The invention field relates to electrocatalytic conversion and to processes for reducing emissions of carbon dioxide into the atmosphere.
It is generally accepted that atmospheric carbon dioxide (CO2) is a greenhouse gas that the planet currently has in excess, is extremely stable, and that the current rates of generating additional carbon dioxide should be reduced or controlled. One approach to such control involves injecting the CO2 produced by an industrial process into a subterranean well that prevents it from reaching the atmosphere; another may rely on a chemically stable capture of the CO2 in a mineral species. Other methods potentially involve converting or recycling the CO2 into a different carbon compound such as an organic acid or carbon monoxide (CO) to use as a feedstock for other chemical syntheses. However conversion of carbon dioxide into carbon monoxide has in the past been performed chemically only at great expense. A less expensive and more convenient and energy-efficient process for such CO2 reduction would therefore be desirable.
Some perspective may be gained by considering that the ever-increasing worldwide consumption of fossil fuels for energy and chemical applications has accelerated the depletion of these finite natural resources and led to over-production of the greenhouse gas carbon dioxide (CO2) (Goeppert, A. et al., Am. Chem. Soc. 2011, 133, 20164). To meet the world's fuel and chemical demands in a sustainable way, the overly produced CO2 could perhaps be converted into reusable carbon forms (Graves, C. et al. Renewable Sustainable Energy Rev. 2011, 15,1). Among many different approaches developed thus far for CO2 reactivation, electrochemical reduction of CO2 is considered a potentially “clean” method, as the reduction may proceed at the expense of a sustainable supply of electric energy (Whipple, D. T. et al. J. Phys. Chem. Lett. 2010, 1, 345). Theoretically, CO2 can be reduced in a neutral aqueous solution (pH=7, 1 M electrolyte at 25° C. and 1 atm CO2) to form carbon monoxide (CO), formic acid (HCO2H), methanol (CH3OH), methane (CH4), ethylene (C2H4) or other hydrocarbons, at potentials around +0.2 to −0.2 V (vs. reversible hydrogen electrode, RHE) (Benson, E. E. et al. Chem. Soc. Rev. 2009, 38, 89). Experimentally, however, very negative potentials must be applied to initiate CO2 reduction (Benson et al., supra). These large over-potentials not only consume more electrical energy but also promote the uncontrolled formation of competitive reduction products, such as hydrogen (H2), causing the reaction to have low energetic efficiencies and poor selectivity (Costentin, C. et al. Chem. Soc. Rev. 2013, 42, 2423; Gattrell, M. et al. Electroanal. Chem. 2006, 594,1).
To succeed in CO2 reduction and conversion, highly efficient catalysts must be developed to lower the CO2 reduction over-potentials and to control the energy pathways of reaction intermediates. Various metal electrocatalysts have been screened experimentally (De Jesus-Cardona, H. et al. Electroanal. Chem. 2001, 513, 45; Innocent, B. et al. J. Appl. Electrochem. 2009, 39, 227; Chen, Y. H. et al. J. Am. Chem. Soc. 2012, 134, 1986; Jitaru, M. et al. J. Appl. Electrochem. 1997, 27, 875; Noda, H. et al. Bull. Chem. Soc. Jpn. 1990, 63, 2459; Hori, Y. et al. J. Chem. Soc., Chem. Commun. 1987, 728) and analyzed computationally (Peterson, A. A et al. J. Phys. Chem. Lett. 2012, 3, 251; Peterson, A. A. et al. Energy Environ. Sci. 2010, 3, 1311; Durand, W. J. et al. Surf. Sci. 2011, 605, 1354) to rationalize their activity and selectivity for CO2 reduction. Recent advances in the synthesis of nanoparticles (NPs) allow for testing of potentially increased reaction kinetics due to the controlled surface area and surface morphology achievable in fabrication of NPs. This is demonstrated by electrochemical reduction of CO, into hydrocarbons on Cu, or reduction into CO on Au-based NPs/clusters (Chen, Y. H. et al. J. Am. Chem. Soc. 2012, 134, 19969; Xu, Z. C. et al. Chem. Commun. 2012, 48, 5626; Kauffman, D. R. et al. J. Am. Chem. Soc. 2012, 134, 10237). Recently, a new form of Au nanostructured catalyst made by anodization and electroreduction of an Au electrode has been demonstrated to show high selectivity for catalyzing CO2 reduction to CO with current densities between 2 to 4 mA/cm2 and Faradaic efficiencies (FE) around 96% at −0.35 V (vs. RHE) (Chen, Y. H. et al, supra). It is believed that the increased stabilization of the reduced CO2 radical or the reaction-intermediate COOH* and the weakened CO binding on the Au surface contribute to this selective reduction of CO2 to CO (Chen, Y. H. et al., supra; Kauffman, D. R. et al., supra). However, the structure features of the catalyst surface are difficult to characterize, a factor that complicates further catalyst optimization.
An embodiment of the invention provides a process for electrocatalytic reduction of CO2 to CO in which the reduction is catalyzed by gold nanoparticles on a conductive support, and the nanoparticles are sized to present a surface structure for efficient CO2 reduction.
For example, the nanoparticles are tuned to present a crystalline structure in which the nanoparticles, have a lower amount of hydrogen-evolving crystal corner sites and greater amount of CO-converting edge sites, so as to constitute a clean CO2 conversion medium with low formation of undesired by-product species.
In an embodiment of the process, the conductive support is Ketjen carbon.
In another embodiment of the process, the gold nanoparticles are formed with a diameter less than 10 nm to tune the catalytic activity of the particles. For example, the gold nanoparticles are formed with a diameter of approximately 8 nm.
An embodiment of the invention is a method in which the reduction is performed in alkaline solution.
An embodiment of the invention provides a catalyst that includes gold nanoparticles of approximately 8 nm diameter for use in electrocatalytic reduction of carbon dioxide to carbon monoxide.
An embodiment of the invention provides a catalyst that contains gold nanoparticles of a cuboctahedral crystalline configuration of a size to present CO2-converting edge sites with relatively fewer hydrogen-evolving corner sites, resulting in a clean CO2 conversion medium with low formation of by-product.
These and other features of the invention will be understood from the description and claims herein, taken together with the drawings, wherein:
Considering the size effect commonly observed in NPs and the promising results demonstrated from nanostructured Au, Applicants determined to study monodisperse Au NPs as a catalyst for electrochemical reduction of CO2 in 0.5 M KHCO3 (pH 7.3) at room temperature. Applicants screened 4-, 6-, 8-, and 10-nm Au NPs and found that the 8 nm Au NPs were especially active for CO2 reduction into CO. Using density functional theory (DFT) calculations, Applicants hypothesized that this enhanced activity and selectivity is due to the presence of dominant edge sites on the 8 nm NP surface, which facilitate the adsorption/stabilization of key reaction intermediates (such as COOH*) involved in the CO2 reduction into CO, and which inhibits the hydrogen evolution reaction (HER). This reaction model gained further support experimentally as Au NPs embedded in a matrix of butyl-3-methylimidazolium hexafluorophosphate, a more efficient COOH* stabilizer, were indeed found to be more active and selective for CO2 reduction into CO. The composite catalyst containing 8 nm NPs exhibited up to 97% Faraday efficiency (FE) towards CO and a mass activity of 3 A/g at −0.52 V. The work reported herein demonstrates great potential of tuning electrocatalysis of Au NPs for diverse reactions, in particular by creating optimal edge sides on the surface of NPs of controlled size for more effective CO2 reduction into CO. The reduction process as described herein is being published as “Monodisperse Au Nanoparticles for Selective Electrocatalytic Reduction of CO2 to CO” by co-authors Wenlei Zhu, Ronald Michalsky, Onder metin, Haifeng Lv, Shaojun guo, Christopher Wright, Xiaolian Sun, Andrew A. Peterson and Shouheng Sun, in J. Am. Chem. Soc. 2013, 135, 16833-16836, to which reference may be made for further details and review of the supporting information regarding electrocatalytic properties described herein and associated content. The publications mentioned and material from these publications are incorporated herein by reference, to the extent such supporting information may be deemed useful.
Monodisperse 4-, 6-, 8- and 10 nm Au NPs were prepared by procedures described in Lee, Y. et al. Chem. Mater. 2010, 22, 755; Peng, S. et al. Nano Res. 2008, 1, 229; Lee, Y. M. et al. Angew. Chem., Int. Ed. 2010, 49, 1271.
The Au NPs were deposited on Ketjen carbon support (Kejen EC300J) at a weight ratio of 1:1, and annealed in air for 8 h at 165° C. to remove the organic surfactant as reported in Metin, O. et al. Nanoscale 2013, 5, 910 and Li, D. G. et al. ACS Catal. 2012, 2, 1358, giving C—Au. TEM analyses of the C—Au showed no NP morphological changes or aggregation after the treatment (
To study electrocatalytic reduction of CO2 on the C—Au catalyst, a C—Au paste was first prepared by grinding 20 mg of C—Au NPs and 3 mg of polyvinylidene fluoride (PVDF, 15% wt) followed by addition of a few drops of N-methyl-2-pyrrolidone (NMP) (see the Supporting Information). The C—Au-PVDF paste was then painted onto the carbon paper (Toray TGP-H-060)—see Mu, J. B. et al. Nanoscale 2011, 3, 5034 and Ravikumar, R. et al. Phys. Chem. Chem. Phys. 2013, 15, 3712, and dried under vacuum to serve as working electrodes.
The electrocatalysis was performed in a conventional two-compartment H-cell (separated by a Nafion membrane) containing 60 ml of 0.5 M KHCO3 solution (pH 7.3). At the reported reduction conditions, CO and H2 were the only two detectable reaction products with net FE at 100.6%±3.9%.
Electrochemical reduction of CO2 to CO in an aqueous solution depends on the energetic stabilization of CO2 reduction intermediates by catalytically active surfaces Peterson, A. A et al. J. Phys. Chem. Lett., supra and Peterson, A. A. et al. Energy Environ. Sci., supra; Hansen, H. A. et al. J. Phys. Chem. Lett. 2013, 4, 388).
The reaction can be summarized with the following steps:
CO2(g)+H+(aq)+e−+*→COOH* (1)
COOH*+H+(aq)+e−→CO*+H2O(1) (2)
CO*→CO(g)+* *3)
H+(aq)+e−+*→H* (4)
H*+H+(aq)+e−→H2+* (5a)
where the asterisk denotes either a surface-bound species or a vacant catalytically active site. The formation of CO depends not only on the stabilization step (1) and the reduction step (2) of a COOH*, but also on the ability of the catalyst to liberate the CO product, step (3). For high CO selectivity, the catalyst needs to balance steps 1-3 while inhibiting the hydrogen evolution reaction (HER) via H+ reduction of steps (4)-(5), a major side reaction that is often observed in studying electrochemical reduction of CO2.
To understand the origin of the high CO selectivity of the Au NPs, we applied density functional theory (DFT) to calculate the free energies of these five elementary reaction steps. The catalyst was modeled in a number of different geometries with the Grid-based projector-augmented wave (GPAW) electronic-structure code in order to understand the reactivity of different Au features. The method of calculation is further described and may be found in the Supporting Information. The total energy of these surfaces or clusters with or without adsorbates was calculated and converted to free energy (ΔG) at 25° C., 1 atm and −0.11 V, the theoretical equilibrium potential of CO2 reduction into CO.
The calculated ΔG diagram suggests that the over-potential of CO2 reduction or the partial current of CO formation on Au NPs at a given potential can be controlled by the density of catalytically active edges, which is controllable by NP size and surface structure. Similar trends can be seen with the calculated ΔG changes of adsorbed hydrogen on Au(111), Au(211), and the Au13 cluster (
To address size-dependent electrocatalytic properties of the gold NPs, we treated the NPs as perfect cuboctahedra and obtained the relationship between the density of catalytically active surface sites and the cluster diameter (
The ΔG diagram of the CO2 reduction into CO shows that the major fraction of the overpotential comes from the need to energetically stabilize COOH* (
To test this hypothesis, we prepared C—Au-IL by adding IL to C—Au-PVDF paste containing 20 mg of C—Au NPs catalyst and painted the new paste onto carbon paper. The IL effect on CO2 reduction was further studied by mixing 20 mg of the C—Au (8 nm Au NPs) with different volumes of IL.
In summary, we have synthesized a series of monodisperse Au NPs and studied their electrocatalytic reduction of CO2 to CO. Among the 4-, 6-, 8- and 10-nm Au NPs tested, the 8 nm Au NPs show the highest selectivity with their FE reaching 90% at −0.67 V. DFT calculations suggest that the highly selective CO formation on the 8 nm Au NPs is due to the presence of optimum ratio of the edge sites, which are active for CO2 reduction, over corner sites, which are active for H2 evolution. When embedded in a matrix of butyl-3-methylimidazolium hexafluorophosphate, the Au NPs become even more active for CO2 reduction. The composite catalyst containing 8 nm Au NPs has FE up to 97% and mass activity of about 3 A/g at −0.52 V. Our study proves that effective stabilization of COOH* is key to the CO2 reduction activity enhancement, and demonstrates great potentials of monodisperse Au NPs for the selective electrochemical reduction of CO2 to CO.
The foregoing elucidation of reaction processes together with the recent advances in chemical syntheses of monodisperse NPs and computational methodology, therefore enables design and evaluation or testing of various NP catalysts, making it possible to control specific reaction pathways and to achieve selective electrochemical reactivation of CO2 into a desired form of carbon, which may, for example, be applied as a feed stock for other hydrocarbon processes or materials. The discoveries herein thus open the door for reducing global CO2 emissions by removing and/or recycling the CO2 from industrial and combustion processes into a sustainable feed stock, for more effective and non-polluting utilization of hydrocarbons and carbon-based material and processes.
The invention being thus disclosed, adaptations and variations that tailor NP catalysts for other reductions reactions will be understood by those skilled in the art and are encompassed within the invention, as defined by the following claims.
The present application is a continuation of and claims the benefit of international application serial number PCT/US2014/060818 filed Oct. 16, 2014, which claims the benefit of U.S. provisional application Ser. No. 61/891,960 filed Oct. 16, 2013, each of which is hereby incorporated herein by reference in its entirety.
This invention was made with government support under grant CHE1240020 awarded by the National Science Foundation and grant N00014-12-1-0851 awarded by the Office of Naval Research. The government has certain rights in the invention.
Number | Date | Country | |
---|---|---|---|
61891690 | Oct 2013 | US |
Number | Date | Country | |
---|---|---|---|
Parent | PCT/US2014/060818 | Oct 2014 | US |
Child | 15099691 | US |