On-site Electro-synthesis of Potassium Formate from Recycled CO2 - Phase II

OCO’s goal for Phase II is to quickly reach a minimum viable commercial-scale level of maturity for its direct electrochemical potassium formate generation technology-based manufacturing system from its current TRL-4 state to TRL-6 and meeting otr exceeding all Phase II US Army specified objectives.  In Phase II, OCO will develop and demonstrate the successful operation of a complete, full-size commercial reactor cell of size 1.3 m2, capable of producing >100 lb./day of potassium formate continuously at a concentration level of 40%. We propose achieving this in two scale-up steps at two progressively larger cell sizes. In order to attain the optimally operating commercial size reactor system, OCO will perform a step-wise, size scale-up and optimization of its process technology during Phase II.   This scale-up process will begin with a 100cm2 system(“small cell”), scale to an intermediate  1725cm2 system (“tall cell”), and complete with a 1.3m2 system (“full cell”).  The full cell size was selected to exactly match the existing standard material and form factor attributes common to the high-volume Chlor-alkali industry’s use of electrochemical reactor cells.  By leveraging an existing and at-scale supply chain, built on standard-sized components, we will be able to scale-up faster, using lower-cost parts and reduce non-recurring engineering costs associated with development. The production rate of the full cell (107 lb./day) is significantly larger than the DOD target (20 lb./day) and could be achieved by numbering up two tall cells (each having a 14 lb./day capacity) rather than commit to an additional challenge of developing and optimizing a significantly larger (about 8x) full cell. However, a full cell system, as targeted by OCO, achieves the end-state of a commercially standardized minimum viable size which will demonstrate the technical maturity and lead to more rapid deployment of this technology for DOD and other potential commercial interests. It is the intent of OCO to supplement the DOD support in Phase II with its own financial cost-share contribution (investor funding etc., amounting to an estimated $350,000) to achieve and demonstrate this ‘commercial level’ production feasibility. OCO has the means and expertise, to build on its Phase I accomplishments, to meet and exceed DOD’s Phase II targets. The potassium formate will be generated in the form of a 40wt% concentrated solution without need of further separation or concentration directly from OCO’s electrochemical process utilizing non-flammable, inexpensive and widely available feedstocks (recycled carbon dioxide, water and potassium sulfate) and renewable electricity operating at ambient temperature(25C) and pressure (1 atm).  OCO will also demonstrate that the pilot system’s catalytic performance and degradation operated continuously over 200 hours as a basis for projecting a level of durability sufficient to last for over 8000 hours.