Method and apparatus for an electrolytic cell including a three-phase interface to react carbon-based gases in an aqueous electrolyte

Abstract

A process for converts carbon-based gases such as non-polar organic gases and carbon oxides to longer chained organic gases such as liquid hydrocarbons, longer chained gaseous hydrocarbons, branched-chain liquid hydrocarbons, branched-chain gaseous hydrocarbons, as well as chained and branched-chain organic compounds. In general, the method is for chain modification of hydrocarbons and organic compounds, including chain lengthening, and eventual conversion into liquids including, but not limited to, hydrocarbons, alcohols, and other organic compounds.

What is claimed: 
     
         1 . An electrolytic cell, comprising:
 at least one reaction chamber into which, during operation, a aqueous electrolyte and a gaseous feedstock including are introduced, wherein the gaseous feedstock comprises a carbon-based gas; and   a pair of reaction electrodes disposed within the reaction chamber, at least one of the reaction electrodes including a solid catalyst and defining, in conjunction with the aqueous electrolyte and the gaseous feedstock, a three-phase interface.   
     
     
         2 . The electrolytic cell of  claim 1 , wherein the aqueous electrolyte is mixed with the gaseous feedstock when the aqueous electrolyte has been introduced into the reaction chamber. 
     
     
         3 . The electrolytic cell of  claim 1 , wherein the aqueous electrolyte directly contacts the reaction electrode without the intercession of a polymer exchange membrane when the aqueous electrolyte has been introduced into the first chamber and mixed with the gaseous feedstock. 
     
     
         4 . The electrolytic cell of  claim 1 , wherein the aqueous electrolyte is selected from potassium chloride, potassium bromide, potassium iodide, or hydrogen chloride. 
     
     
         5 . The electrolytic cell of  claim 1 , wherein the solid catalyst contains an element selected from copper, silver, gold, iron, tin, zinc, ruthenium, platinum, palladium, rhenium, or a lanthanide metal. 
     
     
         6 . The electrolytic cell of  claim 5 , wherein the copper containing solid catalyst is Cuprous Chloride or Cuprous Oxide. 
     
     
         7 . The electrolytic cell of  claim 1 , wherein the carbon-based gas comprises a non-polar gas, a carbon oxide, or a mixture of the two. 
     
     
         8 . The electrolytic cell of  claim 7 , wherein the non-polar gases include a hydrocarbon gas. 
     
     
         9 . The electrolytic cell of claim wherein the carbon oxide includes carbon monoxide, carbon dioxide, or a mixture of the two. 
     
     
         10 . The electrolytic cell of  claim 1 , further wherein the catalyst is powdered and mixed in a slurry with the aqueous electrolyte. 
     
     
         11 . A method for chain modification of hydrocarbons and organic compounds comprising:
 contacting a gaseous feedstock including a carbon-based gas, an aqueous electrolyte, and a catalyst in a reaction area; and   activating the carbon-based gas in an aqueous electrochemical reaction at the reaction electrode and yield a product.   
     
     
         12 . The method of  claim 11 , wherein reacting the aqueous electrolyte, the catalyst, and the gaseous feedstock includes powering a pair of reaction electrodes. 
     
     
         13 . The method of  claim 11 , wherein reacting the aqueous electrolyte, the catalyst, and the gaseous feedstock includes electrically short circuiting a pair of reaction electrodes within the electrolyte while maintaining a three phase interface. 
     
     
         14 . The method of  claim 11 , wherein contacting the aqueous electrolyte with the catalyst and the gaseous feedstock includes introducing the aqueous electrolyte into direct contact with a gas diffusion electrode. 
     
     
         15 . The method of  claim 11 , wherein contacting the aqueous electrolyte with the catalyst and the gaseous feedstock includes introducing liquid reactants into direct contact with a gas diffusion electrode. 
     
     
         16 . The method of  claim 11 , wherein:
 the catalyst is a solid; and   the reaction occurs at a three-phase interface between the aqueous electrolyte, the solid catalyst, and the gaseous feedstock.   
     
     
         17 . The method of  claim 11 , further comprising leaving the aqueous electrolyte unfiltered during the reaction. 
     
     
         18 . The electrolytic cell of  claim 11 , wherein the carbon-based gas comprises a non-polar gas, a carbon oxide, or a mixture of the two. 
     
     
         19 . The electrolytic cell of  claim 18 , wherein the non-polar gases include a hydrocarbon gas. 
     
     
         20 . The electrolytic cell of  claim 18 , wherein the carbon oxide includes carbon monoxide, carbon dioxide, or a mixture of the two. 
     
     
         21 . The method of  claim 11 , wherein the catalyst comprises a metal, an inorganic salt of a metal, or an organometallic compound. 
     
     
         22 . The method of  claim 11 , wherein the catalyst is powdered and mixed in a slurry with the aqueous electrolyte. 
     
     
         23 . The method of  claim 11 , wherein the aqueous electrolyte is selected from magnesium sulfate, sodium chloride, sulfuric acid, potassium chloride, hydrogen chloride), potassium chloride, potassium bromide, potassium iodide, sea salt or brine. 
     
     
         24 . The method of  claim 11 , wherein the aqueous electrolyte has a concentration of between 0.1M-3M. 
     
     
         25 . A method for chain modification of hydrocarbons and organic compounds comprising:
 contacting an aqueous electrolyte with a a catalyst and a gaseous feedstock including a carbon-based gas within a reaction area; and   reacting the aqueous electrolyte, the catalyst, and the gaseous feedstock at temperatures in the range of −10 C to 1000 C and at pressures in the range of 0.1 ATM to 100 ATM to yield a long chained hydrocarbon.   
     
     
         26 . The method of  claim 25 , wherein reacting the aqueous electrolyte, the catalyst, and the gaseous feedstock includes powering a pair of reaction electrodes. 
     
     
         27 . The method of  claim 25 , wherein reacting the aqueous electrolyte, the catalyst, and the gaseous feedstock includes electrically short circuiting a pan of reaction electrodes within the electrolyte while maintaining a three phase interface. 
     
     
         28 . The method of  claim 25 , wherein contacting the aqueous electrolyte with the catalyst and the gaseous feedstock includes introducing: the aqueous electrolyte into direct contact with a gas diffusion electrode. 
     
     
         29 . The method of  claim 25 , wherein contacting the aqueous electrolyte with the catalyst and the gaseous feedstock includes introducing liquid reactants into direct contact with a gas diffusion electrode. 
     
     
         30 . The method of  claim 25 , wherein:
 the catalyst is a solid; and   the reaction occurs at a three-phase interface between the aqueous electrolyte, the solid catalyst, and the gaseous feedstock.   
     
     
         31 . The method of  claim 25 , further comprising leaving the aqueous electrolyte unfiltered during the reaction. 
     
     
         32 . The electrolytic cell of  claim 25 , wherein the carbon-based gas comprises a non-polar gas, a carbon oxide, or a mixture of the two. 
     
     
         33 . The electrolytic cell of  claim 32 , wherein the non-polar gases include a hydrocarbon gas. 
     
     
         34 . The electrolytic cell of  claim 32 , wherein the carbon oxide includes carbon monoxide, carbon dioxide, or a mixture of the two. 
     
     
         35 . The method of  claim 25 , wherein the catalyst comprises a metal, an inorganic salt of a metal, or an organometallic compound. 
     
     
         36 . The method of  claim 35 , wherein the catalyst contains an element selected from copper, silver, gold, nickel, iron, tin, zinc, ruthenium, platinum, palladium, rhenium, or a lanthanide metal. 
     
     
         37 . The method of  claim 35 , wherein the catalyst contains an organometallic salt of an element selected from copper, silver, gold, nickel, iron, tin, zinc, ruthenium, platinum, palladium, rhenium, or a lanthanide metal. 
     
     
         38 . The method of  claim 25 , wherein the catalyst is powdered and mixed in a slurry with the aqueous electrolyte. 
     
     
         39 . The method of  claim 35 , wherein the aqueous electrolyte includes Alkali or Alkaline Earth Salts. 
     
     
         40 . The method of  claim 39 , wherein the Alkali or alkaline Earth Salts include Halides, Sulfates, sulfites, Carbonates, Nitrates or Nitrites. 
     
     
         40 . The method of  claim 39 , wherein the aqueous electrolyte is selected from magnesium sulfate, sodium chloride, sulfuric acid, potassium chloride, hydrogen chloride), potassium chloride, potassium bromide, potassium iodide, sea salt, or brine. 
     
     
         41 . The method of  claim 25 , wherein the aqueous electrolyte is selected from magnesium sulfate, sodium chloride, sulfuric acid, potassium chloride, hydrogen chloride), potassium chloride, potassium bromide, potassium iodide, sea salt, or brine. 
     
     
         42 . The method of  claim 25 , wherein the aqueous electrolyte has a concentration of between 0.1M-3M. 
     
     
         43 . A gas diffusion electrode, comprising:
 a hydrophobic layer porous to carbon dioxide and impermeable to aqueous electrolytes;   a hydrophilic layer bonded to the hydrophobic layer; and   a cuprous halide coating disposed about the bonded hydrophobic and hydrophilic layers.   
     
     
         44 . The gas diffusion electrode of  claim 43 , further comprising:
 a high surface area powder electroplated to the cuprous halide coating; and   a capping reducing agent.   
     
     
         45 . The gas diffusion electrode of  claim 43 , wherein the hydrophilic layer includes:
 a hydrophilic carbon paper with a polytetrafluoroethylene dispersion;   an activated carbon coating on the polytetrafluoroethylene dispersion; and   the copper catalyst deposited into the pores of the activated carbon.   
     
     
         46 . The gas diffusion electrode of  claim 43 , wherein the copper catalyst is plated onto particles of silver. 
     
     
         47 . A method for fabricating a gas diffusion electrode, comprising:
 bonding a hydrophobic layer porous to carbon dioxide and impermeable to aqueous electrolytes to a hydrophilic layer supporting a copper catalyst; and   treating the copper catalyst to create a cuprous halide.   
     
     
         48 . The method of  claim 47 , further comprising;
 electroplating the cuprous halide with a high surface area powder; and   using a capping reducing agent to create nanoparticles.   
     
     
         49 . The method of  claim 47 , further comprising preparing the hydrophilic layer, wherein preparing the hydrophilic layer includes:
 treating a hydrophilic carbon paper with a polytetrafluoroethylene dispersion;   coating the polytetrafluoroethylene dispersion with a porous activated carbon; and   depositing the copper catalyst into the pores of the activated carbon.   
     
     
         50 . The method of  claim 49 , further comprising:
 mixing the treated, coated hydrophilic carbon paper with the deposited copper catalyst with a hydrophilic binding agent; and   creating an ink from the mixture and an organic solvent;   painting the mixture onto the hydrophobic layer.   
     
     
         51 . The method of  claim 50 , wherein the organic solvent includes PVA, PVAc, or Nafion. 
     
     
         52 . The method of  claim 47 , wherein treating the copper catalyst to create a cuprous halide includes:
 submerging the bonded hydrophobic layer and hydrophilic layer in a solution of hydrochloric acid and cupric chloride; and   heating the submerged the bonded hydrophobic layer and hydrophilic layer to approximately 100° C. for approximately 2 hours.   
     
     
         53 . The method of  claim 52 , wherein treating the copper catalyst further includes:
 plating particles of the copper catalyst with silver; and   plating the silver plated particles with the copper catalyst prior to submerging the bonded hydrophobic layer and hydrophilic layer.   
     
     
         54 . The method of  claim 52 , wherein treating the copper catalyst further includes:
 impregnating the hydrophilic layer with silver; and   plating the impregnated silver with the copper catalyst prior to submerging the bonded hydrophobic layer and hydrophilic layer.   
     
     
         55 . The method of  claim 47 , wherein treating the copper catalyst to create a cuprous halide includes:
 submerging the bonded hydrophobic layer and hydrophilic layer in 3 M KBr or 3 M KI; and   running a 4V pulse of electricity to the the bonded hydrophobic layer and hydrophilic layer.