Electrolyzers and use of the same for carbon dioxide capture and mining

Patent metadata

Field	Value
Publication number	US-2025161880-A1
Application number	US-202519032902-A
Country	US
Kind code	A1
Filing date	Jan 21, 2025
Priority date	Jul 28, 2022
Publication date	May 22, 2025
Grant date	—

Abstract

Disclosed herein is an electro-synthesizer unit comprising a first compartment comprising a cathode and a first electrolyte, a second compartment comprising an anode and a second electrolyte and a third compartment comprising a third electrolyte. The unit is configured to produce acid and base solution at desired concentrations. Also disclosed are methods of using the electro-synthesizer unit and producing the acid and base solution at desired concentrations. Also disclosed are systems for direct capturing of carbon dioxide. Also disclosed are mining systems utilizing the disclosed herein electro-synthesizer units.

First claim

1 .- 50 . (canceled)

51 . A system comprising:
one or more flow electro-synthesizer units configured to produce an acid solution and a base solution; one or more carbon dioxide capturing apparatuses that is in fluid communication with the one or more flow electro-synthesizer units and that are configured to capture a carbon dioxide from a gas source by converting the carbon dioxide to a bicarbonate solution, carbonate solution, or a combination thereof; one or more acid leachers that are in fluid communication with the one or more flow electro-synthesizer units and that are configured to receive a mineral ore comprising one or more metal minerals and to form one or more solubilized minerals; and one or more precipitators that are in fluid communication with the one or more acid leachers and with the one or more carbon dioxide capturing apparatuses and that are configured to precipitate at least a portion of the one or more solubilized minerals.

52 . The system of claim 51 , wherein the one or more flow electro-synthesizer units comprise:
a first compartment comprising:
a cathode;
a first electrolyte solution that is in electrical and fluid communication with the cathode; wherein a pH of the first electrolyte solution is 6≤pH≤15.5;
wherein the cathode is configured to generate a hydrogen gas and a base solution;
a second compartment comprising:
an anode; and
a second electrolyte solution that is in electrical and fluid communication with the anode; wherein a pH of the second electrolyte solution is −1.5≤pH≤8;
wherein the anode is configured to generate an acid solution; and
a third compartment positioned between and in fluid communication with the first compartment and the second compartment and comprising:
a third electrolyte solution, wherein a pH of the third electrolyte solution is 4≤pH≤10.

53 . The system of claim 52 , wherein the first electrolyte solution comprises a base and optionally one or more inorganic salts, and the second electrolyte solution comprises an acid and optionally one or more inorganic salts, and the third electrolyte solution comprises one or more inorganic salts, wherein each of the electrolyte solutions are independently provided at a predetermined flow rate.

54 .- 55 . (canceled)

56 . The system of claim 53 , wherein the base comprises one or more of sodium hydroxide, lithium hydroxide, potassium hydroxide, magnesium hydroxide, calcium hydroxide, ammonium hydroxide, amine-based bases, sodium acetate, or any combination thereof.

57 . The system of claim 53 , wherein the acid comprises one or more of hydrochloric acid, hydrobromic acid, hydroiodic acid, sulfurous acid, sulfuric acid, nitric acid, phosphorous acid, phosphoric acid, hypochlorous acid, chlorous acid, chloric acid, perchloric acid, formic acid, acetic acid, carbonic acid, or any combination thereof.

58 .- 59 . (canceled)

60 . The system of claim 53 , wherein the generated in the first compartment base solution is the same or different as the first electrolyte solution, and/or the generated in the second compartment acid solution is the same or different as the second electrolyte solution.

61 . (canceled)

62 . The system of claim 53 , wherein the one or more inorganic salts in the first electrolyte solution are the same or different as the one or more inorganic salts in the second electrolyte solution and are the same or different as one or more inorganic salts in the third electrolyte solution.

63 .- 64 . (canceled)

65 . The system of claim 52 , wherein the second compartment is configured to receive a hydrogen stream to be oxidized on the anode to produce the acid solution, wherein the hydrogen stream comprises the hydrogen gas formed in the first compartment, a hydrogen provided from an external source, or a combination thereof.

66 . The system of claim 52 , wherein the third compartment is separated from the first compartment with one or more cation exchange membranes and is separated from the second compartment with one or more anion exchange membranes.

67 . The system of claim 55 , wherein the predetermined flow of the first electrolyte solution, the second electrolyte solution, and/or the third electrolyte solution is the same as or different from one another.

68 . (canceled)

69 . The system of claim 52 , wherein the one or more flow electro-synthesizer units operate at a voltage of about 1.0 V to about 10.0 V.

70 .- 71 . (canceled)

72 . The system of claim 52 , wherein at least a portion of the base solution formed in the first compartment is fed to the one or more carbon dioxide capturing apparatuses configured to capture the carbon dioxide such that the carbon dioxide is converted to the bicarbonate solution, carbonate solution, or a combination thereof by reacting the carbon dioxide from the source with the at least a portion of the base solution.

73 . The system of claim 51 , wherein one or more carbon dioxide capturing apparatuses comprise at least one air contactor.

74 .- 75 . (canceled)

76 . The system of claim 51 , wherein the gas source is an ambient air, industrial gas source, or any combination thereof.

77 . (canceled)

78 . The system of claim 52 , wherein at least a portion of the acid solution formed in the second compartment is fed to one or more acid leachers.

79 . The system of claim 51 , wherein at least a portion of the bicarbonate solution, carbonate solution, or a combination thereof collected from the one or more carbon dioxide capturing apparatuses and at least a portion of the one or more solubilized minerals formed in the one or more acid leachers are fed into the one or more precipitators to generate a precipitate comprising one or more mineral oxides, hydroxides, bicarbonates, carbonates, or any combination thereof.

80 . The system of claim 79 , wherein the one or more mineral oxides, hydroxides, bicarbonates, carbonates, or any combination thereof, comprise alkaline-earth metals, Group III metals, transition metals, rare-earth minerals, or any combination thereof.

81 . (canceled)

82 . The system of claim 79 , wherein the one or more mineral oxides, hydroxides, bicarbonates, carbonates, or any combination thereof, are precipitated together or separately.

83 .- 84 . (canceled)

85 . The system of claim 79 , wherein the one or more precipitators further comprise one or more inorganic salts, where the one or more inorganic salts are fed to the third compartment of the one or more of flow electro-synthesizer units.

86 . (canceled)

87 . A method comprising
providing one or more of the systems of claim 51 ; electrochemically generating a hydrogen gas and hydroxide ions on the cathode in the first compartment; and flowing a stream comprising a generated hydrogen gas, a hydrogen gas provided by an external source, or a combination thereof, such that electrochemically generated hydrogen ions are formed on the anode; directing a portion of the cathode electrolyte solution comprising the hydroxide ions to one or more carbon dioxide capturing apparatuses configured to capture a carbon dioxide from a gas source by converting the carbon dioxide to a bicarbonate solution, carbonate solution, or a combination thereof; directing a portion of the anode electrolyte solution comprising hydrogen ions to one or more acid

Assignees

• Univ Johns Hopkins

Inventors

• Wang Chao
• Shen Hao
• Zong Han
• Liu Yulin

Classifications

• C25B13/04

  characterised by the material · CPC title

• C25B1/22

  Inorganic acids · CPC title

• C22B3/06

  in inorganic acid solutions {, e.g. with acids generated in situ; in inorganic salt solutions other than ammonium salt solutions} · CPC title

• B01D2257/504

  Carbon dioxide · CPC title

• B01D2251/604

  Hydroxides · CPC title