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Docket #: S24-130

Plasmonic gas diffusion reactor for CO2 conversion to high-value chemicals

Industry, government, and private investment in CO2 capture is growing to address climate change. Without carbon utilization, however, high costs impede large scale capture efforts. Alexander Al Zubeidi, a Stanford post doc in the D-Lab, has developed an inexpensive, scalable gas flow cell based system to convert atmospheric CO2 to other hydrocarbon based chemicals (like ethylene) using light and excess renewable electricity.

Figure 1 – Prototype Cell Process
(Image courtesy the D-Lab)

In the prototype system, gas enters the reactor cell via a gas flow channel, flows over the gas diffusion electrode covered in copper nanoparticles and electrolyte solution at ambient temperature. Visible light (450-800 nm) enters through the cell window, exciting copper nanoparticle electrons that reduce CO2 to ethylene. These electrolyzers can produce hydrocarbon based chemicals and syngas, a mixture of H2 and O2. Unlike competing electrolyzers that are built to operate on large scales, with long payback periods that typically require high capacity factors, the D-Lab system (Figure 2) can operate when renewable energy is in excess, generating net-zero emissions and converting point-source CO2 emissions to high-value products. This inexpensive, scalable plasmonic gas flow reactor system provides cost effective carbon capture CO2 gas separation and storage while producing valuable feedstocks for the chemical industry or zero-carbon fuels.

Figure 2 – Scaled Up Reactor Array
(Image courtesy the D-Lab)

Stage of Development – Proof of Concept Prototype

Applications

  • Industrial chemical production, especially ethylene
  • Green fuel / hydrocarbon based fuel production
  • Syngas production

Advantages

  • Low cost ethylene production with high cap-ex return: A 20 x 20 cm2 reactor operating at 80% selectivity for ethylene at 0.5 A/ cm2 operated 6 h a day can produce enough ethylene in 1 month to pay for itself.
  • Compact, scalable and mass producible: Easy to ship and scale up using eletrolyzers in parallel to keep production and supply chain uncomplicated.
  • No purification of reactants: The gas diffusion electrode operates with captured CO2 and gas mixtures containing CO2, which reduces upfront costs and energy consumption.
  • Operates at ambient temperature: The electrolyzer can be started and shut down rapidly, allowing it to only operate when electricity costs are low.
  • Does not require CH3

Publications

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