Patent Description:
The system and method are based on improvements related to the electrolyser which is fed by a CO<NUM>-rich, post-capture (bi)carbonate solution, wherein said improvements enable isolation of a <NUM>:<NUM> wt. % (or <NUM>:<NUM> vol. %) CO<NUM>/O<NUM> gas mixture from the anolyte during operation, with an in line CO<NUM>/O<NUM> separation at the anode of the electrolyser.

Carbon dioxide continues to build up in the environment. According to the National Oceanic and Atmospheric Administration (NOAA), the growth of carbon dioxide in the earth's atmosphere was <NUM> parts per million (ppm) per year in <NUM> and <NUM>, and <NUM> ppm in <NUM>. Techniques to remove carbon dioxide from the air have become a critical area of research.

CO<NUM>-emissions from industry and electricity production consists of large and localized streams (<NUM> kt to <NUM> Mt per year) and smaller point sources with cumulative emissions in the Mt range. It is recognized that CO<NUM> capture at these point sources is the border stone of emission reduction, and that even in case existing value chains proceed without change, yearly emission reduction by capture remains important. Novel more environmentally friendly production technologies can of course, reduce CO<NUM> capture need, if they could be implemented faster or cheaper.

As mentioned above, it is an object of the present invention to provide a CO<NUM> capture method and system using water electrolysis which produces O<NUM> and hydrogen. The market demand for hydrogen has grown significantly over the recent years with growth rates from <NUM> to <NUM> %. The chemical industry represents the largest demand, with the refining industry as an important end-user (<NUM> % of total demand). Smaller end users are steel producers apply H<NUM> for direct reduction of iron ore (<NUM> %). This industry plays an important role, as CO<NUM> emitter and depends on carbon-based feedstocks for production of (in)organic chemicals. This industry is energy-intensive and accordingly could also acts as enabler in the energy sector and its renewable transition, with the development of large-scale (Carbon Capture Use (CCU) / Carbon Capture Storage (CCS) Hubs through their industrial clusters and connections.

Current technologies of CCU and CCS are typically based on scrubbing with amine solutions. An alternative is potassium carbonate capture that combines low capture costs with little toxicity, ease of regeneration, low corrosiveness, high stability and favorable absorption capacity. As a result, the process has been applied in more than <NUM> plants. The process is based on (bi)carbonate cycles, where dissolved K<NUM>CO<NUM> captures CO<NUM>, resulting in KHC0<NUM>, which is pre-crystallized and dissociated as solid into CO<NUM> and carbonate above <NUM>. However, absorption kinetics are rather slow, which can be remediated by using engineered (thermostable) carbonic anhydrase enzymes, and doesn't produce Hydrogen often used by the energy-intensive industries mentioned herein before. <CIT> discloses a method and system for removing carbon dioxide (CO2) from an atmosphere and generating hydrogen comprising;- Capturing carbon dioxide from the atmosphere in an aqueous alkaline capture solution. Feeding the thus obtained aqueous (bi)carbonate solution to the anode cell of a water electrolyser. OER in the aqueous (bi)carbonate solution at the anode with formation of CO2 and O2. HER at the cathode with formation of H2 and regeneration of the aqueous alkaline capture solution so that the anode cell of the alkaline water electrolyser comprises an integrated CO2 / O2 separator wherein the aqueous alkaline capture solution is selected from a KOH or a NaOH solution with a pH of at least <NUM> wherein the anode cell comprising the integrated CO2 / O2 separator is configured to perform the OER of the (bi)carbonate solution at a temperature of <NUM>-100C and pressure of <NUM> atm.

There is accordingly a need for a cost-competitive CCU system that combines the supply of low cost CO<NUM> and green H<NUM> at a point sources of CO<NUM> emission. It is an object of the present invention to provide such CCU/CCS system relying on an electrolyser which produces O<NUM> and H<NUM> from water, and that comprises an integrated CO<NUM> capture and release configuration. This system of integrated CO<NUM> capture and Hydrogen production will hereinafter also be referred to as ICO<NUM>CH system.

The present invention provides a method according to claim <NUM>.

As is generally known, the overall reaction of water electrolysis can be divided into two half-cell reactions: hydrogen evolution reaction (HER) and oxygen evolution reaction (OER). HER is the reaction where water is reduced at the cathode to produce H<NUM>, and OER is the reaction where water is oxidized at the anode to produce O<NUM>. Using an alkaline capturing solution, the electrolyser used is an alkaline water electrolyser, wherein the alkaline capturing solution, regenerated at the cathode typically comprises hydroxide solutions of alkali metals (e.g., sodium and potassium) and alkaline earth metals (e.g., calcium) with a pH of at least <NUM>. In a particular embodiment the aqueous alkaline capture solution is selected from a KOH or a NaOH solution. Key to the method according to the invention is the presence of the integrated CO<NUM>/ O<NUM> separator in the anode cell of the electrolyser. This integrated configuration allows the ICO<NUM>CH system for example to be part of oxy-fuel combustion in a reciprocating engine with CO<NUM> dilution. In this combustion mode, some or all of the incoming air is replaced with a mixture of oxygen and CO<NUM> recirculated from the exhaust of the engine. The quantity of CO<NUM> that can be fed back to the engine intake is dependent on the concentration of oxygen in the fuel/oxidizer mixture. The stream of CO<NUM>/O<NUM> produced at the anode of the ICO<NUM>CH system, can be directly valorised by a natural gas (NG) fuelled Internal Combustion (IC) engine to realise ultra-low carbon emitting, partial oxy-fuel combustion, i.e. displacement of a portion of the engine air with a stream of CO<NUM>/O<NUM> oxidizer. With an engine appropriately sized to a given electrolyser rating, a substantial portion of CO<NUM> remains captive in the system, as the CO<NUM> in engine exhaust is combined with KOH and recirculated to the electrolyser, where CO<NUM> is eventually produced from the anode and cycled back to engine as diluent for the partial oxy-fuel combustion process. It is accordingly an object of the present invention to the use of the ICO<NUM>CH system as part oxy-fuel combustion in a reciprocating engine with CO<NUM> dilution.

In another aspect the present invention provides a system according to claim <NUM>.

Such set-up accordingly allows an instant and in-line separation of the Oxygen produced at the anode without the need of an additional CO<NUM> / O<NUM> separator. As such it simplifies the installation, and enables for example, the system according to the invention to be part of oxy-fuel combustion in a reciprocating engine with CO<NUM> dilution.

In the system according to the invention, and relying on an aqueous alkaline solution-based CO<NUM> capturing system, the OER at the anode is expected to yield CO<NUM>/O<NUM> mixtures comprising a mole fraction of at least <NUM>% CO<NUM>; in particular from about <NUM>:<NUM> CO<NUM>:O<NUM> to about <NUM>:<NUM> CO<NUM>:O<NUM>; more in particular from about <NUM>:<NUM> CO<NUM>:O<NUM> to about <NUM>:<NUM> CO<NUM>:O<NUM>. For such CO<NUM>/O<NUM> mixtures the anode is kept at temperatures from about <NUM> to about -<NUM> and respective pressure from about <NUM> bar to about <NUM> bar.

The present invention is directed to an improved system and method for capturing CO<NUM> from an atmosphere and converting it in an output gas for valorisation such as green H<NUM> use, Carbon Capture Use (CCU), Carbon Capture Storage (CCS) and partial oxy-fuel combustion. The system and method herein disclosed are based on an electrolyser as core technology in combination with CO<NUM> capturing technology relying an alkaline capturing solution. Compared to existing systems and methods the present invention differs at least in the configuration of the reaction environment at the anode of the according to the independent claims <NUM> and <NUM>.

A schematic representation of the cell setup of an electrolyser is provided in <FIG>. It shows M+ transport across an ion-permeable membrane held between the two electrodes. As membranes for electrolysis, asbestos, nonwoven fabric, ion exchange membranes, polymer porous membranes, composite membranes of inorganic substances and organic polymers, and the like have been proposed. For example, <CIT> includes an organic fiber cloth incorporated in a mixture of a hydrophilic inorganic material of calcium phosphate compound or calcium fluoride and an organic binder selected from polysulfone, polypropylene, and polyvinylidene fluoride. An ion permeable diaphragm is shown. Further, for example, in <CIT>, a granular inorganic hydrophilic material selected from antimony, zirconium oxide and hydroxide, and a fluorocarbon polymer, polysulfone, polypropylene, polyvinyl chloride, and polyvinyl butyral are selected. An ion permeable membrane comprising stretched organic fiber fabrics is shown in a film-forming mixture consisting of a modified organic binder. The electrolyser used in the context of the invention is in particular a water electrolyser, more in particular an alkaline water electrolyser.

As part of the system any currently known CO<NUM> Capturing technologies using an aqueous alkaline solution to absorb the CO<NUM> can be used. Various scrubbing processes have been proposed to remove CO2 from the air, or from flue gases, but for use in the ICO2CH system according to the invention, the scrubbing process is preferably based on a potassium or sodium hydroxide solution. The CO<NUM> is absorbed in the solution to produce the corresponding (bi)carbonate. The CO<NUM> is subsequently released by applying a nominal voltage across the (bi)carbonate solution in the electrolyser. In general, the alkaline capturing solution is selected from hydroxide solutions of alkali metals (e.g., sodium and potassium) and alkaline earth metals (e.g., calcium) with a pH of at least <NUM>.

According to the invention the anode cell is configured to perform the OER of the (bi)carbonate solution at pressures from about and between <NUM> bar to up to <NUM> bar and at reduced temperatures from about and between <NUM> to -<NUM>.

In an even further embodiment the cathode cell is configured to be operated at pressures up to <NUM> bar. If a a common pressure is maintained at both the anode and the cathode cell of the electrolyser, a pressure difference across the ion-permeable membrane held between the two electrodes can be prevented, simplifying the design of the electrolyser.

In an embodiment according to the invention the methods or systems as herein provided are further characterized in that the cathode is configured to perform the HER with formation of H<NUM> and regeneration of the aqueous alkaline capture solution at pressures up to <NUM> bar; in particular at pressures from about and between <NUM> bar to up to <NUM> bar.

In another embodiment according to the invention the methods or systems as herein provided are further characterized in that the HER at the cathode and the OER at the anode are performed at the same pressure from about and between <NUM> bar to up to <NUM> bar.

The methods and systems of the present invention produce high purity CO<NUM> and O<NUM> streams which make it suitable in oxy-fuel combustion. Thus in a further aspect the present invention provides the use of the ICO2CH system as defined in any of the foregoing embodiments as part oxy-fuel combustion in a reciprocating engine with CO<NUM> dilution.

As an example of the potential CO<NUM> reduction, when using the ICO2CH system as part of an oxy-fuel combustion, consider a single <NUM> kW natural gas-fired reciprocating engine that is used to produce electricity and operates for the equivalent of <NUM> days in a year. This engine operates at stoichiometry such that all the oxygen is used to oxidize the fuel. Also, take the anode product stream from the electrolyser to have a nominal composition of <NUM> % O<NUM> and <NUM> % CO<NUM> by volume. As the incoming air to the engine is replaced by the recirculated anode gas mixture, a portion of the combustion CO<NUM> emissions are retained in the ICO2CH system, therefore decreasing the carbon-intensity of the combustion process. <FIG> illustrates this concept for a range of volumetric air replacement by the electrolyser anode products.

As shown, replacing only <NUM> % of the incoming air to the engine with the O<NUM>-CO<NUM> mixture results in a system retention of <NUM> % of the exhaust CO<NUM> emissions per unit of fuel combusted. At this level of air replacement (and assuming the engine is able to operate robustly in a partial oxy-fuel combustion mode), a <NUM> kW, state-of-the-art natural gas generator set running for <NUM> days per year at a fuel conversion efficiency of <NUM> % (including both the efficiency of the engine and generator) would avoid nearly <NUM> metric tons of CO<NUM>. This figure discounts the possibility for increasing engine efficiency by operating with excess oxidizer relative to the fuel (lean-burn) or other advanced combustion strategies, and therefore this reduction is considered conservative. In short, the integrated electrolyser and reciprocating engine system within ICO2CH has a significant potential to abate carbon emissions related to heat and power generation.

A set of electrolysis experiments were performed to underscore the conceptual workability of the method and systems of the invention. In a first experiment (Example <NUM>) it is demonstrated that an ICO2CH system, for removing carbon dioxide (CO<NUM>) from an atmosphere and generating hydrogen, in agreement with <FIG> will actually work in a water electrolyser with the formation of H<NUM> and regeneration of the aqueous alkaline capture solution, with the release of CO<NUM> at the anode. In a second example (Example <NUM>) it is further demonstrated that an in situ separation of CO<NUM> and O<NUM> at the anode can be further controlled without affecting the electrochemical cell performance (cell voltage / current / conductivity).

Electrolysis experiments have been carried out in a two-compartment cell (H-cell) under the following conditions:.

Chronopotentiometry (CP) at <NUM> different currents (<NUM>, <NUM>, <NUM>, <NUM> mA) was carried out each for <NUM> hours. Gas analysis of the headspace of the anolyte is performed with Differential Electrochemical Mass Spectrometry (DEMS). Moreover, the pH is monitored as a function of the time.

A schematic of the experimental setup is depicted in <FIG>.

In <FIG>, the accumulated charge for the chronopotentiometry at <NUM>, <NUM>, <NUM>, <NUM> mA is shown. Based on the measured pH, the increase of H+ concentration in the anolyte is plotted on the right y-axis. The sudden decrease in [H+] around t = <NUM> minutes is presumably due to gas bubbles that block the pH sensor. The protons are produced by the oxygen evolution reaction (OER) given in Eq. 1a (acidic media) and Eq. 1b (alkaline media).

<NUM><NUM>O → O<NUM> + <NUM>+ +4e     Eq. 1a.

<NUM> OH- → O<NUM> + <NUM><NUM>O + 4e-     Eq. 1b.

Simultaneously, hydrogen evolution reaction (HER) occurs at the cathode leading to the formation of H<NUM> (not measured). It is clearly seen that the trend of [H+] follows the accumulated charge vs. time.

Moreover, the gases in the headspace were continuously measured with Differential Electrochemical Mass Spectrometry (DEMS). In <FIG>, the evolution of the gas composition of the headspace of the anodic compartment is shown. N<NUM>, which is present from the start of the experiments is decreasing during the experiments. The trends of the gases in time can be explained by CO<NUM> production which displaces N<NUM> and O<NUM> in the headspace.

In <FIG>, the ratio of the CO<NUM>/O<NUM> signals are plotted together with the [H+] vs. time. The increase of CO<NUM> in the headspace is proportional with the charge (H+ formation rate), since the protons that are formed from Eq. <NUM> lead to protonation of HCO<NUM>- present in the anolyte (Eq. <NUM>) which results in liberation of CO<NUM> according to the following acid-base reaction.

H+ + HCO<NUM> → H<NUM>O + CO<NUM>     Eq. <NUM>.

Since the OER produces <NUM> protons per O<NUM> molecule, and <NUM> proton is consumed for the formation of CO<NUM>, the theoretical ratio of CO<NUM>/O<NUM> should be <NUM>. This theoretical value is also observed after steady state is reached for the last CP of <NUM> mA in <FIG>.

Similar trends are observed in case of a nafion membrane or different electrolytes such as KOH, NaOH or K<NUM>CO<NUM> (data not shown). This experiment accordingly demonstrates the working principle of the ICO2CH concept as brought forward in the instant application.

Example <NUM> not according to the invention In this example, it is demonstrated that the CO<NUM> release at the anode can be controlled without affecting the electrochemical cell performance. Thereto the eventual effect of pressure on the ICO2CH system has been studied.

Experiments are carried out employing a <NUM><NUM> round cell using a Nafion membrane, a Ni foam (<NUM> <NUM>% porosity) as well as a wide-meshed Ni mesh in between Ni foam and the current collector to achieve a zero-gap configuration. During the experiment, a constant temperature is desired, so the cryostat is operated at <NUM> during the whole experiment. Prior to each experiment, the catholyte and anolyte vessels are purged with nitrogen and filled with respectively <NUM> of <NUM> KOH and <NUM> of <NUM> KHCO<NUM>.

Gas analysis of the headspace of the anolyte is performed with Differential Electrochemical Mass Spectrometry (DEMS). The release of gases and mass balance of the electrolyte are studied during water electrolysis (HER at the cathode and OER at the anode) at (<NUM>) atmospheric pressure, (<NUM>) p = <NUM> bar and (<NUM>) p = <NUM> bar. Pressurization of the cell is realized by purging nitrogen gas. The experiments run at least until steady state is reached in the gas phase (i.e. at least till the expected CO<NUM>/O<NUM> ratio of <NUM> is reached, similar to previous experiments in the H-cell), ideally longer, or until the cell voltage or ohmic heating becomes critical.

A current density of <NUM> mA/cm<NUM> or <NUM> mA/cm<NUM> is applied (galvanostatic operation), corresponding to <NUM> A or <NUM> A total current. The electrolyte is recirculated with a flow rate is <NUM>/min.

Looking at the cell voltage for the different experiments, it can be seen from <FIG> that for the experiment at I = <NUM> mA/cm<NUM> (i=<NUM>. 4A; p=<NUM> bar - Top graph both in <NUM>(A) and <NUM>(B)) this increase starts earlier, while for I = <NUM> mA/cm<NUM> (i=<NUM>. 2A) the onset is later. It can be seen that for each experiment, the cell voltage starts to increase after a certain amount of time, when ca. <NUM>-<NUM> kC have passed (curves for I = <NUM> mA/cm<NUM>). Fout! Verwijzingsbron niet gevonden. C, shows that the initial conductivity is lower for I = <NUM> mA/cm<NUM> at <NUM> bar (in <FIG> at <NUM> from bottom to top curves for I = <NUM> mA/cm<NUM> at respectively 6bar, 1bar and 12bar), which may explain a slightly earlier onset of the cell voltage increase. There is no qualitative difference observed for the different pressures.

The increase in cell voltage when ca. <NUM>-<NUM> kC have passed is related to the decrease in conductivity of the anolyte. This is caused by the transport of K+ ions from the anolyte to the catholyte, which is dependent on the current (charge). It can be seen that the increase in cell voltage after ca. <NUM> hours of operation also induces a change in gas composition. It is believed that the membrane is damaged (due to high cell voltage stemming from ion depletion on one side of the membrane), leading to cross over of gases as the CO<NUM> concentration starts to decrease while the H<NUM> concentration starts to increase.

For all pressures at I = <NUM> mA/cm<NUM>, the liberation of CO<NUM> could be observed (data not shown) which means that the ICO2CH principle at elevated pressure is proven. However, and as expected the CO<NUM> flow rate decreases with increasing pressure. In other words, the CO<NUM>/O<NUM> ratio measured in these experiments is pressure dependent.

The reason for this is the increasing CO<NUM> solubility with pressure. This is also visible from the strong increase in CO<NUM> concentration during depressurization of the system from p = <NUM> bar as shown by the dashed circle in <FIG>.

Claim 1:
A method of removing carbon dioxide (CO<NUM>) from an atmosphere and generating hydrogen, comprising;
- Capturing carbon dioxide from the atmosphere in an aqueous alkaline capture solution;
- Feeding the thus obtained aqueous (bi)carbonate solution to the anode cell of a water electrolyser;
- OER in the aqueous (bi)carbonate solution at the anode with formation of CO<NUM> and O<NUM>;
- HER at the cathode with formation of H<NUM> and regeneration of the aqueous alkaline capture solution; characterized in that the anode cell of the electrolyser comprises an integrated CO<NUM> / O<NUM> separator configured on performing the OER of the alkaline capture solution at pressures from and between <NUM> bar to up to <NUM> bar and at reduced temperatures from and between <NUM> to -<NUM>, such that the produced Oxygen will be in the gas phase whilst the produced Carbon Dioxide remains in solution.