Patent Application
20190177861
The disclosure, in various embodiments, relates to methods, systems, and apparatuses for producing hydrocarbon products and hydrogen gas through electrochemical activation of methane.
Large reserves of natural gas continue to be discovered throughout the world, and have resulted in surpluses of methane (CH4). CH4 is predominantly formed into other hydrocarbon products such as ethylene (C2H4) through conventional stream cracking processes. However, conventional stream cracking of CH4 can require high temperatures (e.g., temperatures greater than or equal to about 750° C.) to activate CH4, resulting in undesirable energy expenditures (e.g., thermal energy expenditures) and/or environmental impacts (e.g., greenhouse gas emissions effectuated by the energy needs of the stream cracking processes). In addition, conventional stream cracking processes can require the use of complicated and costly systems and methods to purify (e.g., refine) the resulting hydrocarbon products.
It would be desirable to have new methods, systems, and apparatuses for synthesizing hydrocarbon products from CH4. It would also be desirable if new methods, systems, and apparatuses facilitated the production of a variety of hydrocarbons, and also facilitated the production (e.g., co-production) and isolation of hydrogen gas. It would further be desirable if the new methods, systems, and apparatuses facilitated increased production efficiency, increased operational life, and were relatively inexpensive and simple in operation.
Embodiments described herein include methods, systems, and apparatuses for producing hydrocarbon products and hydrogen gas through electrochemical activation of CH4. In accordance with one embodiment described herein, a method of forming a hydrocarbon product and hydrogen gas comprises introducing CH4 to a positive electrode of an electrochemical cell comprising the positive electrode, a negative electrode, and a proton-conducting membrane between the positive electrode and the negative electrode. The proton-conducting membrane comprises an electrolyte material having an ionic conductivity greater than or equal to about 10−2 S/cm at one or more temperatures within a range of from about 150° C. to about 600° C. A potential difference is applied between the positive electrode and the negative electrode of the electrochemical cell.
In additional embodiments, a CH4 activation system comprises a source of CH4 and an electrochemical apparatus in fluid communication with the source of CH4. The electrochemical apparatus comprises a housing structure configured and positioned to receive a CH4 stream from the source of CH4, and an electrochemical cell within an internal chamber of the housing structure. The electrochemical cell comprises a positive electrode, a negative electrode, and a proton-conducting membrane between the positive electrode and the negative electrode. The positive electrode comprises a catalyst material formulated to accelerate reaction rates to produce CH3+, H+, and e−, from CH4, and to accelerate reaction rates to synthesize at least one hydrocarbon product from the produced CH3+. The negative electrode comprises another catalyst material formulated to accelerate reaction rates to produce H2(g) from H+ and e−. The proton-conducting membrane comprises an electrolyte material having an ionic conductivity greater than or equal to about 10−2 S/cm at one or more temperatures within a range of from about 150° C. to about 600° C.
In further embodiments, an electrochemical cell comprises a positive electrode, a negative electrode, and a proton-conducting membrane between the positive electrode and the negative electrode. The positive electrode comprises a first catalyst material formulated to accelerate to CH4 deprotonation reaction rates to produce CH3+, H+, and e−, from CH4, and to accelerate coupling reaction rates to synthesize at least one hydrocarbon product from the produced CH3+. The negative electrode comprises a second catalyst material formulated to accelerate hydrogen evolution reaction rates to produce H2(g) from H+ and e−. The proton-conducting membrane comprises an electrolyte material having an ionic conductivity greater than or equal to about 10−2 S/cm at one or more temperatures within a range of from about 150° C. to about 600° C.
Methods, systems, and apparatuses for producing (e.g., co-producing) hydrocarbon products and hydrogen gas (H2(g) through electrochemical activation of CH4 are disclosed. In some embodiments, a method of producing hydrocarbon products and H2(g) includes directing CH4 into an electrochemical apparatus including an electrochemical cell therein. The electrochemical cell comprises a positive electrode (anode), a negative electrode (cathode), and a proton-conducting membrane between the positive electrode and the negative electrode. The proton-conducting membrane includes an electrolyte material having an ionic conductivity greater than or equal to about 10−2 Siemens per centimeter (S/cm) at one or more temperatures within a range of from about 150° C. to about 600° C. The positive electrode includes a catalyst material formulated to accelerate CH4 deprotonation reaction rates to produce CH3+, H+, and e− from CH4, and also formulated to accelerate coupling reaction rates (e.g., at least methyl coupling reaction rates) to synthesize one or more hydrocarbon products from the produced CH3+. The negative electrode comprises another catalyst material formulated to accelerate hydrogen evolution reaction rates to produce H2(g) from H+ and e−. Electrical current is applied to the CH4 across the positive electrode and the negative electrode of the electrochemical cell at a temperature within the range of from about 150° C. to about 600° C. to produce at least one hydrocarbon product at the positive electrode and H2(g) at the negative electrode. The methods, systems, and apparatuses of the disclosure may be more efficient (e.g., increasing higher hydrocarbon and H2(g) production efficiency; reducing equipment, material, and/or energy requirements; etc.), more durable, and/or less complicated as compared to conventional methods, conventional systems, and conventional apparatuses for producing one or more of higher hydrocarbons and H2(g) from CH4.
The following description provides specific details, such as material compositions and processing conditions (e.g., temperatures, pressures, flow rates, etc.) in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art will understand that the embodiments of the disclosure may be practiced without necessarily employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional systems and methods employed in the industry. In addition, only those process components and acts necessary to understand the embodiments of the present disclosure are described in detail below. A person of ordinary skill in the art will understand that some process components (e.g., pipelines, line filters, valves, temperature detectors, flow detectors, pressure detectors, and the like) are inherently disclosed herein and that adding various conventional process components and acts would be in accord with the disclosure. In addition, the drawings accompanying the application are for illustrative purposes only, and are not meant to be actual views of any particular material, device, or system.
As used herein, the term “lower hydrocarbon” means and includes an aliphatic hydrocarbon having from one carbon atom to four carbon atoms (e.g., methane, ethane, ethylene, acetylene, propane, propylene, n-butane, isobutene, butane, isobutene, etc.).
As used herein, the terms “higher hydrocarbon” and “hydrocarbon product” mean and include an aliphatic or cyclic hydrocarbon having at least one more carbon atom than a lower hydrocarbon used to form the higher hydrocarbon.
As used herein, the term “cyclic hydrocarbon” means and includes at least one closed ring hydrocarbon, such as an alicyclic hydrocarbon, an aromatic hydrocarbon, or a combination thereof. The cyclic hydrocarbon may include only carbon and hydrogen, or may include carbon, hydrogen, and at least one heteroatom.
As used herein, the term “heteroatom” means and includes an element other than carbon and hydrogen, such as oxygen (O), nitrogen (N), or sulfur (S).
As used herein, the terms “catalyst material” and “catalyst” each mean and include a material formulated to promote one or more reactions, resulting in the formation of a product.
As used herein, the term “negative electrode” means and includes an electrode having a relatively lower electrode potential in an electrochemical cell (i.e., lower than the electrode potential in a positive electrode therein). Conversely, as used herein, the term “positive electrode” means and includes an electrode having a relatively higher electrode potential in an electrochemical cell (i.e., higher than the electrode potential in a negative electrode therein).
As used herein the term “electrolyte” means and includes an ionic conductor, which can be in a solid state, a liquid state, or a gas state (e.g., plasma).
As used herein, spatially relative terms, such as “beneath,” “below,” “lower,” “bottom,” “above,” “upper,” “top,” “front,” “rear,” “left,” “right,” and the like, may be used for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Unless otherwise specified, the spatially relative terms are intended to encompass different orientations of the materials in addition to the orientation depicted in the figures. For example, if materials in the figures are inverted, elements described as “below” or “beneath” or “under” or “on bottom of” other elements or features would then be oriented “above” or “on top of” the other elements or features. Thus, the term “below” can encompass both an orientation of above and below, depending on the context in which the term is used, which will be evident to one of ordinary skill in the art. The materials may be otherwise oriented (e.g., rotated 90 degrees, inverted, flipped) and the spatially relative descriptors used herein interpreted accordingly.
As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
As used herein, “and/or” includes any and all combinations of one or more of the associated listed items.
As used herein, the term “configured” refers to a size, shape, material composition, material distribution, and arrangement of one or more of at least one structure and at least one apparatus facilitating operation of one or more of the structure and the apparatus in a pre-determined way.
As used herein, the term “substantially” in reference to a given parameter, property, or condition means and includes to a degree that one of ordinary skill in the art would understand that the given parameter, property, or condition is met with a degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0% met, at least 95.0% met, at least 99.0% met, at least 99.9% met, or even 100.0% met.
As used herein, the term “about” in reference to a given parameter is inclusive of the stated value and has the meaning dictated by the context (e.g., it includes the degree of error associated with measurement of the given parameter).
As used herein, the term “compatible” means that a material does not undesirably react, decompose, or absorb another material, and also that the material does not undesirably impair the chemical and/or mechanical properties of the another material.
An embodiment of the disclosure will now be described with reference to
During use and operation, the CH4 activation system 100 directs a CH4 stream 120 into the electrochemical apparatus 104 to interact with the positive electrode 108 of the electrochemical cell 106. A potential difference (e.g., voltage) is applied between the positive electrode 108 and the negative electrode 112 of the electrochemical cell 106 by the power source 116 so that as the CH4 interacts with the positive electrode 108, H atoms of the CH4 release their electrons (e−) to produce methyl radicals (CH3+), hydrogen ions (H+) (i.e., protons), and electrons (e−) through non-oxidative deprotonation according to the following equation:
CH4→CH3++H++e− (1).
The generated H+ permeate (e.g., diffuse) across the proton-conducting membrane 110 to the negative electrode 112, and the generated e− are directed to the power source 116 through external circuitry. At the negative electrode 112, the generated H+ exiting the proton-conducting membrane 110 react with e− received from the power source 116 to form H atoms that the combine to form H2(g) through a hydrogen evolution reaction, according to the following equation:
4H++4e−→2H2(g) (2).
The H2(g) then exits the electrochemical apparatus 104 as a H2(g) stream 126. At the positive electrode 108, the produced CH3+ undergoes at least one methyl coupling reaction in the presence of a catalyst material of the positive electrode 108 to synthesize at least one higher hydrocarbon. By way of non-limiting example, two (2) produced CH3+ may react with one another to produce ethane (C2H6), which may then react with additional produced CH3+ to produce ethyl radicals (C2H5+) according to the following equations:
2CH3+→C2H6 (3).
C2H6→C2H5++CH4 (4).
The C2H5+ may then be deprotonated to produce ethylene (C2H4) according to the following equation:
C2H5+→C2H4+H+ (5).
In addition, at least partially depending on the conditions (e.g., catalyst material(s), temperatures, pressures) at the positive electrode 108, the produced C2H4 may undergo at least one ethyl coupling reaction to synthesize at least one other hydrocarbon product, according to the following equation:
nC2H4→C2nH4n (6).
The hydrocarbon product exits the electrochemical apparatus 104 as a hydrocarbon product stream 124.
As described in further detail below, the hydrocarbon products synthesized at the positive electrode 108 and the production of H2(g) at the negative electrode 112 may at least partially depend on the material composition and flow rate of the CH4 stream 120; the configuration (e.g., size, shape, material composition, material distribution, arrangement) of the positive electrode 108, including the types, quantities, distribution, and properties (e.g., geometric properties, thermodynamic properties, etc.) of catalyst materials thereof promoting CH4 deprotonation reactions and coupling reactions (e.g., methyl coupling reactions, ethyl coupling reactions (if any)); the configuration of the proton-conducting membrane 110, and the impact thereof on the diffusivity (e.g., diffusion rate) of generated H+ therethrough; the configuration of the negative electrode, including the types, quantities, and properties (e.g., geometric properties, thermodynamic properties, etc.) of catalyst materials thereof promoting hydrogen evolution reactions; and the operational parameters (e.g., temperatures, pressures, etc.) of the electrochemical apparatus 104. Such operational factors may be controlled (e.g., adjusted, maintained, etc.) as desired to control the types, quantities, and rate of production of the hydrocarbon product(s) synthesized at the positive electrode 108 and to control the quantity and rate of production of the H2(g) produced at the negative electrode 112. In some embodiments, the hydrocarbon product(s) exiting the electrochemical apparatus 104 in the hydrocarbon product stream 124 may be examined (e.g., through in-line gas chromatography-mass spectrometry (GS-MS)) and compared to a mathematically modeled Anderson-Schulz-Flory distribution to analyze whether or not sufficient coupling reactions are occurring at the positive electrode 108 for the synthesis of one or more desired higher hydrocarbons. One or more operational factors of the CH4 activation system 100 (e.g., one or more of the type, quantity, and distribution of catalyst material(s) in the positive electrode 108, the operating temperature of the electrochemical apparatus 104, etc.) may be adjusted or maintained based on the results of the analysis. Accordingly, the operational factors of the CH4 activation system 100 may be tailored to facilitate the production of H2(g) and one or more specific higher hydrocarbons from the components (e.g., CH4) of the CH4 stream 120.
The CH4 stream 120 may be formed of and include CH4. In addition, the CH4 stream 120 may, optionally, include one or more other materials (e.g., molecules), such as one or more other lower hydrocarbons (e.g., one or more C2 to C4 hydrocarbons, such as one or more of C2H6, propane (C3H8), and butane (C4H10)) that may undergo a chemical reaction in the presence of the positive electrode 108 of the electrochemical cell 106 to produce at least one higher hydrocarbon, and/or one or more other materials (e.g., H2, nitrogen (N2), etc.). In some embodiments, the CH4 stream 120 is substantially free of materials other than CH4. In additional embodiments, the CH4 stream 120 includes CH4 and C2H6. The CH4 stream 120 may be substantially gaseous (e.g., may only include a single gaseous phase), may be substantially liquid (e.g., may only include a single liquid phase), or may include a combination of liquid and gaseous phases. The phase(s) of the CH4 stream 120 (and, hence, a temperature and a pressure of the CH4 stream 120) may at least partially depend on the operating temperature of the electrochemical cell 106 of the electrochemical apparatus 104. In some embodiments, the CH4 stream 120 is substantially gaseous.
A single (e.g., only one) CH4 stream 120 may be directed into the electrochemical apparatus 104 from the CH4 source 102, or multiple (e.g., more than one) CH4 streams 120 may be directed into the electrochemical apparatus 104 from the CH4 source 102. If multiple CH4 streams 120 are directed into the electrochemical apparatus 104, each of the multiple CH4 streams 120 may exhibit substantially the same properties (e.g., substantially the same material composition, substantially the same temperature, substantially the same pressure, substantially the same flow rate, etc.), or at least one of the multiple CH4 streams 120 may exhibit one or more different properties (e.g., a different material composition, a different temperature, a different pressure, a different flow rate, etc.) than at least one other of the multiple CH4 streams 120.
The heating apparatus 118, if present, may comprise at least one apparatus (e.g., one or more of a combustion heater, an electrical resistance heater, an inductive heater, and an electromagnetic heater) configured and operated to heat one or more of the CH4 stream 120, and at least a portion of the electrochemical apparatus 104 to an operating temperature of the electrochemical apparatus 104. The operating temperature of the electrochemical apparatus 104 may at least partially depend on a material composition of the proton-conducting membrane 110 of the electrochemical cell 106 thereof, as described in further detail below. In some embodiments, the heating apparatus 118 heats one or more of the CH4 stream 120, and at least a portion of the electrochemical apparatus 104 to a temperature within a range of from about 150° C. to about 600° C. In additional embodiments, such as in embodiments wherein a temperature of the CH4 stream 120 is already within the operating temperature range of the electrochemical cell 106 of the electrochemical apparatus 104, the heating apparatus 118 may be omitted (e.g., absent) from the CH4 activation system 100.
With continued reference to
The housing structure 114 may at least partially define at least one internal chamber 128 at least partially surrounding the electrochemical cell 106. The electrochemical cell 106 may serve as a boundary between a first region 130 (e.g., an anodic region) of the internal chamber 128 configured and positioned to receive the CH4 stream 120 and to direct the hydrocarbon product stream 124 from the electrochemical apparatus 104, and a second region 132 (e.g., a cathodic region) of the internal chamber 128 configured and positioned to receive the H2(g) produced at the positive electrode 108 of the electrochemical cell 106. Molecules (e.g., CH4) of the CH4 stream 120 may be substantially limited to the first region 130 of the internal chamber 128 by the configurations and positions of the housing structure 114 and the electrochemical cell 106. Keeping the second region 132 of the internal chamber 128 substantially free of molecules from the CH4 stream 120 circumvents additional processing of the produced H2(g) (e.g., to separate the produced H2(g) from CH4) that may otherwise be necessary if the components of the CH4 stream 120 were also delivered to within the second region 132 of the internal chamber 128.
As shown in
The proton-conducting membrane 110 may be formed of and include at least one electrolyte material exhibiting an ionic conductivity (e.g., H+ conductivity) greater than or equal to about 10−2 S/cm (e.g., within a range of from about 10−2 S/cm to about 1 S/cm) at one or more temperatures within a range of from about 150° C. to about 600° C. (e.g., from about 200° C. to about 600° C.). In addition, the electrolyte material may be formulated to remain substantially adhered (e.g., laminated) to the positive electrode 108 and the negative electrode 112 at relatively high current densities, such as at current densities greater than or equal to about 0.1 amperes per square centimeter (A/cm2) (e.g., greater than or equal to about 0.5 A/cm2, greater than or equal to about 1.0 A/cm2, greater than or equal to about 2.0 A/cm2, etc.). For example, the proton-conducting membrane 110 may comprise one or more of a perovskite material, a solid acid material, and a polybenzimidazole (PBI) material. The material composition of the proton-conducting membrane 110 may provide the proton-conducting membrane 110 with enhanced ionic conductivity at a temperature within the range of from about 150° C. to about 600° C. as compared to conventional membranes (e.g., membranes employing conventional electrolyte materials, such as yttria-stabilized zirconia (YSZ)) of conventional electrochemical cells. By way of non-limiting example, the electrolyte material (e.g., perovskite material, solid acid material, PBI material) of the proton-conducting membrane 110 may have orders of magnitude higher ionic conductivity than YSZ at operational temperatures thereof within the range of from about 150° C. to about 600° C.
In some embodiments, the proton-conducting membrane 110 is formed of and includes at least one perovskite material having an operational temperature (e.g., a temperature at which the H+ conductivity of the perovskite material is greater than or equal to about 10−2 S/cm, such as within a range of from about 10−2 S/cm to about 10−1 S/cm) within a range of from about 400° C. to about 600° C. By way of non-limiting example, the proton-conducting membrane 110 may comprise one or more of a yttrium- and ytterbium-doped barium-zirconate-cerate (BZCYYb), such as BaZr0.8-yCeyY0.2-xYbxO3-δ, wherein x and y are dopant levels and δ is the oxygen deficit (e.g., BaZr0.3Ce0.5Y0.1Yb0.1O3-δ); a yttrium- and ytterbium-doped barium-strontium-niobate (BSNYYb), such as Ba3(Sr1-xNb2-yYxYby)O9-δ, wherein x and y are dopant levels and δ is the oxygen deficit; doped barium-cerate (BaCeO3) (e.g., yttrium-doped BaCeO3 (BCY)); doped barium-zirconate (BaZrO3) (e.g., yttrium-doped BaCeO3 (BZY)); barium-yttrium-stannate (Ba2(YSn)O5.5); and barium-calcium-niobate (Ba3(CaNb2)O9). In some embodiments, the proton-conducting membrane 110 comprises BZCYYb.
In further embodiments, the proton-conducting membrane 110 is formed of and includes at least one solid acid material having an operational temperature (e.g., a temperature at which the H+ conductivity of the solid acid material is greater than or equal to about 10−2 S/cm, such as within a range of from about 10−2 S/cm to about 1 S/cm) within a range of from about 200° C. to about 400° C. By way of non-limiting example, the proton-conducting membrane 110 may comprise a solid acid phosphate material, such as solid acid cesium dihydrogen phosphate (CsH2PO4). The solid acid material may be doped (e.g., doped CsH2PO4), or may be undoped (e.g., undoped CsH2PO4). In some embodiments, the proton-conducting membrane 110 comprises CsH2PO4.
In additional embodiments, the proton-conducting membrane 110 is formed of and includes at least one PBI material having an operational temperature (e.g., a temperature at which the H+ conductivity of the PBI material is greater than or equal to about 10−2 S/cm, such as within a range of from about 10−2 S/cm to about 1 S/cm) within a range of from about 150° C. to about 250° C. By way of non-limiting example, the proton-conducting membrane 110 may comprise a doped PBI, such as phosphoric acid (H3PO4) doped PBI. In some embodiments, the proton-conducting membrane 110 comprises H3PO4-doped PBI.
The proton-conducting membrane 110 may be substantially homogeneous or may be substantially heterogeneous. As used herein, the term “homogeneous” means amounts of a material do not vary throughout different portions (e.g., different lateral and longitudinal portions) of a structure. Conversely, as used herein, the term “heterogeneous” means amounts of a material vary throughout different portions of a structure. Amounts of the material may vary stepwise (e.g., change abruptly), or may vary continuously (e.g., change progressively, such as linearly, parabolically) throughout different portions of the structure. In some embodiments, the proton-conducting membrane 110 is substantially homogeneous. In additional embodiments, the proton-conducting membrane 110 is heterogeneous. The proton-conducting membrane 110 may, for example, be formed of and include a stack of at least two (e.g., at least three, at least four, etc.) different materials. As a non-limiting example, the proton-conducting membrane 110 may comprise a stack of at least two (e.g., at least three, at least four, etc.) different perovskite materials individually having an operational temperature within a range of from about 400° C. to about 600° C. As another non-limiting example, the proton-conducting membrane 110 may comprise a stack of at least two (e.g., at least three, at least four, etc.) different solid acid materials individually having an operational temperature within a range of from about 200° C. to about 400° C. As a further non-limiting example, the proton-conducting membrane 110 may comprise a stack of at least two (e.g., at least three, at least four, etc.) different PBI materials individually having an operational temperature within a range of from about 150° C. to about 250° C.
The proton-conducting membrane 110 may exhibit any desired dimensions (e.g., length, width, thickness) and any desired shape (e.g., a cubic shape, cuboidal shape, a tubular shape, a tubular spiral shape, a spherical shape, a semi-spherical shape, a cylindrical shape, a semi-cylindrical shape, a conical shape, a triangular prismatic shape, a truncated version of one or more of the foregoing, and irregular shape). The dimensions and the shape of the proton-conducting membrane 110 may be selected such that the proton-conducting membrane 110 substantially intervenes between opposing surfaces of the positive electrode 108 and the negative electrode 112, and exhibits an H+ conductivity greater than or equal to about 10−2 S/cm (e.g., from about 10−2 S/cm to about 1 S/cm) at a temperature within a range of from about 150° C. to about 600° C. A thickness of the proton-conducting membrane 110 may be within a range of from about 5 micrometers (μm) to about 1000 μm, and may at least partially depend on the material composition of the proton-conducting membrane 110. For example, a proton-conducting membrane 110 formed of and including at least one perovskite material may have a thickness with a range of from about 5 μm to about 1000 μm; a proton-conducting membrane 110 formed of and including at least one solid acid material may have a thickness with a range of from about 5 μm to about 1000 μm; and a proton-conducting membrane 110 formed of and including at least one PBI material may have a thickness with a range of from about 50 μm to about 1000 μm.
The positive electrode 108 and the negative electrode 112 may individually be formed of and include at least one catalyst-doped material compatible with the material composition of the proton-conducting membrane 110 and the operating conditions (e.g., temperature, pressure, current density, etc.) of the electrochemical cell 106, and facilitating the formation of the hydrocarbon product stream 124 and the H2(g) stream 126 from the CH4 stream 120 at an operational temperature within the range of from about 150° C. to about 600° C. Accordingly, the material compositions of the positive electrode 108 and the negative electrode 112 may be selected relative to one another, the material composition of the proton-conducting membrane 110, the material composition of the CH4 stream 120, and the operating conditions of the electrochemical cell 106.
The catalyst-doped material of the positive electrode 108 includes at least one catalyst material thereon, thereover, and/or therein that accelerates reaction rates at the positive electrode 108 to produce CH3+, H+, and e− from CH4 in accordance with Equation (1) above, and that also accelerates reaction rates at the positive electrode 108 to synthesize one or more higher hydrocarbons from the produced CH3+ (e.g., in accordance with one or more of Equations (3) through (6) above). The catalyst material may, for example, comprise a metallic material formulated to accelerate reaction rates at the positive electrode 108 to produce CH3+, H+, and e− from CH4, and to accelerate reaction rates for the synthesis of higher hydrocarbons from the produced CH3+. In some embodiments, the catalyst material comprises elemental particles of a first metal formulated to accelerate reaction rates at the positive electrode 108 to produce CH3+, H+, and e− from CH4, and additional elemental particles of a second metal discrete from the elemental particles of the first metal and formulated to accelerate reaction rates for the synthesis of higher hydrocarbons from the produced CH3+. In additional embodiments, the catalyst material comprises alloy particles individually including an alloy comprising the first metal and the second metal. In further embodiments, the catalyst material comprises composite particles including one of the first metal and the second metal partially (e.g., less than completely) coating (e.g., covering, encapsulating) the other of the first metal and the second metal, such as composite particles individually including a shell of the second metal partially coating a core of the first metal, and/or composite particles individually including a shell of the first metal partially coating a core of the second metal. In yet further embodiments, the catalyst material comprises composite particles including an alloy including one of the first metal and the second metal partially coating the another alloy including the other of the first metal and the second metal, such as composite particles individually including a shell of an alloy including the second metal partially coating a core of another alloy including the first metal, and/or composite particles individually including a shell of an alloy including the first metal partially coating a core of another alloy including the second metal. In still further embodiments, the catalyst material comprises composite particles including one of the first metal and the second metal partially coating an alloy including the other of the first metal and the second metal, such as composite particles individually including a shell of the second metal partially coating a core of an alloy including the first metal, and/or composite particles individually including a shell of the first metal partially coating a core of an alloy including the second metal. In yet still further embodiments, the catalyst material comprises composite particles including an alloy including one of the first metal and the second metal partially coating the other of the first metal and the second metal, such as composite particles individually including a shell of an alloy including the second metal partially coating a core of the first metal, and/or composite particles individually including a shell of an alloy including the first metal partially coating a core of the second metal.
Particles (e.g., elemental particles, alloy particles, composite particles) of the catalyst material of the catalyst-doped material of the positive electrode 108 may be nano-sized (e.g., individually having a cross-sectional width or diameter less than about one (1) μm, such as less than or equal to about 100 nanometers (nm), less than or equal to about 20 nm, or less than or equal to about 10 nm). In addition, the catalyst-doped material of the positive electrode 108 may exhibit any amount (e.g., concentration) and distribution of the catalyst material and any ratio of components thereof (e.g., any ratio of a first metal formulated to accelerate reaction rates at the positive electrode 108 to produce CH3+, H+, and e− from CH4 to a second metal formulated to accelerate reaction rates for the synthesis of higher hydrocarbons from the produced CH3+) facilitating desired CH4 deprotonation reaction rates and desired coupling reaction rates (e.g., methyl coupling reaction rates, ethyl coupling reaction rates (if any), etc.) at the positive electrode 108.
The catalyst-doped material of the negative electrode 112 includes at least one a catalyst material thereon, thereover, and/or therein that accelerates reaction rates at the negative electrode 112 to produce H2(g) from H+ and e− in accordance with Equation (2) above. The catalyst material may, for example, comprise a metallic material including at least one metal, such as one or more of Ni and platinum (Pt), formulated to accelerate reaction rates at the negative electrode 112 to produce H2(g) from H+ and e− in accordance with Equation (2) above. The catalyst material of the catalyst-doped material of the negative electrode 112 may comprise nano-sized particles (e.g., nano-sized elemental particles, nano-sized alloy particles, and/or nano-sized composite particles). The catalyst-doped material of the negative electrode 112 may exhibit any amount (e.g., concentration) and distribution of the catalyst material any ratio of components thereof facilitating desired hydrogen evolution reaction (HER) rates at the negative electrode 112.
By way of non-limiting example, if the proton-conducting membrane 110 comprises a perovskite material (e.g., a BZCYYb, a BSNYYb, a doped BaCeO3, a doped BaZrO3, Ba2(YSn)O5.5, Ba3(CaNb2)O9, etc.) having an operational temperature within a range of from about 400° C. to about 600° C., the positive electrode 108 may comprise one or more of (e.g., two or more of, three or more of) ruthenium (Ru), rhodium (Rh), nickel (Ni), iridium (Ir), molybdenum (Mo), zinc (Zn), and iron (Fe); and the negative electrode 112 may comprise a catalyst-doped perovskite material. The positive electrode 108 may, for example, comprise a catalyst-doped material including elemental particles individually including Ru, Rh, Ni, Ir, Mo, Zn, or Fe; alloy particles individually including one or more of Ru, Rh, Ni, Ir, Mo, Zn, and Fe; composite particles (e.g., core/shell particles) individually including silicon dioxide (SiO2) and one or more of Ru, Rh, Ni, Ir, Mo, Zn, and Fe, such as composite particles of Fe and SiO2 (Fe@SiO2) and/or composite particles of Mo and SiO2 (Mo@SiO2); composite particles individually including silicon carbide (SiC) and one or more of Ru, Rh, Ni, Ir, Mo, Zn, and Fe, such as composite particles of Fe and SiC (Fe@SiC) and/or composite particles of Mo and SiC (Mo@SiC); aluminosilicate zeolite (e.g., Zeolite Socony Mobil-5 (ZSM-5), Hollow Zeolite Socony Mobil-5 (HZSM-5)) structures embedded with one or more of Ru, Rh, Ni, Ir, Mo, Zn, and Fe, such as Fe/HZ SM-5 and/or Mo/HZSM-5; particles individually including a carbide of one or more of Ru, Rh, Ni, Ir, Mo, Zn, and Fe, such as molybdenum carbide (Mo2C); and/or particles individually including a multi-metallic compound (e.g., a bimetallic compound, a trimetallic compound) comprising two or more (e.g., two, three, more than three) of Ru, Rh, Ni, Ir, Mo, Zn, and Fe. In addition, the negative electrode 112 may, for example, comprise a cermet material comprising at least one catalyst material including Ni, and at least one perovskite, such as a Ni/perovskite cermet (Ni-perovskite) material (e.g., Ni—BZCYYb, Ni—BSNYYb, Ni—BaCeO3, Ni—BaZrO3, Ni—Ba2(YSn)O5.5, Ni—Ba3(CaNb2)O9). In some embodiments, the proton-conducting membrane 110 comprises BZCYYb, the positive electrode 108 comprises Fe@SiO2, and the negative electrode 112 comprises Ni—BZCYYb. In additional embodiments, the proton-conducting membrane 110 comprises BZCYYb, the positive electrode 108 comprises Mo2C, and the negative electrode 112 comprises Ni—BZCYYb.
As another non-limiting example, if the proton-conducting membrane 110 comprises a solid acid material (e.g., a doped CsH2PO4, an undoped CsH2PO4) having an operational temperature within a range of from about 200° C. to about 400° C., the positive electrode 108 may comprise one or more of Ni, and a metallic material (e.g., an alloy, a bimetallic compound) including Ru and cobalt (Co); and the negative electrode 112 may comprise a cermet material comprising at least one catalyst material including Pt and at least one solid acid. The positive electrode 108 may, for example, comprise Ni; and/or a Ru—Co bimetallic compound. In addition, the negative electrode 112 may, for example, comprise a cermet material comprising Pt and CsH2PO4 (Pt—CsH2PO4 cermet). In some embodiments, the positive electrode 108 comprises Ni, and the negative electrode 112 comprises Pt—CsH2PO4 cermet. In additional embodiments, the positive electrode 108 comprises a Ru—Co bimetallic compound, and the negative electrode 112 comprises Pt—CsH2PO4 cermet.
As a further non-limiting example, if the proton-conducting membrane 110 comprises a PBI material (e.g., a doped PBI) having an operational temperature within a range of from about 150° C. to about 250° C., the positive electrode 108 may comprise a metallic material (e.g., an alloy, a bimetallic compound, a trimetallic compound) including two or more of Pd, Co, and platinum (Pt), and the negative electrode 112 may comprise one or more of Ni and Pt. The positive electrode 108 may, for example, comprise an alloy of Pd and one of more of Pt and Co (e.g., a Pd—Co alloy, a Pd—Pt alloy, a Pd—Pt—Co alloy); a bimetallic compound comprising Pd and one of Co and Pt; and/or a trimetallic compound including Pd, Pt, and Co. In addition, the negative electrode 112 may, for example, comprise one or more of elemental (e.g., non-alloyed, non-compounded) Ni, elemental Pt, a Ni alloy, and a Pt alloy. In some embodiments, the positive electrode 108 comprises a Pd—Co bimetallic compound, and the negative electrode 112 comprises one or more of Ni and Pt. In additional embodiments, the positive electrode 108 comprises a Pd—Pt bimetallic compound, and the negative electrode 112 comprises one or more of Ni and P. In further embodiments, the positive electrode 108 comprises a Pd—Pt—Co trimetallic compound, and the negative electrode 112 comprises one or more of Ni and P.
The positive electrode 108 and the negative electrode 112 may individually exhibit any desired dimensions (e.g., length, width, thickness) and any desired shape (e.g., a cubic shape, cuboidal shape, a tubular shape, a tubular spiral shape, a spherical shape, a semi-spherical shape, a cylindrical shape, a semi-cylindrical shape, a conical shape, a triangular prismatic shape, a truncated version of one or more of the foregoing, and irregular shape). The dimensions and the shapes of the positive electrode 108 and the negative electrode 112 may be selected relative to the dimensions and the shape of the proton-conducting membrane 110 such that the proton-conducting membrane 110 substantially intervenes between opposing surfaces of the positive electrode 108 and the negative electrode 112. Thicknesses of the positive electrode 108 and the negative electrode 112 may individually be within a range of from about 10 μm to about 1000 μm.
The electrochemical cell 106, including the positive electrode 108, the proton-conducting membrane 110, and the negative electrode 112 thereof, may be formed through conventional processes (e.g., rolling process, milling processes, shaping processes, pressing processes, consolidation processes, etc.), which are not described in detail herein. The electrochemical cell 106 may be mono-faced or bi-faced and may have a prismatic, folded, wound, cylindrical, or jelly rolled configuration. The electrochemical cell 106 may be placed within the housing structure 114 to form the electrochemical apparatus 104, and may be electrically connected to the power source 116.
Although the electrochemical apparatus 104 is depicted as including a single (i.e., only one) electrochemical cell 106 in
In addition, although the CH4 activation system 100 is depicted as including a single (i.e., only one) electrochemical apparatus 104 in
Still referring to
Thermal energy input into (e.g., through the heating apparatus 118 (if present)) and/or generated by the electrochemical apparatus 104 may also be used to heat one or more other components and/or streams (e.g., the CH4 stream 120) of the CH4 activation system 100. By way of non-limiting example, the hydrocarbon product stream 124 and/or the H2(g) stream 126 exiting the electrochemical apparatus 104 may be directed into a heat exchanger configured and operated to facilitate heat exchange between the hydrocarbon product stream 124 and/or the H2(g) stream 126 of the CH4 activation system 100 and one or more other relatively cooler streams (e.g., the CH4 stream 120) of the CH4 activation system 100 to transfer heat from the hydrocarbon product stream 124 and/or the H2(g) stream 126 to the relatively cooler stream(s) to facilitate the recovery of the thermal energy input into and generated within the electrochemical apparatus 104. The recovered thermal energy may increase process efficiency and/or reduce operational costs without having to react (e.g., combust) higher hydrocarbon products of the hydrocarbon product stream 124 and/or H2(g) of the H2(g) stream 126.
The methods, systems (e.g., the CH4 activation system 100), and apparatuses (e.g., the electrochemical apparatus 104, including the electrochemical cell 106 thereof) of the disclosure facilitate the simple and efficient co-production of higher hydrocarbons (e.g., butylene, gasoline, diesel, etc.) and H2(g) from CH4 at intermediate temperatures, such as temperatures within a range of from about 150° C. to about 600° C. The methods, systems, and apparatuses of the disclosure may reduce one or more of the time (e.g., processing steps), costs (e.g., material costs), and energy (e.g., thermal energy, electrical energy, etc.) required to produce higher hydrocarbons from CH4 relative to conventional methods, systems, and apparatuses of producing higher hydrocarbons from CH4. The methods, systems, and apparatuses of the disclosure may be more efficient, durable, and reliable that conventional methods, conventional systems, and conventional apparatuses of producing higher hydrocarbons and H2(g).
While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, the disclosure is not limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the following appended claims and their legal equivalent. For example, elements and features disclosed in relation to one embodiment may be combined with elements and features disclosed in relation to other embodiments of the disclosure.
This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 62/597,004, filed Dec. 11, 2017, the disclosure of which is hereby incorporated herein in its entirety by this reference.
This invention was made with government support under Contract Number DE-AC07-05ID14517 awarded by the United States Department of Energy. The government has certain rights in the invention.
| Number | Date | Country | |
|---|---|---|---|
| 62597004 | Dec 2017 | US | |
| 62597004 | Dec 2017 | US |
