co2 reduction to hydrocarbons via copper gas-diffusion ......may 12, 2017 · • mit (fikile...
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CO2 Reduction to Hydrocarbonsvia Copper Gas-Diffusion Electrocatalysts
DOE SBIR-STTR 2017 Phase I Release 1 Webinar
Carbon Capture & Carbon Utilization
Brian SkinnFaraday Technology, Inc.
Sponsored by:
US DOE
Contract No. DE-SC0017199
12 May 2017
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Introduction to Faraday Technology, Inc.
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FARADAY TECHNOLOGY, INC.
o Electrochemical engineering
• ~29 Issued Patents and ~15
Pending Patents in this area
• www.FaradayTechnology.com
o Subsidiary of Physical Sciences,
Inc. (Boston, MA)
• www.psicorp.com
o Collective employment ~160;
~90 MS/PhDs
o Annual revenue of ~ $60 million
o ~ 100 patents company-wide in
numerous fields
PSI Locations
PSI
Employees by
Education
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VISION - TECHNOLOGY PLATFORM
Electrochemical Machining, Polishing, Deburring, Through-Mask Etching
Electrodeposition/Plating
“…to be known as the company that changed the focus of electrochemical engineering from
the art of complex chemistries to the science of pulse/pulse reverse electric fields...”
o 2011 R&D 100 for Co-Mn Alloy Plating
o 2013 Presidential Green Chemistry Challenge
Award for Cr+3 Plating
o 2008 Blum Scientific Achievement Award for
Pulse Reverse Surface Finishing
o 2016 R&D 100 Finalist for HF-Free Nb SRF
Cavity Polishing
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FARADAY’S BUSINESS MODEL: OPEN INNOVATION
o Establish IP (29 issued U.S. patents +
know-how)
o Leverage Federal SBIR opportunities
as non-equity technology funding
• Retain IP rights
o Collaborate with universities and
government laboratories
o Develop electrochemical engineering
solutions based on PC/PRC processes
o Transition technology & competitive
advantage to large companies via
• Field-of-use licenses
• Patent sale (8)
o Direct transition to interested
government entities
Detailed mechanistic understanding is not required;
Development of robust process is critical!
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FARADAY’S TECHNOLOGY DEVELOPMENT
Technology development begins conceptually and is demonstrated at the
bench-scale and developed through /-scale validation.
Technology/IP Alignment
Bench-Top Feasibility
Pilot-Scale Validation
Cell
Design IP: Issued
7,553,401
(6-30-09)
Novel
Flow
Production-Scale Validation
IP: CIP
Pending
11/836,903
(8-10-07)IP: Pending
12/431,030
(4-28-09)
Further IP
Enhancement
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APPARATUS – PROCESS
Primary Current Distribution:
Agitation, Anode-Cathode Design and Spacing
Panel Uniformity
Must be Optimized Before Implementing
Process
Secondary
and Tertiary Current
Distribution:
Chemistry/Waveform
Parameters, Temperature
Throwing Power, Feature
Size/Shape
Primary Current Distribution:
Agitation, Anode-Cathode Design and Spacing
Panel Uniformity
Must be Optimized Before Implementing
Process
Secondary
and Tertiary Current
Distribution:
Chemistry/Waveform
Parameters, Temperature
Throwing Power, Feature
Size/Shape
Cell
Geometry
Process
Parameters
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3
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55 1
2
3
44
55
Figure 1: Diagram of pilot-scale cell for 200
mm wafer metallization/planarization.
1
2
3
44
55 1
2
3
44
55
Figure 1: Diagram of pilot-scale cell for 200
mm wafer metallization/planarization.
(-)
(+)
(-)
(+)
(-)
(+)
(-)
(+)
(-)
(+)
(-)
(+)
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Program Overview
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▪ Timeline• Start date: 21 Feb 2017
• End date: 20 Nov 2017
▪ Challenges• Copper deposition optimization
• Catalyst performance evaluation
▪ Partners• MIT (Fikile Brushett)
Program Overview
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Project Team Members
• Faraday– Brian Skinn (PI)
Phone: 937.836.7749
Email: [email protected]
• DOE– TPOC: I. A. Aurelio
• Massachusetts Institute of Technology– Fikile Brushett
• Ph: 617.324.7400
• Email: [email protected]
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Problem or Opportunity
• Problem
– Development of conversion/utilization technologies for
transforming captured CO2 to value-added products are needed
to enhance the cost proposition of carbon capture technologies.
• Opportunity
– Demonstrate potential for tailored micro-/nanoparticulate Cu
GDE electrocatalysts fabricated by FARADAYIC®
ElectroDeposition in combination with state-of-the-art MIT
GDE electroreactor system to enable cost-effective CO2
conversion to hydrocarbons such as ethylene.
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Problem or Opportunity
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Objective of Program
• The objective of the program is to develop an
electrocatalytic system for economical conversion of CO2
to ethylene, encompassing:
– FARADAYIC® ElectroDeposition of Cu electrocatalyst with
tuned microstructure and other properties onto GDL substrates
– State-of-the-art electroreactor technology incorporating modern
gas-diffusion electrode (GDE) materials
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Technical Approach
• For the Phase I program Faraday will:
– Construct a benchtop FARADAYIC® ElectroDeposition Cell
– Develop candidate FARADAYIC® ElectroDeposition protocols
– Perform a preliminary techno-economic analysis of the
electrocatalytic system
• For the Phase I program MIT will:
– Evaluate/analyze Cu electrocatalysts
– Build/Retrofit demonstration-scale electroreactor
– Perform electrocatalysis tests & products analysis
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Prior Work
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Prior Work: FARADAYIC® Tin Electrocatalysis
• FARADAYIC® Sn Deposition
• CO2 Conversion to Formate
• GDE-Based Electroreactor
Bipolar Plate
“Conventional”
“High Utilization”
GDL
(Paper/Cloth)
Catalyst -
Ionomer
MPL
DOE STTR Contract #DE-SC0015173
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Preliminary Results
• Preliminary FARADAYIC®
ElectroDeposition (ED) samples show
significantly increased total and
FA-efficient current densities relative to
conventional spray-coating method and
literature data
– jtotal ≥ 275 mA cm–2
– %FA ≥ 70%
• Favorable short-term catalyst durability
• Significant potential for optimization
– Ionomer loading
– Sn electrocatalyst loading
– Sn electrocatalyst ED parameters
– GDE (GDL/MPL) parameters
(Half-cell potentials vs SHE)
Li and Oloman. J Appl Electrochem 35: 955, 2005.
Agarwal et al. ChemSusChem 4: 1301, 2011.
Kopljgar et al. J Appl Electrochem 44: 1107, 2014.
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DOE STTR Contract #DE-SC0015173
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FARADAYIC® Cu Film Electrocatalysts
• Flow channels for electrolytes
• CO2 reduction on Cu catalyst
• O2 evolution on commercial
mixed oxide anode
• Anticipate direct use of CO2-
laden capture media
– Amines, etc.
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NASA SBIR Contract #NNX14CC53P
DOE STTR Contract #DE-SC0015812
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Testing of FARADAYIC® Cu Film Electrocatalysts
Deposit Oxidize Reduce
Chronoamperometry
GC Product Analysis
&
Li & Kanan, J Am Chem Soc 134: 7231 (2012)
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NASA SBIR Contract #NNX14CC53P
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Testing of FARADAYIC® Cu Film Electrocatalysts
Deposit Oxidize Reduce
Cyclic Voltammetry
GC Product Analysis
&
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DOE STTR Contract #DE-SC0015812
1 cm
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Prior Work: FARADAYIC® ElectroCatalyzation
Batch System Continuous Reel-to-Reel
TEM of Pt on Carbon
2D Graph 2
Current density (A/cm2)
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Po
ten
tia
l (V
)
0.65
0.70
0.75
0.80
0.85
0.90
0.95
1.00
ETEK electrode
Pulse electrodeposited electrode
Performance Comparison
H2/O2
75 °C
1 atm
Superior Performance
w/38% Lower Pt Loading
• Low-loading deposition of Pt fuel cell catalyst
• Beta-scale batch system (NSF)
• Pilot-scale reel-to-reel system (OH)
U.S. Patent 6,080,504 Granted
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Prior Work: MIT Electroreactor Design
• Brushett Group – Electroreactor fabrication expertise
• Available tools include: CNC mill, laser cutter, 3-D printer
• Direct fabrication of SolidEdge/SolidWorks 3-D models
• COMSOL Multiphysics simulation of 3-D models
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Program Description
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Objective of Phase I Base
The questions to be answered in the Phase I program are:
1. Can the potential be shown to fabricate by FARADAYIC® Electrodeposition
techniques micro-structured copper electrocatalysts suitable for use in GDE
electrocatalytic systems?
2. Can the potential be shown for the catalysts of Objective 1 to afford high activity
and selectivity for the reductive conversion of CO2 to hydrocarbons?
3. Can the potential be demonstrated for these electrocatalysts and reactors to afford
competitive process economics as compared to currently available carbon
sequestration/conversion technologies?
The Phase I objective is to demonstrate the potential for economical, scalable
pulsed FARADAYIC® ElectroDeposition of Cu GDE electrocatalysts for
carbon dioxide reduction to ethylene.
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Program Tasks
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Task “0”: Kickoff Meetings (Faraday)
Task 1: Benchtop ElectroDeposition Cell (Faraday)
Task 2: FARADAYIC® Copper ElectroDeposition Tests (Faraday)
Task 3: Cu GDE Catalyst Characterization / Evaluation (MIT)
Task 4: Laboratory-Scale Electroreactor (MIT)
Task 5: Economic / Scale-Up Analysis (Faraday)
Task 6: Reporting and Program Management (Faraday)
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Task: Kickoff Meeting(s)
• Faraday & DOE TPOC
– Engage TPOC
– Identify DOE priorities
• Faraday & MIT
– Review program goals
– Identify / discuss milestones and
completion targets
– Synchronize work plans
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Task 1: Construction of Cu Deposition Apparatus
• Patented FARADAYIC® ElectroCell
– U.S. 8,329,006 – 8,226,804
7,947,161 – 7,553,401
Anode holderCathode holder
Anode
position
Cathode
position
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Task 1: Construction of Cu Deposition Apparatus
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Task 2: FARADAYIC® Copper ElectroDeposition
• Modified FARADAYIC® Copper
ElectroDeposition Bath
– CuSO4
– H2SO4
– HCl
– PEG
• Exploration of deposition parameter space
– DC vs PC vs PRC
– Peak currents
– Frequency & duty cycle
– CuSO4, PEG concentrations
• Deposits analyzed for, e.g.:
– Microstructure (SEM)
– Electrocatalytic properties (CV, CA)
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Task 3: Catalyst Characterization / Evaluation
• Instrumental Analysis
– SEM
– XRD
• Products Analysis
– GC
• Electrocatalytic Performance
– Polarization curves
– Chronoamperometry
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Task 3: Catalyst Characterization / Evaluation
• Baseline GDE Catalyst– Disperse 70 nm Cu in
ionomer/alcohol
– Spray paint onto GDL
• Preliminary Results– Polarization curves
– Electrocatalytic activity
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Task 4: Laboratory-Scale Reactor
• SolidWorks 3-D CAD
• COMSOL Multiphysics
Modeling
• Benchtop CNC
• Electroreactor Prototype
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Task 4: Laboratory-Scale Reactor
• SolidWorks 3-D CAD
• COMSOL Multiphysics
Modeling
• Benchtop CNC
• Electroreactor Prototype
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Task 5: Economic / Scale-Up Analysis
5.1. Techno-Economic Analysis
• Standard methodologies
– EPA, DOE/NETL, etc.
• Evaluate cost/benefit of novel
technology relative to existing
processes
5.2. Scale-Up Analysis
• Technology evaluation
• Market-entry / pre-
commercial analysis
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Task 6: Reporting and Program Management
• Centered on the management of the project to ensure milestones
and reporting requirements are met
• Contractual reporting requirements
– Final report due 4 Dec 2017
• Faraday will convene periodic internal review meetings to assess
program progress toward milestones/objectives
• Faraday will continue telephone/WebEx briefings with MIT
partners and/or DOE program/technical staff.
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Program Tasks Status
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Task “0”: Kickoff Meetings (Faraday)Completed by this webinar
Task 1: Benchtop ElectroDeposition Cell (Faraday)Cell in final stage of build
Task 2: FARADAYIC® Copper ElectroDeposition Tests (Faraday)Pending ElectroDeposition Cell
Task 3: Cu GDE Catalyst Characterization / Evaluation (MIT)Apparatus & assay methods ready
First baseline GDE catalysts prepared; testing initiated
Task 4: Laboratory-Scale Electroreactor (MIT)First-model reactor fabricated; future enhancements pending
Task 5: Economic / Scale-Up Analysis (Faraday)Pending GDE performance results
Task 6: Reporting and Program Management (Faraday)Ongoing
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Action Items
1. Commission plating cell
2. Procure Cu plating bath components
3. Develop initial experimental matrix
4. Initiate copper plating tests
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