# US 2014/0194539 A1 · Carbon dioxide conversion to hydrocarbon fuel via syngas production cell harnessed from solar radiation

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- Number: US 2014/0194539 A1
- Document ID: US20140194539A1
- Status: Published application
- Kind: A1
- Application number: 14/147,067
- Filed: 2014-01-03
- Published: 2014-07-10
- Earliest claimed: 2013-01-04
- Assignees: Saudi Arabian Oil Company
- Applicants: Saudi Arabian Oil Company
- Inventors: Ahmad D. Hammad; Zaki Yusuf; Stamatios Souentie; Nayif A. Al-Rasheedi; Bandar A. Fadhel; Atef Saeed Al-Zahrani
- Web page: https://patentgrep.com/patent/US20140194539A1

## CPC

- C25B 13/04: characterised by the material
- C01B 3/38: using catalysts
- C07C 1/0455: {Reaction conditions}
- C10G 2/32: {with the use of catalysts}
- C10G 2/34: {Apparatus, reactors}
- C10L 1/04: essentially based on blends of hydrocarbons
- C25B 1/00: Electrolytic production of inorganic compounds or non-metals
- C25B 1/04: by electrolysis of water
- C25B 1/23: Carbon monoxide or syngas
- C25B 9/19: with diaphragms
- C25B 11/031: Porous electrodes
- C25B 11/061: Metal or alloy
- C25B 13/07: based on ceramics
- F03G 6/063: {Tower concentrators}
- F03G 6/067: {Binary cycle plants where the fluid from the solar collector heats the working fluid via a heat exchanger}
- F03G 6/071: {with energy storage devices}
- F03G 6/114: {Molten salts}
- C01B 2203/0233: the reforming step being a steam reforming step
- C01B 2203/0238: the reforming step being a carbon dioxide reforming step
- C01B 2203/06: Integration with other chemical processes
- C01B 2203/061: Methanol production
- C01B 2203/062: Hydrocarbon production, e.g. Fischer-Tropsch process
- C01B 2203/067: the reforming process taking place in the fuel cell
- C01B 2203/1241: Natural gas or methane
- C10L 2290/38: Applying an electric field or inclusion of electrodes in the apparatus
- C10L 2290/42: Fischer-Tropsch steps
- Y02B 10/20: Solar thermal
- Y02E 10/46: Conversion of thermal power into mechanical power, e.g. Rankine, Stirling or solar thermal engines
- Y02E 60/36: Hydrogen production from non-carbon containing sources, e.g. by water electrolysis
- Y02E 60/50: Fuel cells
- Y02P 20/129: Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
- Y02P 20/133: Renewable energy sources, e.g. sunlight
- Y02P 30/00: Technologies relating to oil refining and petrochemical industry
- C25B: ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR (anodic or cathodic protection C23F13/00; single-crystal growth C30B)
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10L: FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G OR C10K; LIQUIFIED PETROLEUM GAS; USE OF ADDITIVES TO FUELS OR FIRES; FIRE-LIGHTERS
- F03G: SPRING, WEIGHT, INERTIA OR LIKE MOTORS; MECHANICAL-POWER PRODUCING DEVICES OR MECHANISMS, NOT OTHERWISE PROVIDED FOR OR USING ENERGY SOURCES NOT OTHERWISE PROVIDED FOR (arrangements in connection with power supply in vehicles from force of nature B60K16/00; electric propulsion with power supply in vehicles from force of nature B60L8/00)
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A process for converting carbon dioxide to hydrocarbon fuels using solar energy harnessed with a solar thermal power system to create thermal energy and electricity, using the thermal energy to heat a fuel feed stream, the heated fuel feed stream comprising carbon dioxide and water, the carbon dioxide captured from a flue gas stream, converting the carbon dioxide and water in a syngas production cell, the syngas production cell comprising a solid oxide electrolyte, to create carbon monoxide and hydrogen, and converting the carbon monoxide and hydrogen to hydrocarbon fuels in a catalytic reactor. In at least one embodiment, the syngas production cell is a solid oxide fuel cell. In at least one embodiment, the syngas production cell is a solid oxide electrolyzer cell.

## Claims

### Claim 1

A process for converting carbon dioxide to hydrocarbon fuels using solar energy, the process comprising the steps of:
receiving direct sunlight with a plurality of heliostats and reflecting the direct sunlight from the heliostats as reflected sunlight onto a tower receiver, wherein the reflected sunlight heats a heat transfer fluid in the tower receiver;
converting a water stream to a generated steam stream in a steam generator, wherein the heat transfer fluid provides heat to the steam generator;
feeding the generated steam stream to a steam turbine, wherein the steam turbine converts thermal energy in the generated steam stream to mechanical energy to drive an electric generator to generate electricity;
heating a fuel feed stream by transferring thermal energy from the heat transfer fluid to create a heated fuel feed stream, such that the heated fuel feed stream reaches a temperature of between 650° C. and 800° C.;
feeding the heated fuel feed stream to a syngas production cell, wherein the heated fuel feed stream comprises carbon dioxide and water, wherein the carbon dioxide is captured from a flue gas stream;
converting the carbon dioxide and water in the heated fuel feed stream to carbon monoxide and hydrogen in the syngas production cell to produce a syngas stream, wherein the syngas production cell comprises a solid oxide electrolyte;
feeding the syngas stream to a catalytic reactor, wherein the catalytic reactor operates in the presence of a catalyst; and
converting the syngas stream to a hydrocarbon fuel stream in the catalytic reactor.

### Claim 2 (depends on 1)

The process as claimed in claim 1, wherein the syngas production cell comprises a solid oxide electrolyzer cell, wherein the solid oxide electrolyzer cell comprises a porous cathode, the solid oxide electrolyte, and a porous anode.

### Claim 3 (depends on 2)

The process as claimed in claim 2, wherein the step of converting the carbon dioxide and water in the heated fuel feed stream to carbon monoxide and hydrogen in the syngas production cell further comprises the steps of:
supplying the electricity to the porous cathode of the solid oxide electrolyzer cell;
contacting the porous cathode with the heated fuel feed stream;
reducing the carbon dioxide to create carbon monoxide and oxygen ions, wherein the oxygen ions pass through the porous cathode to the solid oxide electrolyte;
reducing the water to create hydrogen and oxygen ions, wherein the oxygen ions pass through the porous cathode to the solid oxide electrolyte;
diffusing the oxygen ions through the solid oxide electrolyte to the porous anode; and
releasing electrons from the oxygen ions at the porous anode, such that oxygen molecules are formed to create an oxygen stream.

### Claim 4 (depends on 1)

The process as claimed in claim 1, wherein the syngas production cell comprises a solid oxide fuel cell, wherein the solid oxide fuel cell comprises a porous anode, the solid oxide electrolyte, and a porous cathode.

### Claim 5 (depends on 4)

The process as claimed in claim 4, wherein the step of converting the carbon dioxide and water in the heated fuel feed stream to carbon monoxide and hydrogen in the syngas production cell further comprises the steps of:
adding a gaseous hydrocarbon to the heated fuel feed stream, wherein the gaseous hydrocarbon;
feeding the heated fuel feed stream to the porous anode of the solid oxide fuel cell;
reforming the water and the gaseous hydrocarbon in the heated fuel feed stream to create carbon monoxide and hydrogen;
reforming the carbon dioxide and the gaseous hydrocarbon in the heated fuel feed stream to create carbon monoxide and hydrogen;
reducing oxygen from an oxygen supply on the porous cathode of the solid oxide fuel cell to generate oxygen ions;
diffusing the oxygen ions through the solid oxide electrolyte to the porous anode;
oxidizing the hydrogen at the porous anode with the oxygen ions to create water and electrons;
oxidizing the methane at the porous anode with the oxygen ions to create carbon monoxide, hydrogen, and electrons; and
supplying the electrons to an electrical substation, wherein the electrical substation is configured to combine the electrons from the syngas production cell with the electricity generated by the electric generator.

### Claim 6 (depends on 5)

The process as claimed in claim 5, wherein the gaseous hydrocarbon comprises methane.

### Claim 7 (depends on 1)

The process as claimed in claim 1, further comprising the step of:
feeding the hydrocarbon fuel to a power plant for consumption.

### Claim 8

A system to convert carbon dioxide to hydrocarbon fuels using solar energy, the system comprising:
a solar thermal power system configured to convert solar energy to thermal energy and electricity, the solar thermal power system being in thermal communication with a syngas production cell, wherein the syngas production cell is configured to receive thermal energy from the solar thermal power system;
the syngas production cell comprises a fuel side comprising a fuel inlet configured to receive a fuel feed stream and a fuel outlet configured to receive a syngas stream, and an oxygen side comprising an oxygen outlet configured to receive an oxygen stream,
wherein the fuel feed stream comprises carbon dioxide and water,
wherein the syngas production cell is configured to convert the carbon dioxide and water into carbon monoxide and hydrogen, the carbon monoxide and hydrogen operable to form the syngas stream; and
a catalytic reactor fluidly connected to the fuel side of the syngas production cell, the catalytic reactor being configured to convert the syngas stream from the fuel side of the syngas production cell to a hydrocarbon fuel stream, the catalytic reactor comprising a reactor bed, the reactor bed comprising a catalyst and a distributor, wherein the catalytic reactor is configured to operate from 250° C. to 650° C.

### Claim 9 (depends on 8)

The system as claimed in claim 8, wherein the syngas production cell comprises a solid oxide electrolyzer cell.

### Claim 10 (depends on 9)

The system as claimed in claim 9, wherein the solid oxide electrolyzer cell comprises:
a porous cathode in fluid communication with the fuel side of the syngas production cell, the porous cathode having a fuel side of the porous cathode configured to transfer electrons to the fuel feed stream, such that carbon monoxide, hydrogen, and oxygen ions are produced, and an electrolyte side configured to release the oxygen ions into a solid oxide electrolyte,
wherein the porous cathode is configured to allow passage of oxygen ions;
a porous anode in fluid communication with the oxygen side of the syngas production cell, the porous anode comprising an electrolyte side configured to receive oxygen ions from the solid oxide electrolyte, and an outlet side configured to convert oxygen ions to oxygen molecules to form an oxygen stream,
wherein the porous anode is configured to allow passage of oxygen ions;
the solid oxide electrolyte, the solid oxide electrolyte lies between the porous cathode and the porous anode, wherein the solid oxide electrolyte is configured to allow passage of oxygen ions; and
an electron supply, wherein the electricity from the solar thermal power system provides the electron supply to the porous cathode and accepts electrons from the porous anode.

### Claim 11 (depends on 10)

The system as claimed in claim 10, wherein the porous cathode and the porous anode are selected from the group consisting of nickel/yttria-stabilized zirconia (Ni-YSZ), Lanthanum Strontium Manganese Oxide-YSZ (LSM-YSZ), and a ceramic oxide of perovskite.

### Claim 12 (depends on 10)

The system as claimed in claim 10, wherein the solid oxide electrolyte consists of yttria stabilized zirconia.

### Claim 13 (depends on 8)

The system as claimed in claim 8, wherein the syngas production cell comprises a solid oxide fuel cell, and wherein the fuel feed stream further comprises a gaseous hydrocarbon.

### Claim 14 (depends on 13)

The system as claimed in claim 13, wherein the gaseous hydrocarbon comprises methane.

### Claim 15 (depends on 14)

The system as claimed in claim 14, wherein the solid oxide fuel cell comprises:
a porous anode in fluid communication with the fuel side of the syngas production cell, the porous anode comprising a fuel side of the porous anode configured to accept electrons, such that the methane undergoes an oxidation reaction to form carbon monoxide, hydrogen, and electrons, and an electrolyte side configured to accept oxygen ions from a solid oxide electrolyte,
wherein the porous anode is configured to allow passage of oxygen ions,
wherein the methane and water react in the presence of the fuel side of the porous anode to generate carbon monoxide and hydrogen, and
wherein the methane and carbon dioxide react in the presence of the fuel side of the porous anode to generate carbon monoxide and hydrogen;
a porous cathode in fluid communication with the oxygen side of the syngas production cell, the porous cathode comprising an outlet side configured to convert oxygen into oxygen ions and an electrolyte side configured to release oxygen ions into the solid oxide electrolyte,
wherein the porous cathode is configured to allow passage of oxygen ions; and
the solid oxide electrolyte, the solid oxide electrolyte lies between the porous cathode and the porous anode, wherein the solid oxide electrolyte is configured to allow passage of oxygen ions.

### Claim 16 (depends on 15)

The system as claimed in claim 15, wherein the hydrogen in the fuel side of the syngas production cell undergoes an oxidation reaction to form water and electrons.

### Claim 17 (depends on 15)

The system as claimed in claim 15, wherein the porous cathode and the porous anode are selected from the group consisting of nickel/yttria-stabilized zirconia (Ni-YSZ), Lanthanum Strontium Manganese Oxide-YSZ (LSM-YSZ), and a ceramic oxide of perovskite.

### Claim 18 (depends on 15)

The system as claimed in claim 15, wherein the solid oxide electrolyte consists of yttria stabilized zirconia.

### Claim 19 (depends on 8)

The system as claimed in claim 8, wherein the solar thermal power system comprises a tower concentrating solar power system, the tower concentrating solar power system comprising:
a tower receiver configured to heat a heat transfer fluid;
a plurality of heliostats in proximity to the tower receiver, wherein the heliostats are configured to receive direct sunlight and reflect the direct sunlight from the heliostats as reflected sunlight onto the tower receiver;
a hot storage tank fluidly connected to the tower receiver, the hot storage tank configured to store the heat transfer fluid;
a steam generator fluidly connected to the hot storage tank, the steam generator configured to transfer heat from the heat transfer fluid to a water stream to create a generated steam stream;
a steam turbine fluidly connected to the steam generator, wherein the generated steam stream is configured to drive the steam turbine; and
an electric generator mechanically connected to the steam turbine, wherein the steam generator is configured to drive the electric generator to create electricity.

### Claim 20 (depends on 8)

The system as claimed in claim 8, wherein the syngas production cell is configured to operate from 650° C. to 800° C.

### Claim 21 (depends on 8)

The system as claimed in claim 8, further comprising a carbon capture system configured to capture carbon dioxide from a flue gas stream to create a carbon dioxide stream, the carbon capture system in fluid communication with a power plant, wherein the power plant is configured to produce the flue gas stream.