of a technology that has been labeled by some as "syntrolysis", that is, the co-electrolysis of Steam, H2O, and Carbon Dioxide, CO2, with the breakdown of those compounds into their simpler elemental and molecular constituents; most significantly Hydrogen and Carbon Monoxide, which can then serve as the components of a synthesis gas and be catalytically condensed, as via the venerable, almost generic, Fischer-Tropsch process, into liquid and gaseous hydrocarbons.

The essential principle of H2O-CO2 co-electrolysis for the purpose of hydrocarbon synthesis has been around for at least a quarter of a century, as seen in our report of:

Standard Oil Electrolyzes CO2 to Carbon Monoxide | Research & Development; concerning: "United States  Patent 4,668,349 - Electrocatalytic Reduction of CO2 by Square Planar Transition Metal Complexes; 1987; Assignee: The Standard Oil Company; Abstract: A process for the electrocatalytic reduction of carbon dioxide comprises immersing a transition metal complex with square planar geometry into an aqueous or nonaqueous solution which has been acidified to a (specified) hydrogen ion concentration ... , adding the carbon dioxide, applying an electrical potential of from about -0.8 volts to about -1.5 volts ... , and reducing the carbon dioxide to carbon monoxide."

However, our United States Department of Energy later began to work with a Utah-based company, Ceramatec, Incorporated, on an advanced version such concepts, developed in part by Ceramatec, wherein the electrochemical reduction of H2O and CO2, into hydrocarbon synthesis gas, became much more efficient when both were in their gaseous states, and processed in specially-designed electrical "cells".

Some examples of our reportage on those developments can be accessed, on the West Virginia Coal Association's web site, via the links:

More USDOE CO2 "Syntrolysis" | Research & Development; concerning: "Co-Electrolysis of Steam and Carbon Dioxide for Production of Syngas; Fifth International Fuel Cell Science, Engineering and Technology Conference; 2007; Idaho National Laboratory, USDOE; and Ceramatec, Inc., Utah; An experimental study has been completed to assess the performance of single-oxide electrolysis cells ... simultaneously electrolyzing steam and carbon dioxide for the direct production of syngas. Syngas, a mixture of hydrogen and carbon monoxide, can be used for the production of synthetic liquid fuels via Fischer-Tropsch processes."; and: .

Utah Recycles CO2 | Research & Development; concerning: Co-Electrolysis of Steam and Carbon Dioxide as Feed to a Methanation Reaction; Lyman Frost, Joseph Hartvigsen and S. Elangovan; Ceramatec, Inc, Salt Lake City, UT; Abstract: Solid oxide fuel cells can be operated in reverse by applying an electric potential across the fuel cells and forcing the oxygen ion to flow in the opposite direction from the fuel cell mode. If a mixture of high temperature steam and carbon dioxide are fed to a fuel cell stack operating in this electrolysis mode, the result will be a mixture of carbon monoxide and hydrogen. By adjusting the input ratios of steam and carbon dioxide, the output of the electrolysis system can be modified to be in the proper ratio for the formation of a number of different hydrocarbons by catalytic process through either Fischer Tropsch or methanation reactions".

Concurrent with Ceramtec's work in concert with the USDOE's Idaho National Laboratory, they also applied for a United States Patent on their CO2-H2O co-electrolysis technology, as seen in our report of:

USDOE and Utah CO2 + H2O = Hydrocarbon Syngas | Research & Development; concerning: "US Patent Application 2007/0045125A1 - Electrochemical Cell for Production of Synthesis Gas; 2007; Inventors: Joseph Hartvigsen, et. al., Utah; Assignee: Ceramatec, Inc.; Abstract: A method is provided for synthesizing synthesis gas from carbon dioxide obtained from atmospheric air or other available carbon dioxide source and water using a sodium-conducting electrochemical cell. The synthesis gas produced may then be further processed and eventually converted into a liquid fuel suitable for transportation or other applications."

Herein, we learn that "US Patent Application 2007/0045125A1" was quite recently, just in time for Christmas, approved by our own United States Government's technically astute patent examiners, who agreed that we can, in fact, using Ceramatec's invention, convert, on a practical basis, a blend of Carbon Dioxide and Steam into a subsequent blend of Carbon Monoxide and Hydrogen synthesis gas, which can itself be further "converted into a liquid fuel".

Comment follows, and is inserted within, excerpts from the initial link in this dispatch to the quite recent, maybe even newsworthy:

"United States Patent 8,075,746 - Electrochemical Cell for Production of Synthesis Gas Using Atmospheric Air and Water

Date: December 13, 2011

Inventors: Joseph Hartvigsen, et. al., Utah

Assignee: Ceramatec, Inc., Salt Lake City

Abstract: A method is provided for synthesizing synthesis gas from carbon dioxide obtained from atmospheric air or other available carbon dioxide source and water using a sodium-conducting electrochemical cell. Synthesis gas is also produced by the coelectrolysis of carbon dioxide and steam in a solid oxide fuel cell or solid oxide electrolytic cell. The synthesis gas produced may then be further processed and eventually converted into a liquid fuel suitable for transportation or other applications.

Claims: An electrochemical cell for producing synthesis gas comprising: an anode chamber comprising an electrochemically active anode having a source of water in which the water is decomposed (and) wherein O2 is collected and removed from the anode chamber; an intermediate chamber separated from the anode chamber by a separator which permits transport of H+ ions, wherein the intermediate chamber has a source of Na2CO3 and H.+ ions, in which the Na2CO3 is decomposed (yielding CO2, and) wherein CO2 is collected and removed from the intermediate chamber; a cathode chamber comprising an electrochemically active cathode separated from the intermediate chamber by a membrane which permits transport of Na+ ions, wherein the cathode chamber has a source of water and Na+ ions, in which the water is decomposed (and)wherein H2 is collected and removed from the cathode chamber and wherein NaOH is collected and removed from the cathode chamber; and means for facilitating the reaction of CO2 and H2 to form synthesis gas comprising CO and H2. 

The electrochemical cell ... wherein the source of Na2CO3 comprises Na2CO3 obtained be reacting the NaOH removed from the cathode with a source of CO2. 

The electrochemical cell ... wherein the source of CO2 is atmospheric air.

(Regarding the two above claims, concerning the use of the "NaOH" and "NaCO3", Sodium Hydroxide and Sodium Carbonate, cycle for the capture of atmospheric CO2, see, for just two examples, our reports of:

Carbon Dioxide Capture from Atmospheric Air | Research & Development; concerning: "Carbon Dioxide Capture from Atmospheric Air Using Sodium Hydroxide Spray; Joshuah K. Stolaroff, et. al., University of Calgary (and) Carnegie Mellon University, Pittsburgh, Pennsylvania; The analysis indicates that CO2 capture from air for climate change mitigation is technically feasible using off-the-shelf technology"; and:

US Navy and Columbia University Recycle Atmospheric CO2 | Research & Development; which includes:  "United States Patent 7,833,328 - Scrubber for Capturing Carbon Dioxide from Air; 2010; Columbia University; Abstract: The present invention is directed to methods for carbon dioxide from air, which comprises exposing solvent covered surfaces to air streams where the airflow is kept laminar, or close to the laminar regime. A scrubber apparatus for capturing carbon dioxide from open air ... under ambient conditions ... wherein the solvent is a hydroxide solution".)

The electrochemical cell ... wherein the source of CO2 is combustion gases.

The electrochemical cell ... wherein the source of CO2 is aerobic decomposition gases.

(Actually, we think that they might mean "anaerobic", as opposed to "aerobic", "decomposition gases". See, for example, our report of:

USDOE Algae Recycle CO2 into Liquid Fuels | Research & Development; concerning: "Liquid Fuels from Microalgae; 1987; National Renewable Energy Laboratory (NREL); USDOE; The goal of the DOE/SERI Aquatic Species Program is to develop the technology to produce gasoline and diesel fuels from microalgae. A technical and economic analysis, "Fuels from Microalgae," demonstrates that liquid fuels can be produced from mass-cultured microalgae at prices that will be competitive with those of conventional fuels by the year 2010. Algae are selected for three criteria; tolerance to environmental fluctuations, high growth rates, and high lipid production. The emphasis of the DOE-SERI Aquatic Species Program is to develop the technology base for large-scale production of lipid-yielding microalgae and conversion of the lipids into liquid fuels. The algae can be grown ... using the resources of sunlight, saline water, nitrogen, phosphorus, and carbon dioxide. The algae can convert these raw materials into ... lipids (which can be subjected to) transesterification to produce fuels similar to diesel fuels and catalytic conversion to produce gasoline (and) the cell residue after lipid extraction can be anaerobically digested for the production of methane and carbon dioxide.")

The electrochemical cell ... wherein the means for facilitating the reaction of CO2 and H2 to form synthesis gas comprises a catalyst exposed to the mixture of CO2 and H2. 

The electrochemical cell ... wherein the catalyst comprises a watergas shift catalyst. 

The electrochemical cell ... wherein the catalyst comprises a Fischer-Tropsch catalyst. 

The electrochemical cell ... wherein the means for facilitating the reaction of CO2 and H2 to form synthesis gas further comprises an oxygen ion conducting electrolysis cell to cause electrolysis of CO2 to form CO, which is mixed with H2 to produce synthesis gas.

(In a fashion similar, we believe, to that utilized by Standard Oil, as in our above-cited report of  "United States Patent 4,668,349".)

The electrochemical cell ... wherein the electrochemical cell is embodied within a plurality of stacked electrochemical cells separated by bipolar plates.

Background and Field: The present invention relates in general to methods for producing synthesis gas from easily obtainable precursors, and more particularly, to the generation of such synthesis gas from atmospheric air and water.

In (one) embodiment, sodium hydroxide is ... reacted with a source of carbon dioxide to form sodium carbonate ... . The source of carbon dioxide includes, but is not limited to atmospheric air, combustion gases, and aerobic decomposition gases."

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We'll conclude our excerpts there, although there is, actually, quite a lot more to it of a quite technical nature, concerning the construction and design of the electrochemical cells and things like "ion transport membranes" which help to separate the various products of the co-electrolysis, such as the by-product Oxygen; but, the technical complexities compel us to leave explanation of those details, if anyone out there wants an explanation, to the truly qualified.

Some electrical energy is needed to drive the process; and, we remind you, that, as seen variously in:

Mountaineer Wind Energy Center - Wikipedia, the free encyclopedia; concerning: "Mountaineer Wind Energy Center is a wind farm ... in Preston and Tucker counties in ... West Virginia"; and:

Ground broken for new hydro plant   - News - The Charleston Gazette - West Virginia News and Sports - ; concerning: "Ground broken for new hydro plant; St. Mary's, WV; Construction is under way on a $276 million hydroelectric plant at the Willow Island Locks and Dam";

we do have some options available to us, in the very heart of United States Coal Country, for generating a little, perhaps site-specific and use-dedicated, Carbon-free energy to drive the process herein, of "United States Patent 8,075,746 - Electrochemical Cell for Production of Synthesis Gas Using Atmospheric Air and Water"; and, thereby, produce some "synthesis gas", for subsequent conversion "into a liquid fuel suitable for transportation" out of a little of our abundant Water, and, our, some say too-abundant, Carbon Dioxide.