IP Library Granted Patent US 12,576,393
Granted Patent B2
US 12,576,393 · App. 18/745,807 · Granted Mar 17, 2026

Materials, methods, and systems for reactive capture and conversion of CO

Inventors: Daniel Ruddy (Arvada, CO); Anh The To (Golden, CO); Martha Arellano-Trevino (Golden, CO); William Wilson McNeary, IV (Evergreen, CO); Chae Woon Jeong-Potter (Lakewood, CO); Alex James Hill (Lakewood, CO)
Assignee: Alliance for Sustainable Energy, LLC
B01J23/04B01D53/62B01D53/82B01J20/04B01J23/06B01J23/80B01J37/0201B01J37/03C01B32/40B01D2257/504
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,576,393
App. No.
18/745,807
Granted
Mar 17, 2026
Kind
B2
Abstract

The present disclosure relates to a composition that includes a first oxide that includes zinc, aluminum, and copper; and a metal that includes least one of an alkali metal and/or an alkaline earth metal, where the composition has a first total uptake capacity of CO 2 of greater than 218 μmol CO 2 /g of composition at a first temperature of about 40° C., a second total uptake capacity of CO 2 of greater than 76 μmol CO 2 /g of composition at a second temperature of about 300° C., and the composition is capable of converting CO 2 to at least one of CO, methane, or methanol, when exposed to H 2 at a third temperature greater than the first temperature.

Claims (39)

1 . A composition comprising:

an oxide comprising zinc, aluminum, and copper; and

sodium at a concentration between 5 wt % and 10 wt % present as Na 2 O dispersed on the oxide, wherein:

the composition is capable of reversibly capturing CO 2 .

2 . The composition of claim 1 , wherein the oxide comprises CuO, ZnO, and Al 2 O 3 .

3 . The composition of claim 2 , wherein at least a portion of the oxide is in a crystalline phase.

4 . The composition of claim 1 , wherein the Na 2 O is amorphous.

5 . A method for reducing CO 2 , utilizing a solid composition, the method comprising:

a first contacting of the solid composition with CO 2 at a first temperature and a first pressure, resulting in chemisorption of the CO 2 onto the composition; and

a second contacting of the solid composition with H 2 at a second temperature and a second pressure, resulting in a portion of the chemisorbed CO 2 reacting to form at least one of CO, methane, or methanol, wherein:

the solid composition comprises:

an oxide comprising zinc, aluminum, and copper; and

sodium at a concentration between 5 wt % and 10 wt % present as Na 2 O dispersed on the oxide;

the first temperature is between 0° C. and 450° C.,

the first pressure is between 0.8 bar and 30 bar (absolute),

the second temperature is between 50° C. and 450° C., and

the second pressure is between 0.8 bar and 30 bar (absolute).

6 . The composition of claim 1 , further comprising:

a first total uptake capacity of CO 2 of greater than 218 μmol CO 2 /g of composition at a first temperature of about 40° C., and

a second total uptake capacity of CO 2 of greater than 76 μmol CO 2 /g of composition at a second temperature of about 300° C., wherein:

the composition is capable of converting CO 2 to at least one of CO, methane, or methanol, when exposed to H 2 at a third temperature greater than the first temperature.

7 . The composition of claim 6 , wherein the first total uptake capacity is between 218 μmol CO 2 /g of composition and 300 μmol CO 2 /g of composition.

8 . The composition of claim 6 , wherein the second total uptake capacity is between 76 μmol CO 2 /g of composition and 250 μmol CO 2 /g of composition.

9 . The method of claim 5 , wherein the solid composition is positioned within at least one packed bed reactor.

10 . The method of claim 9 , wherein the first contacting is completed by providing the CO 2 in a continuous flow to the packed bed reactor.

11 . The method of claim 9 , wherein the CO 2 is provided to the packed bed reactor in a gas stream at a molar concentration between 0.2 mol % and 100 mol % CO 2 .

12 . The method of claim 9 , wherein the second contacting is completed by providing the H 2 in a continuous flow to the packed bed reactor.

13 . The method of claim 9 , wherein the H 2 and chemisorbed CO 2 are provided at a molar ratio of H 2 :CO 2 between 1:1 and 10:1.

14 . The method of claim 9 , further comprising:

a separating, wherein:

during the second contacting, a first stream comprising H 2 , CO 2 , and methanol and at least one of CO or methane exit the packed bed reactor,

the first stream is directed to the separating, which separates the first stream into a second stream comprising methanol and a third stream comprising H 2 and CO 2 , and

at least one of CO or methane, and the third stream is recycled to the second contacting.

15 . The method of claim 9 , further comprising:

a reacting; and

a separating, wherein:

during the second contacting, a first stream comprising H 2 and CO 2 , and at least one of CO or methane exit the packed bed reactor,

the first stream is directed to the reacting resulting in at least a portion of the H 2 and CO 2 , and at least one of the CO or methane reacting to form a second stream comprising methanol,

the second stream is directed to the separating, which separates the second stream into a third stream comprising methanol and a fourth stream comprising H 2 and CO 2 , and at least one of CO or methane, and the fourth stream is recycled to the second contacting.

Assignments (3)
CHANGE OF NAME Recorded Dec 16, 2025
From: ALLIANCE FOR SUSTAINABLE ENERGY, LLC
To: ALLIANCE FOR ENERGY INNOVATION, LLC
Reel/Frame 073993/0276 →
CONFIRMATORY LICENSE Recorded Aug 26, 2024
From: ALLIANCE FOR SUSTAINABLE ENERGY, LLC
To: U.S. DEPARTMENT OF ENERGY
Reel/Frame 068400/0470 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 7, 2024
From: RUDDY, DANIEL; TO, ANH THE; ARELLANO-TREVINO, MARTHA; MCNEARY, WILLIAM WILSON; HILL, ALEX JAMES; JEONG-POTTER, CHAE WOON
To: ALLIANCE FOR SUSTAINABLE ENERGY, LLC
Reel/Frame 067921/0047 →
Continuity (2)
Provisional Application 63508797 · Jun 16, 2023
Related Publication 20250161917A1 · May 22, 2025
References Cited (47)
US 20240115987A1 · Jeong-Potter et al. · 2024 [cited by applicant]
WO 2022256361A2 · 2022 [cited by applicant]
WO 2023053067A1 · 2023 [cited by applicant]
Previtali et al., “Low pressure conversion of CO2 to methanol over Cu/Zn/Al catalysts. The effect of Mg, Ca and Sr as basic promoters”, Fuel 274 (2020) 117804. (Year: 2020). [cited by examiner]
Pasupulety et al., “A study on highly active Cu—Zn—Al—K catalyst for CO2 hydrogenation to methanol”, Arabian Journal of Chemistry (2021) 14, 102951. (Year: 2021). [cited by examiner]
Arellano-Treviño et al., “Bimetallic catalysts for CO2 capture and hydrogenation at simulated flue gas conditions”, Chemical Engineering Journal, 2019, vol. 375, 121953, pp. 1-8. [cited by applicant]
Arellano-Treviño et al., “Catalysts and adsorbents for CO2 capture and conversion with dual function materials: Limitations of Ni-containing DFMs for flue gas applications”, Journal of CO2 Utilization, 2019, vol. 31, pp… [cited by applicant]
Bowker, “Methanol Synthesis from CO2 Hydrogenation”, ChemCatChem, Sep. 2019, vol. 11, No. 17, pp. 4238-4246. [cited by applicant]
Cohen et al., “Using Light and Electrons to Bend Carbon Dioxide: Developing and Understanding Catalysts for CO2 Conversion to Fuels and Feedstocks”, Accounts of Chemical Research, 2022, vol. 55, pp. 944-954. [cited by applicant]
Dasireddy et al., “Photocatalytic CO2 reduction to methanol over bismuth promoted BaTiO3 perovskite nanoparticle catalysts”, Renewable Energy, 2022, vol. 195, pp. 885-895. [cited by applicant]
Duyar et al., “Dual function materials for CO2 capture and conversion using renewable H2”, Applied Catalysis B: Environmental, 2015, vol. 168-169, pp. 370-376. [cited by applicant]
Duyar et al., “CO2 utilization with a novel dual function material (DFM) for capture and catalytic conversion to synthetic natural gas: An update”, Journal of CO2 Utilization, 2016, vol. 15, pp. 65-71. [cited by applicant]
Fornero et al., “CO2 capture via catalytic hydrogenation to methanol: Thermodynamic limit vs. ‘kinetic limit’”, Catalysis Today, 2011, vol. 172, pp. 158-165. [cited by applicant]
Freyman et al., “Reactive CO2 capture: A path forward for process integration in carbon management”, Joule, Apr. 2023, vol. 7, No. 4, pp. 631-651. [cited by applicant]
Han et al., “Atomically dispersed Ptn+ species as highly active sites in Pt/In2O3 catalysts for methanol synthesis from CO2 hydrogenation”, Journal of Catalysis, 2021, vol. 394, pp. 236-244. [cited by applicant]
Ioannou et al., “Economic and Environmental Performance of an Integrated CO2 Refinery”, ACS Sustainable Chemistry & Engineering, 2023, vol. 11, No. 5, pp. 1949-1961. [cited by applicant]
Jeong-Potter et al., “Dual function materials (Ru+Na2O/Al2O3) for direct air capture of CO2 and in situ catalytic methanation: The impact of realistic ambient conditions”, Applied Catalysis B: Environmental, 2022, vol. … [cited by applicant]
Kar et al., “Integrative CO2 Capture and Hydrogenation to Methanol with Reusable Catalyst and Amine: Toward a Carbon Neutral Methanol Economy”, Journal of the American Chemical Society, 2018, vol. 140, No. 5, pp. 1580-1… [cited by applicant]
Kar et al., “Integrated CO2 Capture and Conversion to Formate and Methanol: Connecting Two Threads”, Accounts of Chemical Research, 2019, vol. 52, No. 10, pp. 2892-2903. [cited by applicant]
Kothandaraman et al., “Integrated Capture and Conversion of CO2 to Methanol in a Post-Combustion Capture Solvent: Heterogeneous Catalysts for Selective C—N Bond Cleavage”, Advanced Energy Materials, 2022, vol. 12, No. 4… [cited by applicant]
Kowalik et al., “The effect of alkali metals doping on properties of Cu/ZnO/Al2O3 catalyst for water gas shift”, Catalysis Today, 2011, vol. 176, No. 1, pp. 144-148. [cited by applicant]
Leonzio et al., “Methanol production by CO2 hydrogenation: Analysis and simulation of reactor performance”, International Journal of Hydrogen Energy, 2019, vol. 44, No. 16, pp. 7915-7933. [cited by applicant]
Li et al., “Bimetallic catalysts for green methanol production via CO2 and renewable hydrogen: a mini-review and prospects”, Catalysis Science & Technology, 2018, vol. 8, pp. 3450-3464. [cited by applicant]
Numpilai et al., “Tuning Interactions of Surface-adsorbed Species over Fe—Co/K—Al2O3 Catalyst by Different K Contents: Selective CO2 Hydrogenation to Light Olefins”, ChemCatChem, 2020, vol. 12, No. 12, pp. 3306-3320. [cited by applicant]
Ojelade et al., “A Review on Pd Based Catalysts for CO2 Hydrogenation to Methanol: In-Depth Activity and DRIFTS Mechanistic Study”, Catalysis Surveys from Asia, 2020, vol. 24, pp. 11-37. [cited by applicant]
Omodolor et al., “Dual-Function Materials for CO2 Capture and Conversion: A Review”, Industrial & Engineering Chemistry Research, 2020, vol. 59, No. 40, pp. 17612-17631. [cited by applicant]
Pazdera et al., “Conversion of CO2 to methanol over bifunctional basic-metallic catalysts”, Catalysis Communications, 2021, vol. 159, No. 106347, pp. 1-6. [cited by applicant]
Pazdera et al., “Impact of the Local Environment of Amines on the Activity for CO2 Hydrogenation over Bifunctional Basic—Metallic Catalysts”, ChemCatChem, 2022, vol. 14, No. 18, e202200620, pp. 1-10. [cited by applicant]
Porta et al., Storage Material Effects on the Performance of Ru-Based CO 2 Capture and Methanation Dual Functioning Materials, Ind. Eng. Chem. Res., 2021, 60, 6706-6718. [cited by applicant]
Proaño et al., “In-situ DRIFTS study of two-step CO2 capture and catalytic methanation over Ru, Na2O”/Al2O3 Dual Functional Material, Applied Surface Science, 2019, vol. 479, pp. 25-30. [cited by applicant]
Ranjan et al., “Recent Advances in Carbon Dioxide Adsorption, Activation and Hydrogenation to Methanol using Transition MetalCarbides”, ChemSusChem, 2022, vol. 15, e202201183, pp. 1-37. [cited by applicant]
Santiago et al., “Synthesis of MeOH and DME From CO2 Hydrogenation Over Commercial and Modified Catalysts”, Frontiers in Chemistry, Jun. 2022, vol. 10, Article 903053, pp. 1-11. [cited by applicant]
Sen et al., “Glycol assisted efficient conversion of CO2 captured from air to methanol with a heterogeneous Cu/ZnO/Al2O3 catalyst”, Journal of CO2 Utilization, 2021, 54, 101762. [cited by applicant]
Sen et al., Integrated carbon capture and utilization to methanol with epoxide-functionalized polyamines under homogeneous catalytic conditions, Journal of Organometallic Chemistry, 2022, vols. 965-966, 122331, pp. 1-7. [cited by applicant]
Siegel et al., Reactive Capture of CO2□: Opportunities and Challenges, ACS Catalysis, 2023, vol. 13, No. 1, pp. 766-784. [cited by applicant]
Smyrnioti et al., Study of CO2 adsorption on a commercial CuO/ZnO/Al2O3 catalyst, Catalysis Today, 2020, vol. 357, pp. 495-502. [cited by applicant]
Sollai et al., “Renewable methanol production from green hydrogen and captured CO2: A techno-economic assessment”, Journal of CO2 Utilization, 2023, vol. 68, 102345, pp. 1-12. [cited by applicant]
Studt et al., “The Mechanism of CO and CO2 Hydrogenation to Methanol over Cu-Based Catalysts”, ChemCatChem, 2015, vol. 7, No. 7, pp. 1105-1111. [cited by applicant]
Sun et al., “Highly active Pt/In2O3—ZrO2 catalyst for CO2 hydrogenation to methanol with enhanced CO tolerance: The effects of ZrO2”, Applied Catalysis B: Environmental, 2023, vol. 320, 122018, pp. 1-12. [cited by applicant]
To et al., Direct synthesis of branched hydrocarbons from CO2 over composite catalysts in a single reactor, Journal of CO2 Utilization, 2022, vol. 66, 102261, pp. 1-9. [cited by applicant]
Wang et al., “Parametric, cyclic aging and characterization studies for CO2 capture from flue gas and catalytic conversion to synthetic natural gas using a dual functional material (DFM)”, Journal of CO2 Utilization, 20… [cited by applicant]
Wirner et al., “Combined capture and reduction of CO2 to methanol using a dual-bed packed reactor”, Chemical Engineering Journal, 2023, vol. 470, 144227, pp. 1-6. [cited by applicant]
Wu et al., “Mechanistic insight into the catalytically active phase of CO2 hydrogenation on Cu/ZnO catalyst”, Applied Surface Science, 2020, vol. 525, 146481, pp. 1-9. [cited by applicant]
Yang et al., “DFT approach to the stability, the structural, electronic and photocatalytic properties of the ZnV2O6(001) surface terminations”, Materials Science in Semiconductor Processing, 2023, vol. 155, 107220, pp. … [cited by applicant]
Yousaf et al., “Rapid and highly selective conversion of CO2 to methanol by heterometallicporous ZIF-8”, Journal of CO2 Utilization, 2022, vol. 64, 102172, pp. 1-18. [cited by applicant]
Zhou et al., “New horizon in C1 chemistry: breaking the selectivity limitation in transformation of syngas and hydrogenation of CO2 into hydrocarbon chemicals and fuels”, Chemical Society Reviews, Jun. 2019, vol. 48, No… [cited by applicant]
Zhou et al., “Comparative investigation of CO2-to-methanol process using different CO2capture technologies”, Fuel, 2023, vol. 338, 127359, pp. 1-14. [cited by applicant]