IP Library › Granted Patent US 12,320,022
Granted Patent B2
US 12,320,022 · App. 17/444,356 · Granted Jun 3, 2025

System and method for carbon dioxide reactor control

Inventors: Nicholas H. Flanders (San Francisco, CA); Kendra P. Kuhl (Oakland, CA); Etosha R. Cave (Berkeley, CA); Sichao Ma (Dublin, CA); Ziyang Huo (Moraga, CA); Carter S. Haines (Berkeley, CA); Timothy A. Bekkedahl (Sunnyvale, CA); Kathryn L. Corp (Berkeley, CA); Ashley D. Mishra (Danville, CA); Edward Izett (Berkeley, CA)
Assignee: Twelve Benefit Corporation
C25B15/081B01D53/1475B01D53/1493B01D53/18B01D53/229B01J20/08B01J20/10B01J20/20B01J20/3483C01B3/34C01B3/503C07C1/0485C07C4/02C12M43/00C12P5/023C12P7/06C12P7/16C12P7/52C12P7/54C25B1/23C25B3/03C25B3/26C25B9/23C25B13/08C25B15/083B01D2252/30B01J2220/42C01B2203/0216C01B2203/0405C01B2203/062
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Quick Facts
Patent No.
US 12,320,022
App. No.
17/444,356
Granted
Jun 3, 2025
Kind
B2
Abstract

A system optionally including a carbon oxide reactor. A method for carbon oxide reactor control, optionally including selecting carbon oxide reactor aspects based on a desired output composition, running a carbon oxide reactor under controlled process conditions to produce a desired output composition, and/or altering the process conditions to alter the output composition.

Claims (46)

1. A system for producing one or more chemical compounds, the system comprising:

(a) a carbon oxide reduction electrolyzer comprising a membrane electrode assembly, which comprises one or more ion conductive polymer layers and a cathode catalyst layer comprising (i) an ion-conducting polymer, and (ii) a cathode catalyst in the ion-conducting polymer, wherein cathode catalyst is configured to facilitate chemical reduction of carbon oxide to a carbon-containing reaction product, wherein the cathode catalyst layer contacts at least one of the one or more ion conductive polymer layers; and

(b) a gas fermentation reactor configured to receive the carbon-containing reaction product produced by the carbon oxide reduction electrolyzer and produce the one or more chemical compounds,

wherein the gas fermentation reactor is configured to perform aerobic fermentation, and the system is configured to provide oxygen from an anode of the carbon oxide reduction electrolyzer to the gas fermentation reactor.

2. The system of claim 1 , wherein the carbon oxide reduction electrolyzer is configured to produce methane, and wherein the system is configured to transport the methane to the gas fermentation reactor.

3. The system of claim 1 , wherein the carbon oxide reduction electrolyzer is configured to produce carbon monoxide and hydrogen, and wherein the system is configured to transport the carbon monoxide and the hydrogen to the gas fermentation reactor.

4. The system of claim 3 , wherein the gas fermentation reactor is configured to produce ethanol, acetic acid, butanol, butyric acid, or methane.

5. The system of claim 3 , wherein the gas fermentation reactor is configured to produce a ketone, a light hydrocarbon, or phenol, and wherein the system further comprises one or more reactors for converting the ketone, the light hydrocarbon, or phenol to a diol.

6. The system of claim 5 , wherein the gas fermentation reactor is configured to produce the ketone and the ketone is acetone and wherein the diol is bisphenol A.

7. The system of claim 3 , wherein the gas fermentation reactor is configured to produce naphtha.

8. The system of claim 7 , wherein the system further comprises one or more reactors for converting the naphtha to terephthalic acid.

9. The system of claim 1 , wherein the carbon-containing reaction product comprises a ketone, an alkane, and/or an aromatic compound.

10. The system of claim 1 , wherein the gas fermentation reactor is configured to produce protein, a polyhydroxyalkanoate, acetone, isopropanol, or ethanol.

11. The system of claim 1 , wherein the gas fermentation reactor is configured to produce carbon dioxide and wherein the system is configured to transport carbon dioxide from the gas fermentation reactor to the carbon oxide reduction electrolyzer.

12. The system of claim 1 , wherein the carbon oxide reduction electrolyzer and the gas fermentation reactor are located in a single plant.

13. The system of claim 1 , wherein the system is configured to recycle carbon dioxide from the gas fermentation reactor to the membrane electrode assembly.

14. The system of claim 13 , further comprising one or more carbon dioxide capture units comprising a sorbent for capturing carbon dioxide during a first phase of recycling and releasing carbon dioxide during a second phase of recycling.

15. The system of claim 13 , wherein the system is configured to remove oxygen from carbon dioxide recycled from the gas fermentation reactor to the membrane electrode assembly.

16. The system of claim 1 , wherein the gas fermentation reactor is configured to perform biochemical reactions in the Wood-Ljungdahl Pathway (WLP).

17. The system of claim 1 , wherein the membrane electrode assembly is configured to receive a carbon oxide input at a pressure above atmospheric pressure.

18. The system of claim 1 , wherein the gas fermentation reactor is configured to produce an amine, and wherein the system further comprises one or more reactors for converting the amine to a polyisocyanate.

19. A method for producing one or more chemical compounds, the method comprising:

chemically reducing a carbon oxide to a carbon-containing reaction product via the carbon oxide reduction electrolyzer comprising a membrane electrode assembly of the system of claim 1 ; and

in the gas fermentation reactor of the system of claim 1 , receiving oxygen from the carbon oxide reduction electrolyzer and performing aerobic fermentation to produce the one or more chemical compounds from the carbon-containing reaction product.

20. The method of claim 19 , wherein the carbon-containing reaction product comprises methane, and further comprising transporting the methane to the gas fermentation reactor.

21. The method of claim 19 , wherein the carbon-containing reaction product comprises carbon monoxide and hydrogen, and further comprising transporting the carbon monoxide and the hydrogen to the gas fermentation reactor.

22. The method of claim 19 , wherein the one or more chemical compounds comprise ethanol, acetic acid, butanol, butyric acid, and/or methane.

23. The method of claim 19 , wherein the one or more chemical compounds comprise a ketone, an alkane, and/or an aromatic compound.

24. The method of claim 19 , wherein the one or more chemical compounds comprise a protein, a polyhydroxyalkanoate, acetone, isopropanol, or ethanol.

25. The method of claim 19 , wherein the one or more chemical compounds comprise an amine, and

further comprising converting the amine to a polyisocyanate.

26. The method of claim 19 , wherein producing the one or more chemical compounds in the gas fermentation reactor comprises performing aerobic fermentation, and

further comprising providing oxygen from an anode of the carbon oxide reduction electrolyzer to the gas fermentation reactor.

27. The method of claim 19 , further comprising transporting carbon dioxide produced by the gas fermentation reactor to the membrane electrode assembly.

28. The method of claim 19 , further comprising providing the carbon oxide to the membrane electrode assembly at a pressure above atmospheric pressure.

29. A system for producing one or more chemical compounds, the system comprising:

(a) a source of biogas comprising carbon dioxide;

(b) a carbon oxide reduction electrolyzer for receiving the carbon dioxide from the biogas, wherein the carbon oxide reduction electrolyzer comprises a membrane electrode assembly, the membrane electrode assembly comprising one or more ion conductive polymer layers and a cathode catalyst for facilitating chemical reduction of the carbon dioxide to a carbon-containing reaction product; and

(c) a gas fermentation reactor configured to receive the carbon-containing reaction product produced by the carbon oxide reduction electrolyzer and produce the one or more chemical compounds,

wherein the gas fermentation reactor is configured to perform aerobic fermentation, and the system is configured to provide oxygen from an anode of the carbon oxide reduction electrolyzer to the gas fermentation reactor.

30. A system for producing one or more chemical compounds, the system comprising:

(a) a carbon oxide reduction electrolyzer comprising (i) a membrane electrode assembly, which comprises one or more ion conductive polymer layers and a cathode catalyst for facilitating chemical reduction of carbon oxide to a carbon-containing reaction product, (ii) an anode configured to receive a feed stream comprising water, and (iii) an inlet for receiving the feed stream and providing the feed stream to the anode; and

(b) a gas fermentation reactor configured to receive the carbon-containing reaction product produced by the carbon oxide reduction electrolyzer and produce the one or more chemical compounds,

wherein the gas fermentation reactor is configured to perform aerobic fermentation, and the system is configured to provide oxygen from the anode of the carbon oxide reduction electrolyzer to the gas fermentation reactor.

31. The system of claim 30 , wherein the carbon oxide reduction electrolyzer is configured to produce methane, and wherein the system is configured to transport the methane to the gas fermentation reactor.

32. The system of claim 30 , wherein the carbon oxide reduction electrolyzer is configured to produce carbon monoxide and hydrogen, and wherein the system is configured to transport the carbon monoxide and the hydrogen to the gas fermentation reactor.

Assignments (3)
SECURITY INTEREST Recorded Jan 19, 2026
From: TWELVE BENEFIT CORPORATION
To: SUMITOMO MITSUI BANKING CORPORATION
Reel/Frame 074435/0926 →
CHANGE OF NAME Recorded May 13, 2022
From: OPUS 12 INCORPORATED
To: TWELVE BENEFIT CORPORATION
Reel/Frame 060068/0332 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Oct 27, 2021
From: FLANDERS, NICHOLAS H.; KUHL, KENDRA P.; CAVE, ETOSHA R.; MA, SICHAO; HUO, ZIYANG; HAINES, CARTER S.; BEKKEDAHL, TIMOTHY A.; CORP, KATHRYN L.; MISHRA, ASHLEY D.; IZETT, EDWARD
To: OPUS 12 INCORPORATED
Reel/Frame 057935/0344 →
Continuity (6)
Continuation In Part 16254255 · Jan 22, 2019
Provisional Application 63060583 · Aug 3, 2020
Provisional Application 62685771 · Jun 15, 2018
Provisional Application 62619996 · Jan 22, 2018
Provisional Application 62620109 · Jan 22, 2018
Related Publication 20220136119A1 · May 5, 2022
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