Commercial carbon dioxide (CO2) is generally manufactured by separation and purification from CO2-rich gases produced by combustion or biological processes. It is also found in underground formations in some U.S. states.
CO2 is commercially available as high-pressure cylinder gas (about 300 psig), refrigerated liquid or as a solid (dry ice).
Common uses of CO2 include fire extinguishing systems, carbonation of soft drinks and beer; freezing of food products, refrigeration and maintenance of environmental conditions during transportation of food products, enhancement of oil recovery from wells, materials production (plastics, rubber), treatment of alkaline water, etc.
Applications include:
To meet the needs of these various applications, requiring from small quantities of CO2 (less than a pound/day) to extremely large quantities (tons/day), CO2 is available as:
a compressed gas requiring heavy cylinders, or
a liquid under pressure available from tube or liquid trailers, or as solid dry ice.
Very small users rely on high pressure cylinders. Their distribution is generally conducted by locally-focused businesses that buy the gas in bulk liquid form and package it at their facilities.
Small to medium size customers truck-in bulk liquid products that are then processed through evaporation to produce the gas.
Larger customers' needs are often met with “tube trailers”, i.e. bundles of high-pressure cylinders mounted on wheeled platforms.
“Onsite” plants are usually installed by customers consuming more than 10 tons/day of the gas.
There is an increasing interest in user-owned, small, non-cryogenic gas generators, in many markets. Such generators are available for oxygen, hydrogen and nitrogen, but not for carbon dioxide.
For example, small to medium size users of oxygen or nitrogen may find an economical supply alternative in pressure-swing-adsorption (PSA) plants. Or again, hydrogen and oxygen may be produced through electrolysis of water. High purity hydrogen may then be produced by purification of the stream by using palladium foil diffusers.
The benefits of these “on-site” generators are multiple:
generation on demand, as needed
independence from suppliers and possible supply interruptions
cost-insensitivity to supply issues
no need for pressure vessels, their storage and recycling
Etc.
To-date, “on-site” economical carbon dioxide generators, such as are available for hydrogen and oxygen, do not exist, although the demand for carbon dioxide is substantial
It is the primary object of this invention to provide for an “on-site” generator of carbon dioxide which can controllably generate substantial quantities of carbon dioxide, that does not require a combustion or biological process, while producing carbon dioxide on demand in an economical manner.
It is another object of this invention to provide “on-site” systems capable of generating mixed CO2 and H2 streams or streams of the purified gases.
The applicant has invented an electrolytic process and method to produce carbon dioxide from organic acids that were originally described in U.S. Pat. Nos. 6,780,304 B1 and 6,387,228 B1. He has pursued the development of that generation technology by developing multiple electrochemical cells assembled in stacks to achieve production rates and volumes much larger than those described in these patents.
The novel multi-cell generators will now be described by referring to
The multi-cell generator 15 of
The size of electrochemical cells 17 can vary from sub-cm2 areas, as described in a co-pending patent application, to m2 as used for brine electrolysis. The examples discussed later in the description make use of this wide range of sizes.
Current collectors 23 are open-mesh structures that allow easy access of the carboxylated acid solution to the electrodes and they provide for a low resistance path for electron transfer from the external circuit. In some instances a dual current collector is used, i.e. a thin screen is embedded in the electrode and a thicker current collector is maintained in tight contact with the screen.
In
When the DC power supply 51 is connected to the electrochemical stack by means of switch 58 and power lines 75, CO2 and H2 are generated and transported by means of conduit 77 to gas processing unit 74 where the gases are separated and released as H2 through conduit 78 and CO2 through conduit 79. Water entrained by the gas stream is recovered by means of condenser/scrubber 80 and recycled to the generator 72 by means of conduit 81.
In
In
The ease and simplicity of controlling the process was illustrated by an experiment with an AC/DC converter, rated at 3.3 amps, maximum, (input 100-240 volts AC, 47-63 Hz, 0.7 amps), that was directly connected to the generator terminals, without additional current and/or voltage regulation. A steady-state operating condition of 2.85 amps, 4.94 volts and a generator temperature of 55 degree Celsius were observed. This type of “desk-top” generator is capable of producing over 300 liters of CO2 per day (more than 1 lb/day).
Oxalic acid is the preferred carboxylic acid for the generation of CO2. Either anhydrous oxalic acid (COOH)2 or the dihydrate (COOH)2.2H2O can be used for the generator.
By activating switch 33, a current is applied to the electrochemical stack immersed in the aqueous oxalic acid solution.
The anode reaction is: (COOH)2→2CO2+2H++2e− Eqn. 1
The cathode reaction is: 2H++2e−→H2 Eqn. 2
The generation of H2 can be beneficially used as an independent gas stream, or evolve simultaneously with CO2 to create an anaerobic gas mixture of 66.7% CO2 and 33.3% of H2.
Whenever H2 is not beneficially used, the cathode reaction can be mitigated by using an air depolarized cathode, i.e. supplying oxygen or air to the cathode chamber such that reaction of eqn. 2 now becomes:
2H++2e−+½O2→H2O Eqn. 3
and the electrochemical decomposition process results solely in the production of CO2 and water.
The following materials compositions options are available:
Processes 1A and 2A allow for H2 recovery
Processes 1B and 2B allow for oxidation of H2 to water to reduce process energy needs.
In instances where water is a rare commodity, oxalic acid dihydrate can be substituted for anhydrous oxalic acid. The dihydrate (COOH)2.2H2O contains about 28.5% of water by weight that is released during the electrolytic process. The generation of CO2 does not require any additional water, except possibly when immediate full rated output is required. However, even then, only a minimum of water is required to solubilize the oxalic acid to allow access of the solution to the generation electrodes.
Since heating of the acid solution or slurry increases the oxalic acid solubility, it is beneficial to insulate the generator to allow its operation at higher temperatures, which results in a substantial reduction of the specific power requirements, i.e. kilowatts/(lb of CO2/hr).
The electrolytic process can also be conducted under pressure, which can be beneficial for the recovery of water and the separation of CO2 from H2.
The generator systems described so far produce CO2 and H2. In some instances the streams do not need separation, in others it is essential to generate high purities of each constituent.
Whenever separation is desired, multiple processes are available to achieve that result.
Some of these are briefly described in the following:
If H2 is undesirable either in the CO2 gas stream or as a by-product, H2 can be converted into thermal energy in the following manners:
The electrochemical process is DC driven. Power sources can be either AC-DC converters, batteries or solar photovoltaic cells, that are well suited for this process since they also operate at low voltages and high currents.
A single cell is placed in a container holding supersaturated oxalic acid dihydrate in form of a slurry. The cell, having a surface area of 8.3 cm2 is connected to a DC power supply. The following table summarizes some observed currents and voltages displayed by the cell, at 25° C.:
A single cell would be adequate to satisfy the needs of the small, occasional user.
The limiting current is in excess of 6 amps (0.75 amp/cm2). The current limits are caused by diffusion polarization of the slurry to the electrode surface. By mixing the slurry higher currents can be achieved. The second parameter affecting the performance of the stack is the slurry temperature. At room temperature the oxalic acid solubility in water is approximately 10 wt %, increasing rapidly as temperature increases, thus decreasing diffusion polarization, an observation readily noticeable when the generator, operating at fixed current, is allowed to heat up, resulting in a decrease in cell voltage.
Experiments were conducted with the 5-cell stack of example 2, thermally insulated to allow operation at elevated temperatures, without the need for additional heat source. We have, generally observed that the stack voltage decreases by 43 millivolts for each degree Celsius of temperature rise.
At an operating temperature of 60 degrees Celsius, the following conditions were recorded:
These results represent about 27% power consumption reduction over room temperature operation.
A 5-cell stack, essentially in the form of
A small 5-cell stack would be adequate to satisfy the needs of small users consuming less than 2.5 lbs of CO2/day.
Note that by a current adjustment the production rate is changed over a substantial dynamic range. Therefore a simple potentiometer would be adequate as a means of control of the generator output. In addition, the change in current results in an instantaneous change in carbon dioxide production rate.
Based on these experimental results and a reduction in cell resistance the following stack capabilities are possible:
This analysis shows that the electrolytic process is compatible with “on-site” generator capabilities as needed by small to medium-size users.
Based on the previously described stack performance, the following capabilities are possible:
Two 8.3 cm2 cells of the type described in this application, placed back-to-back (anodes facing each other) with cathodes exposed to air, are used to extract H2 from a gas stream generated from a 5-cell CO2 generator stack, described previously.
The voltage at a current of 400 milliamps is 0.5 volts; the limiting current, limited by the air cathode, is about 3 amps. This stack is capable of removing 1.5 liters/hour of hydrogen gas from the gas stream.
Four pairs of cells would be adequate to remove the hydrogen generated from a 12 liters/hour (1.2 lbs/day) CO2 generator.
Although this invention has been described in connection with specific forms and embodiments thereof, it will be appreciated that various modifications other than those discussed above may be resorted to without departing from the spirit or scope of the invention. For example, equivalent elements may be substituted for those specifically shown and described, certain features may be used independently of other features, and the number and configuration of various components described above may be altered, all without departing from the spirit or scope of the invention as defined in the appended Claims.
This application claims the priority of U.S. Provisional Patent Application No. 60/765,392 filed Feb. 3, 2006.
Number | Name | Date | Kind |
---|---|---|---|
4376097 | Emelock | Mar 1983 | A |
6299744 | Narayanan et al. | Oct 2001 | B1 |
6387228 | Maget | May 2002 | B1 |
6432284 | Narayanan et al. | Aug 2002 | B1 |
6780304 | Maget | Aug 2004 | B1 |
Number | Date | Country | |
---|---|---|---|
20070181419 A1 | Aug 2007 | US |
Number | Date | Country | |
---|---|---|---|
60765392 | Feb 2006 | US |