ADVANCEMENT OF HIGH-PERFORMANCE CATALYSTS FOR CARBON CAPTURE AND CONVERSION

Abstract

The present invention relates to a high-performance catalytic system for efficient carbon capture and conversion into value-added products such as methanol, synthetic fuels, and hydrocarbons. The catalyst comprises a porous support material combined with transition metal oxides, rare-earth elements, and surface-functionalized ligands to enhance CO₂ adsorption and activation. The system is engineered for high active site density, superior selectivity, and durability under mild operating conditions. The invention also includes optimized process configurations and scalable synthesis methods, enabling sustainable and economically viable carbon management solutions. This technology addresses global environmental challenges by reducing greenhouse gas emissions and promoting a circular carbon economy.

Specification

Description:The embodiments of the present invention generally relates to advancements in catalytic systems for carbon capture and conversion, particularly focusing on the development of high-performance catalysts that enable efficient capture of atmospheric or industrial CO₂ and its subsequent conversion into value-added chemical products. The invention integrates innovative material design, process optimization, and reactor engineering to address the dual challenges of environmental sustainability and economic feasibility in carbon management technologies.
BACKGROUND OF THE INVENTION
The following description of related art is intended to provide background information pertaining to the field of the disclosure. This section may include certain aspects of the art that may be related to various features of the present disclosure. However, it should be appreciated that this section be used only to enhance the understanding of the reader with respect to the present disclosure, and not as admissions of prior art.

The rapid increase in atmospheric CO₂ levels, primarily driven by industrial emissions, is a significant contributor to climate change. Conventional approaches to mitigate these emissions, such as sequestration, face challenges related to scalability, cost, and long-term storage reliability. As a result, there is growing interest in technologies that not only capture CO₂ but also convert it into commercially useful products.

Existing catalytic systems for CO₂ conversion often suffer from limitations, including low conversion efficiencies, poor selectivity for desired products, and rapid deactivation of catalysts under operational conditions. These drawbacks reduce the economic attractiveness of carbon utilization technologies, hindering their large-scale adoption. Efforts to address these limitations have explored various material systems, such as transition metal oxides and porous supports, but their performance has yet to meet industrial requirements.

Another critical issue lies in the energy-intensive nature of current CO₂ capture and conversion processes. High operating temperatures and pressures increase costs and contribute to secondary emissions. Consequently, there is a pressing need for catalyst systems capable of operating under milder conditions while maintaining high activity and selectivity.

Recent advances in nanomaterials, surface functionalization, and catalyst design have opened new possibilities for addressing these challenges. By leveraging these innovations, this invention aims to create a next-generation catalyst system that offers superior performance in carbon capture and conversion applications.

OBJECTIVE OF THE INVENTION

Some of the objects of the present disclosure, which at least one embodiment herein satisfies are listed herein below.

An objective of the present invention is to develop a novel catalytic system that integrates high-performance materials, including transition metal oxides and rare-earth components, to achieve enhanced CO2 adsorption and conversion efficiency.

Another objective of the present invention is to design catalysts with increased active site density and surface area, enabling higher reaction rates and improved selectivity for desired conversion products, such as methanol or synthetic fuels.

Another objective of the present invention is to reduce the energy requirements of CO₂ conversion processes by creating catalysts that operate effectively under milder conditions, such as lower temperatures and pressures.

Another objective of the present invention is to ensure the long-term stability and reusability of the catalyst by addressing issues of deactivation and degradation, enabling consistent performance over extended periods.

Another objective of the present invention is to explore environmentally friendly and scalable methods for synthesizing the catalyst, ensuring compatibility with industrial production standards while minimizing environmental impact.

Another objective of the present invention is to integrate the catalytic system with optimized reactor designs and process configurations, facilitating seamless integration into existing industrial carbon capture and utilization infrastructures.

Another objective of the present invention is to contribute to global efforts in reducing greenhouse gas emissions by providing an economically viable solution for transforming CO2 into value-added products, supporting a circular carbon economy.

SUMMARY OF THE INVENTION
This section is provided to introduce certain objects and aspects of the present disclosure in a simplified form that are further described below in the detailed description. This summary is not intended to identify the key features or the scope of the claimed subject matter.

This invention presents an advanced catalytic system for carbon capture and conversion, featuring a composition that combines transition metal oxides, rare-earth elements, and porous supports engineered at the nanoscale. The catalyst exhibits high surface area and enhanced active site density, facilitating superior CO₂ adsorption and activation. Surface functionalization further optimizes the system for high selectivity in producing value-added products under mild reaction conditions.

The invention encompasses process innovations that enhance the energy efficiency and scalability of CO₂ conversion technologies. By integrating these advanced catalysts into optimized reactor systems, the invention delivers a sustainable and economically viable solution for addressing global carbon management challenges.

BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, which are incorporated herein, and constitute a part of this invention, illustrate exemplary embodiments of the disclosed methods and systems in which like reference numerals refer to the same parts throughout the different drawings. Components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Some drawings may indicate the components using block diagrams and may not represent the internal circuitry of each component. It will be appreciated by those skilled in the art that invention of such drawings includes the invention of electrical components, electronic components or circuitry commonly used to implement such components.

FIG. 1 illustrates an exemplary method for converting carbon dioxide into hydrocarbons, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.

The ensuing description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.

Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits, systems, networks, processes, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail to avoid obscuring the embodiments.

Also, it is noted that individual embodiments may be described as a process that is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed but could have additional steps not included in a figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination can correspond to a return of the function to the calling function or the main function.

The word "exemplary" and/or "demonstrative" is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as "exemplary" and/or "demonstrative" is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms "includes," "has," "contains," and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term "comprising" as an open transition word without precluding any additional or other elements.

Reference throughout this specification to "one embodiment" or "an embodiment" or "an instance" or "one instance" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

This invention focuses on the development of a high-performance catalytic system for carbon capture and conversion, leveraging innovative materials, surface engineering, and reaction optimization techniques. The described catalyst combines a porous support material, such as silica or zeolite, with transition metal oxides and rare-earth elements. These components are strategically engineered to provide an optimal environment for CO₂ adsorption, activation, and subsequent conversion to value-added products.

The catalyst design emphasizes high surface area and active site density, achieved through nanoscale engineering techniques like sol-gel synthesis and thermal calcination. The porous support material enhances the dispersion of active catalytic sites, reducing aggregation and improving efficiency. Transition metal oxides, such as iron, cobalt, or nickel, serve as the primary active components, enabling CO₂ activation through electron transfer processes. Rare-earth elements like cerium or lanthanum are included to enhance catalytic stability and resistance to deactivation.

Surface functionalization is a key aspect of the invention, wherein the catalyst is modified with organic or inorganic ligands. These ligands increase CO₂ affinity and improve the selectivity of the catalyst for specific reactions, such as methanation or electrochemical reduction. Doping the catalyst with alkali or alkaline earth metals enhances its performance by creating a synergistic effect between components.

The process conditions are optimized to achieve high conversion efficiency under mild temperatures (200-600°C) and pressures (10-50 bar). This reduces the overall energy consumption and makes the system economically viable for industrial applications. Furthermore, the catalyst demonstrates excellent durability, retaining its activity and selectivity over prolonged cycles of operation, which is critical for its large-scale adoption.

First embodiment involves a catalyst comprising a silica-based porous support doped with copper and zinc oxides, along with cerium as a rare-earth additive. The catalyst is synthesized using a co-precipitation method, followed by thermal treatment to enhance the active phase distribution.

In this embodiment, CO₂ is reacted with hydrogen in a continuous flow reactor. The process operates at 250°C and 20 bar, yielding methanol with a selectivity exceeding 90%. The rare-earth element stabilizes the catalyst structure, while the copper-zinc combination ensures high activity. This catalyst finds application in industries focusing on renewable fuel production.

Second embodiment describes a catalyst designed for the electrochemical conversion of CO₂ to formic acid or carbon monoxide. The catalyst comprises a graphene-based support decorated with palladium nanoparticles and lanthanum. The synthesis involves a hydrothermal process to integrate the components uniformly.

In an electrochemical cell, the catalyst operates at ambient temperature and pressure, utilizing renewable electricity as the energy source. The system demonstrates high Faradaic efficiency (above 85%) for formic acid production, making it suitable for applications in sustainable chemical manufacturing and energy storage systems.

Third embodiment focuses on a nickel-based catalyst supported on alumina, doped with potassium and enhanced with cerium oxide. The catalyst is prepared using an impregnation technique, ensuring a homogeneous distribution of active components.

The methanation process occurs in a fixed-bed reactor at 300°C and 10 bar, converting CO₂ and hydrogen into methane with a conversion efficiency of 95%. The potassium doping improves CO₂ adsorption, while cerium enhances catalyst durability under high-temperature conditions. This embodiment is particularly relevant for applications in synthetic natural gas (SNG) production and carbon recycling systems.

While considerable emphasis has been placed herein on the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other changes in the preferred embodiments of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter to be implemented merely as illustrative of the invention and not as limitation.
, Claims:1. A catalyst for carbon capture and conversion comprising:
a porous support material selected from silica, alumina, or zeolite;
transition metal oxides selected from iron, cobalt, or nickel;
rare-earth elements such as cerium or lanthanum;
surface functionalization with organic ligands to enhance CO₂ adsorption and activation.

2. A method for converting carbon dioxide into hydrocarbons, comprising:
exposing the carbon dioxide to a catalytic system under elevated temperatures ranging from 200°C to 600°C and pressures between 10 to 50 bars;
using hydrogen or other reducing agents in a controlled stoichiometric ratio;
collecting the resultant hydrocarbon products, wherein the catalyst exhibits at least 90% conversion efficiency.

3. The catalyst of claim 1, wherein the porous support material is modified with mesoporous structures for enhanced active site accessibility.

4. The method of claim 2, wherein the reducing agent is obtained from renewable sources such as electrolytic hydrogen.

5. The catalyst of claim 1, wherein the rare-earth elements are present in a concentration range of 1-5% by weight.

6. The method of claim 2, further comprising the step of regenerating the catalyst through thermal or chemical treatment.

7. The catalyst of claim 1, wherein the transition metal oxides are doped with alkali metals to enhance catalytic performance.

8. The method of claim 2, wherein the hydrocarbons produced include methanol, ethanol, or C3+ synthetic fuels.

9. The method of claim 2, wherein the reaction system is integrated with an in-situ CO₂ capture mechanism using amine-based sorbents, enabling simultaneous CO₂ sequestration and conversion to hydrocarbons, thereby improving overall process efficiency.

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