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Masel, Richard I.

Publications and source records attributed to Masel, Richard I..

An industrial perspective on catalysts for low-temperature CO 2 electrolysis

Electrochemical conversion of CO 2 to useful products at temperatures below 100 °C are nearing the commercial scale. Pilot units for CO 2 conversion to CO are already in testing. Units to convert CO 2 to formic acid are projected to reach pilot scale in the next year. Further, several investigators are starting to observe industrially relevant rates of the electrochemical conversion of CO 2 conversion to ethanol and ethylene with the needed hydrogen coming from water. In each case, Faradaic efficiencies of 80% or more and currents above 200 mA/cm –2 can be reproducibly achieved. In this study we describe the key advances in nano catalysts that lead to the impressive performance, indicate where additional work is needed and provide benchmarks that others can use to compare their results.

10 SYNTHETIC FUELS↗

Performance and long-term stability of CO 2 conversion to formic acid using a three-compartment electrolyzer design

The electrochemical reduction of CO 2 to formate and formic acid has attracted a great amount of academic and commercial interest over the past five years. A number of experimental studies have generated data on the Faradaic performance and stability of various candidate catalyst materials in producing formate or formic acid. However, most of the data has been conducted at low current densities and over short time periods, typically hours to days. There is a critical need in providing long-term catalyst stability as well as electrolyzer-based operating data, which are needed for the commercial scale-up and operation of this technology, especially at high current densities. In this paper, the electrochemical CO 2 conversion to pure formic acid was conducted using a three-compartment design electrolyzer, demonstrating electrolyzer catalyst and performance stability for over 1000 h at current densities up to 200 mA cm -2 . Depending on the operation conditions, the electrolyzer directly produced a 6.03 to 12.92 wt% (1.3 to 2.8 M) formic acid product at Faradaic efficiencies ranging between 73.0 to 91.3%. Data on electrolyzer performance, including formic acid product generation rate, energy efficiency, and energy consumption are reported at three different current densities, 100, 200, and 250 mA cm -2 . Finally, a long term 1000 h electrolyzer stability run at 200 mA cm -2 is presented, providing information on the operating conditions required in obtaining stable electrolyzer performance. All the data will be extremely useful in the commercial scale-up of this technology.

10 SYNTHETIC FUELS↗

System and process for the production of renewable fuels and chemicals

A renewable fuel production system includes a carbon dioxide capture unit for extracting carbon dioxide from atmospheric air, a carbon dioxide electrolyzer for converting carbon dioxide to carbon monoxide, a water electrolyzer for converting water to hydrogen, a synfuels generator for converting carbon monoxide produced by the carbon dioxide electrolyzer and hydrogen produced by the water electrolyzer to a fuel. The fuel produced can be synthetic gasoline and/or synthetic diesel. A renewable fuel production process includes the steps of extracting carbon dioxide from atmospheric air via a carbon dioxide capture unit, converting carbon dioxide to carbon monoxide via a carbon dioxide electrolyzer, converting water to hydrogen via a water electrolyzer, and converting carbon monoxide produced via the carbon dioxide electrolyzer and H.sub.2 produced via the water electrolyzer to a fuel. The system is also capable of simultaneously or alternatively producing a separate industrial chemical.

Masel, Richard I.↗

Devices for electrocatalytic conversion of carbon dioxide

An electrocatalytic device for carbon dioxide conversion includes a cathode with a Catalytically Active Elementa metal in the form of supported or unsupported particles or flakes with an average size between 0.6 nm and 100 nm. The reaction products comprise at least one of CO, HCO.sup.-, H.sub.2CO, (HCOO).sup.-, HCOOH, CH.sub.3OH, CH.sub.4, C.sub.2H.sub.4, CH.sub.3CH.sub.2OH, CH.sub.3COO.sup.-, CH.sub.3COOH, C.sub.2H.sub.6, (COOH).sub.2, (COO.sup.-).sub.2, and CF.sub.3COOH.

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Ion-conducting membranes

An anion-conducting polymeric membrane comprises a terpolymer of styrene, vinylbenzyl-R.sub.s and vinylbenzyl-R.sub.x. R.sub.s is a positively charged cyclic amine group. R.sub.x is at least one constituent selected from the group consisting Cl, OH and a reaction product between an OH or Cl and a species other than a simple amine or a cyclic amine. The total weight of the vinylbenzyl-R.sub.x groups is greater than 0.3% of the total weight of the membrane. In a preferred embodiment, the membrane is a Helper Membrane that increases the faradaic efficiency of an electrochemical cell into which the membrane is incorporated, and also allows product formation at lower voltages than in cells without the Helper Membrane.

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Electrocatalytic process for carbon dioxide conversion

An electrocatalytic process for carbon dioxide conversion includes combining a Catalytically Active Element and a Helper Polymer in the presence of carbon dioxide, allowing a reaction to proceed to produce a reaction product, and applying electrical energy to said reaction to achieve electrochemical conversion of said carbon dioxide reactant to said reaction product. The Catalytically Active Element can be a metal in the form of supported or unsupported particles or flakes with an average size between 0.6 nm and 100 nm. The reaction products comprise at least one of CO, HCO.sup.-, H.sub.2CO, (HCO.sub.2).sup.-, H.sub.2CO.sub.2, CH.sub.3OH, CH.sub.4, C.sub.2H.sub.4, CH.sub.3CH.sub.2OH, CH.sub.3COO.sup.-, CH.sub.3COOH, C.sub.2H.sub.6, (COOH).sub.2, (COO.sup.-).sub.2, and CF.sub.3COOH.

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Ion-conducting membranes

An ion conducting polymeric composition mixture comprises a copolymer of styrene and vinylbenzyl-R.sub.s. R.sub.s is selected from the group consisting of imidazoliums, pyridiniums, pyrazoliums, pyrrolidiniums, pyrroliums, pyrimidiums, piperidiniums, indoliums, and triaziniums. The composition contains 10%-90% by weight of vinylbenzyl-R.sub.s. The composition can further comprise a polyolefin comprising substituted polyolefins, a polymer comprising cyclic amine groups, a polymer comprising at least one of a phenylene group and a phenyl group, a polyamide, and/or the reaction product of a constituent having two carbon-carbon double bonds. The composition can be in the form of a membrane. In a preferred embodiment, the membrane is a Helper Membrane that increases the faradaic efficiency of an electrochemical cell into which the membrane is incorporated, and also allows product formation at lower voltages than in cells without the Helper Membrane.

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Catalyst mixtures

Catalysts that include at least one catalytically active element and one helper catalyst can be used to increase the rate or lower the overpotential of chemical reactions. The helper catalyst can simultaneously act as a director molecule, suppressing undesired reactions and thus increasing selectivity toward the desired reaction. These catalysts can be useful for a variety of chemical reactions including, in particular, the electrochemical conversion of CO.sub.2 or formic acid. The catalysts can also suppress H.sub.2 evolution, permitting electrochemical cell operation at potentials below RHE. Chemical processes and devices using the catalysts are also disclosed, including processes to produce CO, OH.sup.-, HCO.sup.-, H.sub.2CO, (HCO.sub.2).sup.-, H.sub.2CO.sub.2, CH.sub.3OH, CH.sub.4, C.sub.2H.sub.4, CH.sub.3CH.sub.2OH, CH.sub.3COO.sup.-, CH.sub.3COOH, C.sub.2H.sub.6, O.sub.2, H.sub.2, (COOH).sub.2, or (COO.sup.-).sub.2, and a specific device, namely, a CO.sub.2 sensor.

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Electrocatalytic process for carbon dioxide conversion

An electrocatalytic process for carbon dioxide conversion includes combining a Catalytically Active Element and Helper Catalyst in the presence of carbon dioxide, allowing a reaction to proceed to produce a reaction product, and applying electrical energy to said reaction to achieve electrochemical conversion of said reactant to said reaction product. The Catalytically Active Element can be a metal in the form of supported or unsupported particles or flakes with an average size between 0.6 nm and 100 nm. the reaction products comprise at least one of CO, HCO.sup.-, H.sub.2CO, (HCO.sub.2).sup.-, H.sub.2CO.sub.2, CH.sub.3OH, CH.sub.4, C.sub.2H.sub.4, CH.sub.3CH.sub.2OH, CH.sub.3COO.sup.-, CH.sub.3COOH, C.sub.2H.sub.6, (COOH).sub.2, (COO.sup.-).sub.2, and CF.sub.3COOH.

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