Switzerland Recycles Carbon Dioxide

United States Patent: 6045761

We will begin in this dispatch to attempt redress of an omission in our reportage, an omission which we believe to have been caused by our now long-ago computer meltdown and, despite the, to us, miraculous and magical work of the esteem-worthy Geek Squad(r), the subsequent loss of some electronic files.

First, we remind you of one report we made concerning the Carbon Dioxide recycling achievements of the giant, Switzerland-based, Swedish-Swiss energy and automation conglomerate, ABB, as accessible via:

 

 

West Virginia Coal Association | Switzerland Recycles CO2 to Fuel | Research & Development; concerning:

"Hydrogenation of Carbon Dioxide to Methanol with a Discharge-Activated Catalyst; 1987; B. Eliasson, et. al.; ABB Corporate Research Ltd., Switzerland; Abstract: To mitigate greenhouse gas CO2 emissions and recycle its carbon source, one possible approach would be to separate CO2 from the flue gases of power plants and to convert it to a liquid fuel, e.g., methanol. Hydrogenation of CO2 to methanol is investigated in a dielectric-barrier discharge (DBD) with and without the presence of a catalyst".

More about ABB can be learned via their corporate web site, as accessible via:

The ABB Group - Automation and Power Technologies;

with a more cogent synopsis of who they are and what they do made available by our old friend, the seemingly-omniscient Wikipedia, via:

ABB Group - Wikipedia, the free encyclopedia; "ABB is a Swedish-Swiss multinational corporation headquartered in Zurich, Switzerland, operating in robotics and mainly in the power and automation technology areas. ABB is one of the largest engineering companies as well as one of the largest conglomerates in the world. ABB has operations in around 100 countries, with approximately 124,000 employees in July 2011, and reported global revenue of $31.6 billion for 2010."

In any case, as we begin to learn herein, the above-cited "Hydrogenation of Carbon Dioxide to Methanol with a Discharge-Activated Catalyst; 1987" was something of an opening shot, by ABB, in a coordinated assault on the misperceptions that have been, we contend deliberately, foisted upon all of us concerning an abundant raw material resource; a resource which we have almost freely available to us: Carbon Dioxide.

We will note, that, although Carbon Dioxide could and should be seen as the primary focus of the process, the inventors make reference primarily to, simply, "greenhouse gas", since CO2 isn't the only "greenhouse gas" which can be productively utilized in this process.

As seen, with comment inserted and appended, in excerpts from the initial link in this dispatch to:

"United States Patent 6,045,761 - Process and Device for the Conversion of a Greenhouse Gas

Date: April, 2000

Inventors: Alain Bill, Baldur Eliasson, et. al, Switzerland

Assignee: ABB Research, Ltd., Zurich

Abstract: So that fuels can be produced efficiently from an undesirable greenhouse gas, the gas is subjected, together with a catalyst gas, preferably nitrogen or nitrous oxide, and a hydrogen-containing gas or vapour, to a silent electric discharge in a first reactor. In the process, excited or ionized atoms and/or molecules are formed which are converted, in a catalyst reactor comprising a copper-containing first catalyst, to H2 and possibly CO. Via an expansion valve, a liquid separates from a fuel in a liquid vessel. Gases escaping from the liquid vessel are passed over a thermal reactor containing a second catalyst and expanded via an expansion valve. In a downstream liquid vessel CH3OH (Methanol), for example, separates as the desired liquid fuel. The first reactor and the thermal reactor may be combined in a container comprising a plurality of reaction chambers which are parallel to one another.

(Yeah, we know, it sounds almost indecipherably complicated. Hang in there, it becomes a little more clear; but, only a little. You still have to read pretty deep into it to discover that Carbon Dioxide is the primary "undesirable greenhouse gas" they're concerning themselves with.)

Claims: Apparatus for converting at least one greenhouse gas into a chemically or industrially utilizable substance or into a chemically or industrially utilizable mixture of substances, comprising:

at least one electric reactor for energetically exciting the at least one greenhouse gas, which can be fed on the input side to the ... reactor, and: 

at least one thermal reactor in effective connection with the ... electric reactor, characterized in that the (electric) reactor and the thermal reactor are combined in a hybrid reactor, (and) that the hybrid rector has at least two adjacent reaction chambers, 

(and) in that at least one a.c. voltage electrode is disposed in each reaction chamber, in such a way that the a.c. voltage electrodes of pairs of immediately adjacent reaction chambers are connected to opposite terminals of an a.c. voltage source, 

(and) in that the walls of the reaction chambers comprise at least one catalytic material, and 

(and) in that said a.c. voltage electrodes connected to opposite terminals of an a.c. voltage source are separated from one another by a dielectric barrier. 

Apparatus ..., characterized in that the at least one thermal reactor contains a copper-containing second catalyst. 

Apparatus ... characterized in that said catalytic material is electrically insulating or deposited on an insulator and acts as said dielectric barrier. 

Apparatus ... characterized in that said a.c. voltage electrodes are coated with said dielectric barrier.

(We are compelled to interject a few notes at this point. First of all, the "dielectric barrier discharge", exotic as it might sound, is a well-known phenomenon. Simple lightning is one example, on a very large scale, wherein the atmosphere itself serves as the "dielectric barrier". A description of how DBD's can operate on a smaller scale, and what they can be used for, is accessible, almost of course, via:

Dielectric barrier discharge - Wikipedia, the free encyclopedia; wherein we're told, in part, that: "Dielectric Barrier Discharges (DBDs) are known for their decomposition of different gaseous compounds, such as NH3, H2S and CO2. Other modern applications include semiconductor manufacturing, germicidal processes, polymer surface treatment, high-power CO2 lasers typically used for welding and metal cutting, , pollution control and plasma display panels. The relatively lower temperature of DBDs makes it an attractive method of generating plasma at atmospheric pressure".

Further, we have previously documented the use of DBD's in the recycling of Carbon Dioxide by the United States petroleum industry, as seen in:

West Virginia Coal Association | Exxon CO2 and Methane to Syngas via Microwave Radiation | Research & Development; concerning: "United States Patent 5,266,175 - Conversion of Methane, CO2 and H2O Using Microwave Radiation; 1993; Assignee: Exxon Research and Engineering Company; Abstract: A mixture of methane, water and carbon dioxide can be effectively converted to carbon monoxide and hydrogen by subjecting the mixture to microwave radiation in the presence of at least one plasma initiator that is capable of initiating an electric discharge in an electromagnetic field".

If you want to see a Dielectric Barrier Discharge of your very own, simply toss an empty, crumpled aluminum foil chewing gum wrapper into your microwave oven and turn it on in the "popcorn" mode. But, then, turn it off quickly as soon as you're satisfied that you've seen what you wanted to see.

The aluminum foil serves as the "plasma initiator", as in the Exxon process of "USP 5,266,175".)

Description, Background and Summary: The invention is based on a process and an apparatus for converting a greenhouse gas into a chemically or industrially utilizable substance or into a chemically or industrially utilizable mixture of substances. 

(Applicable prior art is disclosed in a specified German patent wherein) carbon dioxide, CO2, admixed with a substance containing hydrogen atoms, such as e.g. hydrogen gas, H2, water, H2O, or hydrogen sulphide, H2S, is subjected in a reactor to silent electric discharges which produce the fuels methane, CH4, and/or methanol, CH3OH. The reactor contains a reaction accelerator in the form of a catalyst which contains copper and, if required, one or more of the metals Zn, Al, Mn, Cr, Ag, Mo, Ni or V. The catalyst may have been applied to a dielectric, to an electrode, to glass wool, quartz wool or rock wool, to ZrO2, Al2O3, zeolite, silica gel or granular materials. 

(Another specified German patent) discloses a process for producing methanol from carbon dioxide and hydrogen in a thermal reactor which, in its bottom region, contains a copper-based catalyst. The temperature in the reaction chamber is between 220 and 250C ... .

These processes are not sufficiently efficient and, if hydrogen is used as the starting reactant, are still relatively expensive. 

The invention as defined in the claims achieves the object of developing a process and an apparatus for converting a greenhouse gas, of the type mentioned at the outset, in such a way that more efficient production of fuels from an undesirable greenhouse gas becomes possible. 

An advantage of the invention is that these fuels can be produced on a large industrial scale while requiring less energy input. 

According to an advantageous refinement of the invention, CO and H2 can be produced from a greenhouse gas in a first process stage and can be converted, in a second process stage, into the desirable fuels.

As depicted in (accompanying illustrations) at least one greenhouse gas such as e.g. CO2 and/or CH4 and/or N2O and/or ozone, which may contribute to heating of the earth's atmosphere via the undesirable greenhouse effect, is fed, via a first gas supply line, to a first electric reactor comprising a pressure-proof, earthed metal container or steel tube, which at the same time serves as its outer electrode. 

Via a second gas supply line, the 1st reactor is fed with a reaction accelerator in the form of at least one second energy-storing gas or gas mixture, i.e. a catalyst gas, which after a relaxation time transfers energy to at least one greenhouse reactant. Examples of reaction-accelerating catalyst gases which can be used include e.g. N2, N2O, air or a noble gas, preference being given to N2 (very inexpensive elemental, molecular Nitrogen), however. 

Via a third gas supply line, the first reactor is fed with at least one hydrogen-containing gas such as e.g. H2, H2S, CH4, air or a hydrogen-containing vapour, H2O, or a chlorofluorocarbon or a hydro-chlorofluorocarbon, HCFC, as a coreactant for the greenhouse gas."

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And, we'll end our excerpts there, since we want to emphasize the fact that neither elemental Hydrogen or Methane, CH4, with their attendant expense, is actually required by this process.

A number of common Hydrogen-containing gases will work, as well, as the Hydrogen source, including any greenhouse pollutant fugitive "HCFC"s we might have floating about, looking for a way to be disposed of.

See:

Chlorofluorocarbon - Wikipedia, the free encyclopedia; "A chlorofluorocarbon (CFC) is an organic compound that contains carbon, chlorine and fuorine ... . A common subclass are the hydrochlorofluorocarbons (HCFCs), which contain hydrogen, as well. They are also commonly known by the DuPont trade name Freon. The manufacture of such compounds has been phased out by the Montreal Protocol because they contribute to ozone depletion."

Hydrogen Sulfide, i.e., the "H2S", a pollutant commonly, rightly or wrongly, attributed to the burning of Coal for the generation of electrical power, can, as we have already documented, for instance in:

Exxon Methane and Hydrogen from H2S and Carbon Monoxide | Research & Development; concerning: "United States Patent 4,517,171 - Synthesis of H2 and CH4 from H2S and CO; 1985; Assignee: Exxon Research and Engineering Company; Abstract: Hydrogen and methane are synthesized from a gaseous feed comprising a mixture of H2S and CO";

serve as a source of either Hydrogen or Methane, CH4, by being reacted with a gas, Carbon Monoxide, that can itself, as in:

Germany 98% Pure Carbon Monoxide from Coal, CO2 and O2 | Research & Development; concerning: "Carbon Monoxide from Coke, Carbon Dioxide and Oxygen; Hydrocarbon Process(US); 1986; Lurgi GmbH, Frankfurt (Germany). The purpose of the first process step is to gasify coke using a mixture of CO2 and O2 as gasification agent while the second one serves to remove sulfur compounds and residual CO2";

be rather easily made by reacting hot Coal (i.e., "Coke") with Carbon Dioxide.

And, even though plain old "H2O" qualifies as a needed "hydrogen-containing vapor, according the process of ,"United States Patent 6,045,761 - Process and Device for the Conversion of a Greenhouse Gas", if it would be more economical or efficient, we can, as seen in:

NASA Hydrogen from Water and Sunlight | Research & Development; concerning: "United States Patent 4,045,315 - Solar Photolysis of Water; 1977; NASA; Abstract: Hydrogen is produced by the solar photolysis of water in a first photo-oxidation vessel with a transparent wall in the presence of a water soluble photo-oxidizable reagent and an insoluble hydrogen recombination catalyst. Simultaneously oxygen is produced in a second photo-reduction reactor with a transparent wall in the presence of an insoluble photo-reduction reagent catalyst";

simply harness from freely-available environmental energy to generate Hydrogen for use in the process, along with commercially-valuable byproduct Oxygen, from plain old Water.

It is, in any case, clear:

Rather than treating our byproduct Carbon Dioxide as some sort of environmental hazard we must, at great unproductive expense to our vital Coal-use industries and to the consumers of Coal-based electrical power, either tax, through Cap and Trade extortions, out of existence; or, enslave into the service of Big Oil profits through mandated Geologic Sequestration; we can, instead, treat it as what it truly is: a non-hazardous and freely-available raw material which we can, via the process of our subject herein, "United States Patent 6,045,761 - Process and Device for the Conversion of a Greenhouse Gas", rather directly and efficiently convert into an "industrially utilizable substance" such as, in one "advantageous refinement of the invention, CO and H2", which then "can be converted, in a second process stage, into the desirable fuels", such as, for example, "methane, CH4, and/or methanol, CH3OH".