Production of chemical products using electrochemical flow systems and slug flow and associated methods

Patent metadata

Field	Value
Publication number	US-11236429-B2
Application number	US-201916450859-A
Country	US
Kind code	B2
Filing date	Jun 24, 2019
Priority date	Aug 14, 2018
Publication date	Feb 1, 2022
Grant date	Feb 1, 2022

Abstract

Systems and methods for electrochemically producing chemical products are provided. In certain cases, the systems and methods described herein are capable of producing chemical products such as hydrogen peroxide in solutions with relatively low concentrations of electrolyte or other dissolved species at high efficiencies and/or low energetic cost. In some cases, redox mediators are used to temporally decouple direct electrochemical processes from the production of the chemical product.

First claim

What is claimed is:

1. A method for producing a chemical product, comprising:
contacting a first electrode, of an electrochemical cell comprising a first electrode compartment comprising the first electrode, an inlet, and an outlet, and a second electrode compartment separated from the first electrode compartment comprising a second electrode, an inlet, and an outlet, with a first slug comprising a first solution while applying an electrical potential to the first electrode, such that an active form of a redox mediator immobilized on the first electrode is generated;
replacing at least a portion of the first slug with a second slug comprising a second solution comprising a reactant, such that the first electrode is in contact with the second slug and no longer in contact with at least a portion of the first slug, and such that the active form of the redox mediator reacts with the reactant in the second solution to produce the chemical product; and
flowing a sequence of slugs from the inlet of the second electrode compartment to the outlet of the second electrode compartment, each slug of the sequence being essentially immiscible with the slug directly preceding the slug and the slug directly following the slug, such that each slug of the sequence contacts the second electrode.

2. The method of claim 1 , wherein the reactant is oxygen gas and the chemical product is hydrogen peroxide.

3. A method for producing a chemical product, comprising:
(a) providing an electrochemical cell comprising a first electrode compartment comprising a first electrode, an inlet, and an outlet;
(b) flowing a sequence of slugs comprising a first slug and a second slug from the inlet of the first electrode compartment to the outlet of the first electrode compartment, wherein the first slug comprises a first solution and the second slug comprises a second solution comprising a reactant, wherein during the flowing:
the first electrode is contacted with the first slug while an electrical potential is applied to the first electrode, such that an active form of a redox mediator immobilized on the first electrode is generated; and
at least a portion of the first slug is replaced with the second slug, such that the first electrode is in contact with the second slug and no longer in contact with at least a portion of the first slug, and such that the active form of the redox mediator reacts with the reactant in the second solution to produce the chemical product; and

(c) repeating step (b).

4. The method of claim 3 , wherein during the flowing, at least a portion of the first slug is replaced with an inert slug essentially immiscible with both the first slug and the second slug prior to the step of replacing at least a portion of the first slug with the second slug, such that first electrode is in contact with the inert slug and no longer in contact with at least a portion of the first slug.

5. The method of claim 3 , wherein the electrochemical cell comprises a second electrode compartment separated from the first electrode compartment comprising a second electrode, an inlet, and an outlet.

6. The method of claim 5 , wherein the sequence of slugs is a first sequence of slugs, and the method comprises flowing a second sequence of slugs from the inlet of the second electrode compartment to the outlet of the second electrode compartment, each slug of the second sequence being essentially immiscible with the slug directly preceding the slug and the slug directly following the slug, such that each slug of the second sequence contacts the second electrode.

7. The method of claim 5 , wherein the first electrode compartment and the second electrode compartment are separated by a membrane.

8. The method of claim 7 , wherein the membrane is a bipolar membrane.

9. The method of claim 3 , wherein the electrical potential is only applied when the first electrode is in contact with the first slug.

10. The method of claim 3 , wherein the redox mediator comprises a redox-active polymer.

11. The method of claim 10 , wherein the redox-active polymer comprises a quinone.

12. The method of claim 3 , wherein the redox mediator comprises poly(1,4-anthraquinone).

13. The method of claim 3 , wherein the first inlet and/or the first outlet of the first electrode compartment are fluidically connected to at least one valve and/or pump.

14. The method of claim 13 , comprising automatically actuating the at least one valve and/or pump in order to start or stop motion of the first slug and/or the second slug.

15. The method of claim 3 , wherein the second solution comprises less than 5 mM of ionic species.

16. The method of claim 3 , wherein the reactant is oxygen gas and the chemical product is hydrogen peroxide.

17. A method for producing a chemical product, comprising:
(a) providing an electrochemical cell comprising a first electrode;
(b) contacting the first electrode with a first slug comprising a first solution while applying an electrical potential to the first electrode, such that an active form of a redox mediator immobilized on the first electrode is generated;
(c) replacing at least a portion of the first slug with an inert slug, such that the first electrode is in contact with the inert slug and no longer in contact with at least a portion of the first slug; and
(d) replacing at least a portion of the inert slug with a second slug after the step of replacing at least a portion of the first slug with the inert slug, wherein the second slug comprises a second solution comprising a reactant, such that the first electrode is in contact with the second slug and no longer in contact with at least a portion of the first slug, and such that the active form of the redox mediator reacts with the reactant in the second solution to produce the chemical product, wherein the inert slug is essentially immiscible with both the first slug and the second slug; and
(e) repeating steps (b), (c), and (d).

18. The method of claim 17 , wherein the electrochemical cell comprises a first electrode compartment comprising the first electrode, an inlet, and an outlet, and a second electrode compartment separated from the first electrode compartment comprising a second electrode, an inlet, and an outlet.

19. The method of claim 18 , comprising flowing a first sequence of slugs comprising the first slug and the second slug from the inlet of the first electrode compartment to the outlet of the first electrode compartment.

20. The method of claim 17 , wherein the reactant is oxygen gas and the chemical product is hydrogen peroxide.

Assignees

• Massachusetts Inst Technology

Inventors

• Voskian Sahag
• Murray Alexander
• Hatton Trevor Alan
• Surendranath Yogesh

Classifications

• C25B11/075

  consisting of a single catalytic element or catalytic compound · CPC title

• C25B15/08 Primary

  Supplying or removing reactants or electrolytes; Regeneration of electrolytes · CPC title

• C25B9/19

  with diaphragms · CPC title

• C25B1/30

  Peroxides · CPC title

• C25B1/13 Primary

  Ozone · CPC title