INTERCALATION MEMBRANE

Abstract

An ion conductive intercalation membrane is useful to separate anode and cathode compartments in an electrochemical cell and provide ion transport between the anode and cathode compartments. The intercalation membrane does not receive and release electrons during operation of the electrochemical cell. An electric potential and current source is connected to an anode and a cathode disposed in respective anode and cathode compartments to cause oxidation and reduction reactions to occur at the anode and cathode, to cause electrons to flow through an external circuit coupled to the anode and cathode, and to cause ions to transport through the intercalation membrane to maintain charge neutrality within the electrochemical cell. The electrochemical cell operates at a current density greater than 25 mA/cm.sup.2 across the intercalation membrane.

Claims

1. An electrochemical cell comprising: an anode compartment comprising an anode and an anolyte medium; a cathode compartment comprising a cathode and a catholyte medium; an ion conductive intercalation membrane separating the anode compartment and the cathode compartment, wherein the intercalation membrane does not receive and release electrons during operation of the electrochemical cell; and an electric field between the anode and cathode to cause electrons to flow through an external circuit coupled to the anode and cathode and to cause ions to transport through the intercalation membrane to maintain charge neutrality within the electrochemical cell.

2. The electrochemical cell according to claim 1, wherein the anode compartment further comprises inlet and outlet ports configured to introduce anolyte medium into the anolyte compartment and to remove anolyte medium from the anolyte compartment.

3. The electrochemical cell according to claim 1, wherein the cathode compartment further comprises inlet and outlet ports configured to introduce catholyte medium into the catholyte compartment and to remove catholyte medium from the catholyte compartment.

4. The electrochemical cell according to claim 1, wherein the intercalation membrane comprises an intercalation compound having a host lattice structure and characterized by a reversible uptake of ions at a temperature in the range of 0 to 150° C., while conserving its host lattice structure.

5. The electrochemical cell according to claim 1, wherein the intercalation membrane comprises an intercalation compound, with or without a guest ion, selected from MoS.sub.2, MoSe.sub.2, MoTe.sub.2, WS.sub.2, WSe.sub.2, Mo.sub.6S.sub.8, Mo.sub.6Se.sub.8, Mo.sub.6Te.sub.8, Li.sub.xCoO.sub.2, Li.sub.xMn.sub.2O.sub.4, Li.sub.xV.sub.3O.sub.8, Li.sub.xNiO.sub.2 or Li.sub.xMnO.sub.2, Li.sub.xFePO.sub.4, VOPO.sub.4, Na.sub.xFeFe(CN).sub.6, Na.sub.xCrO.sub.2, P2-Na.sub.x[Fe.sub.1/2Mn.sub.1/2]O.sub.2, O3-Na[Ni.sub.1/3Fe.sub.1/3Mn.sub.1/3]O.sub.2, Na.sub.xFePO.sub.4CO.sub.3, Na.sub.xV.sub.2O.sub.2(PO.sub.4).sub.2F, Mg.sub.1.03Mn.sub.0.97SiO.sub.4, MgFeSiO.sub.4, MgCoSiO.sub.4, CaSi.sub.2, RuO.sub.2, where x is from 0 to 3.

6. The electrochemical cell according to claim 1, wherein the intercalation membrane has a density of at least 90%.

7. The electrochemical cell according to claim 1, wherein the intercalation membrane comprises an intercalation compound and a non-intercalation compound, both of which are configured to provide selective transport of ions.

8. The electrochemical cell according to claim 1, wherein the intercalation membrane comprises at least two intercalation compounds configured to provide selective transport of ions.

9. The electrochemical cell according to claim 1, wherein the intercalation membrane is fabricated with a support structure to provide mechanical stability.

10. The electrochemical cell according to claim 1, wherein the intercalation membrane transports metal ions selected from ions of Li, Na, K, Mg, Pb, Zn, Y, and Cs.

11. The electrochemical cell according to claim 1, wherein the intercalation membrane transports a plurality of metal ions selected from ions of Li, Na, K, Mg, Pb, Zn, Y, and Cs.

12. An electrochemical cell comprising: an anode compartment comprising an anode at which an oxidation reaction occurs and an anolyte medium, wherein the anode compartment further comprises inlet and outlet ports configured to introduce anolyte medium into the anolyte compartment and to remove anolyte medium from the anolyte compartment; a cathode compartment comprising a cathode at which a reduction reaction occurs and a catholyte medium, wherein the cathode compartment further comprises inlet and outlet ports configured to introduce catholyte medium into the catholyte compartment and to remove catholyte medium from the catholyte compartment; an ion conductive intercalation membrane separating the anode compartment and the cathode compartment, wherein the intercalation membrane does not receive and release electrons during operation of the electrochemical cell, the intercalation membrane comprises a Chevrel phase (Mo.sub.6T.sub.8, where T is S, Se, or Te), and the intercalation membrane transports metal ions selected from ions of Li, Na, K, Mg, Pb, Zn, Y, and Cs; and an electric field between the anode and cathode to cause electrons to flow through an external circuit coupled to the anode and cathode and cause the oxidation and reduction reactions to occur and to cause the metal ions to transport through the intercalation membrane from the anode compartment to the cathode compartment to maintain charge neutrality within the electrochemical cell.

13. The electrochemical cell according to claim 12, wherein the intercalation membrane has a density of at least 90%.

14. The electrochemical cell according to claim 12, wherein the intercalation membrane transports a plurality of metal ions selected from ions of Li, Na, K, Mg, Pb, Zn, Y, and Cs.

15. A method for operating an electrochemical cell, the method comprising: providing the electrochemical cell, the cell comprising: an anode compartment comprising an anode at which an oxidation reaction occurs and an anolyte medium, wherein the anode compartment further comprises inlet and outlet ports configured to introduce anolyte medium into the anolyte compartment and to remove anolyte medium from the anolyte compartment; a cathode compartment comprising a cathode at which a reduction reaction occurs and a catholyte medium, wherein the cathode compartment further comprises inlet and outlet ports configured to introduce catholyte medium into the catholyte compartment and to remove catholyte medium from the catholyte compartment; an ion conductive intercalation membrane separating the anode compartment and the cathode compartment, wherein the intercalation membrane does not receive and release electrons during operation of the electrochemical cell and the intercalation membrane transports metal ions; and an electric current source connected to the anode and cathode; introducing the catholyte medium to the catholyte compartment and the anolyte medium to the anolyte compartment; and passing a current between the anode and the cathode to cause electrons to flow through an external circuit coupled to the anode and cathode and to cause metal ions to transport through the intercalation membrane from the anode compartment to the cathode compartment to maintain charge neutrality within the electrochemical cell at a current density greater than 25 mA/cm.sup.2 across the intercalation membrane.

16. The method cell according to claim 15, wherein the current density is between 25 mA/cm.sup.2 and 250 mA/cm.sup.2 across the intercalation membrane.

17. The method according to claim 15, wherein the intercalation membrane comprises an intercalation compound having a host lattice structure and characterized by a reversible uptake of ions at a temperature in the range of 0 to 150° C., while conserving its host lattice structure.

18. The method according to claim 15, wherein the intercalation membrane comprises an intercalation compound, with or without a guest ion, selected from MoS.sub.2, MoSe.sub.2, MoTe.sub.2, WS.sub.2, WSe.sub.2, Mo.sub.6S.sub.8, Mo.sub.6Se.sub.8, Mo.sub.6Te.sub.8, Li.sub.xCoO.sub.2, Li.sub.xMn.sub.2O.sub.4, Li.sub.xV.sub.3O.sub.8, Li.sub.xNiO.sub.2 or Li.sub.xMnO.sub.2, Li.sub.xFePO.sub.4, VOPO.sub.4, Na.sub.xFeFe(CN).sub.6, Na.sub.xCrO.sub.2, P2-Na.sub.x[Fe.sub.1/2Mn.sub.1/2]O.sub.2, O3-Na[Ni.sub.1/3Fe.sub.1/3Mn.sub.1/3]O.sub.2, Na.sub.xFePO.sub.4CO.sub.3, Na.sub.xV.sub.2O.sub.2(PO.sub.4).sub.2F, Mg .sub.1.03Mn.sub.0.97SiO.sub.4, MgFeSiO.sub.4, MgCoSiO.sub.4, CaSi.sub.2, RuO.sub.2, where x is from 0 to 3.

19. The method according to claim 15, wherein the intercalation membrane comprises a Chevrel phase (Mo.sub.6T.sub.8, where T is S, Se, or Te), and the intercalation membrane transports metal ions selected from ions of Li, Na, K, Mg, Pb, Zn, Y, and Cs.

20. The method according to claim 19, wherein the intercalation membrane transports a plurality of metal ions selected from ions of Li, Na, K, Mg, Pb, Zn, Y, and Cs.

Description

BRIEF DESCRIPTION OF THE SEVERAL DRAWINGS

[0019] In order that the manner in which the above-recited and other features and advantages of the invention are obtained and will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that the drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail.

[0020] FIG. 1 is a schematic of the cross section showing the basic component of an electrochemical cell.

[0021] FIG. 2 is a schematic of the cross section of an electrochemical flow cell.

[0022] FIG. 3 is the voltage and current transients of the transfer of Na-ions through the intercalation membrane at a single current density.

[0023] FIG. 4 is the voltage and current transients of the transfer of Na-ions through the intercalation membrane at different current densities.

[0024] FIG. 5 is the voltage and current transients of the transfer of Li-ions through the intercalation membrane at a single current density.

[0025] FIG. 6 is the voltage and current transients of the transfer of Li-ions through the intercalation membrane at a multiple current densities.

[0026] FIG. 7 is the voltage and current transients of the transfer of Mg-ions through the intercalation membrane at a single current density.

[0027] FIG. 8 is the voltage and current transients of the transfer of Mg-ions through the intercalation membrane at multiple current densities.

[0028] FIG. 9 is the voltage and current transients of the transfer of K-ions through the intercalation membrane at a single current density.

[0029] FIG. 10 is the voltage and current transients of the transfer of K-ions through the intercalation membrane at multiple current densities.

[0030] FIG. 11 is the voltage and current transients of the transfer of Zn-ions through the intercalation membrane at a single current density.

[0031] FIG. 12 is the voltage and current transients of the transfer of Zn-ions through the intercalation membrane at multiple current densities.

[0032] FIG. 13 is the voltage and current transients of the transfer of Pb-ions through the intercalation membrane at a single current density.

[0033] FIG. 14 is the voltage and current transients of the transfer of Pb-ions through the intercalation membrane at multiple current densities.

[0034] FIG. 15 is the voltage and current transients of the transfer of Ce-ions through the intercalation membrane at a single current density.

[0035] FIG. 16 is the voltage and current transients of the transfer of Ce-ions through the intercalation membrane at multiple current densities.

[0036] FIG. 17 is the voltage and current transients of the transfer of Y-ions through the intercalation membrane at a single current density.

[0037] FIG. 18 is the voltage and current transients of the transfer of Y-ions through the intercalation membrane at multiple current densities.

[0038] FIG. 19 is the voltage and current transients of the transfer of Na- and K-ions through the intercalation membrane at a single current density.

[0039] FIG. 20 is the voltage and current transients of the transfer of Na- and K-ions through the intercalation membrane at multiple current densities.

DETAILED DESCRIPTION OF THE INVENTION

[0040] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. Additionally, while the following description refers to several embodiments and examples of the various components and processes of the described invention, all of the described embodiments and examples are to be considered, in all respects, as illustrative only and not as being limiting in any manner.

[0041] Furthermore, the described features, structures, characteristics, processes, or methods of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of suitable intercalation membranes, etc., to provide a thorough understanding of embodiments of the invention. One having ordinary skill in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, processes, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

[0042] Some terms and their definitions that will be used throughout the description of the disclosed invention follows. An “electrochemical cell” will refer to any system or device for which chemical reactions are occurring at or in electrodes that are connected to an external circuit, such that the external circuit drives the chemical reactions at the electrodes or such that that chemical reactions at the electrodes drive current through the external circuit. “Membrane,” herein will be used to describe a physical barrier that can be used to separate two electrodes of an electrochemical cell and permits at least one ion to be transferred from one compartment of an electrochemical cell to another compartment of an electrochemical cell. “Intercalation material,” is defined as a material that can reversibly incorporate a guest ion or atoms into its structure. “Electrolyte” will be defined and used as a medium that conducts electrical current by the movement of ions present in the medium. “Electrochemical transfer wall” and “electrochemical transfer junction” will be used interchangeably, and will refer to a physical barrier that separates two compartments of an electrochemical cell and requires an electron transfer to accompany the transfer of ions through the material.

[0043] The present invention is generally directed to a method and a device that is used to transfer ions between two compartments of an electrochemical cell using a dense membrane which composition is such that at least one component is a material known as an intercalation material. A schematic that shows the basic components of an electrochemical cell with an intercalation membrane is shown in FIG. 1. In one embodiment the electrochemical cell has an anode 1 at which oxidation reactions occur, a cathode 2 at which reduction reactions occur, an intercalation membrane 3 which separates the medium 4 for which the oxidation reactions are occurring from the medium 5 for which the reduction reactions are occurring. Electrolytes are used in electrochemical cells to provide ion transport between the two electrodes. In electrochemical cells where the electrodes are separated by a barrier as in the present invention, the electrolyte for which the anode is in contact with is termed the anolyte and the electrolyte in contact with the cathode is termed the catholyte. The reactions at the two electrodes are caused by an external electric potential and current source 6 that creates an electric field between the electrodes. Alternatively, in the case of a galvanic cell, reactions at the two electrodes can produce an electric field that can do work external to the cell. In either case the electric field causes electrons 7 to flow through an external circuit and ions 8 to migrate through the electrochemical cell to maintain charge neutrality. Although shown as positive ions migrating through the cell in the same direction as the electrons, in another embodiment negative ions can migrate through the cell in the opposite direction as the electrons to maintain charge neutrality.

[0044] The present invention is applicable to a variety of different applications. Some non-limiting examples are electrolysis, reclamation, electro-wining, recovery, recycling, valorization, energy storage, and sensors. As expected, the cell design for each one of these applications is different and one could imagine numerous possible designs for each application. Referring to FIG. 1, one could imagine that the components of the electrochemical cell can be optimized for the type of medium with which the electrodes contact, such as, for example, aqueous solutions, organic solutions, molten salts, room temperature molten salts or ionic liquids (IL), gases or steam, and super critical systems. It is also known to those skilled in the art that the size and shape of the electrochemical cell and its components will depend on the system and application. In some embodiments the cell is used in a batch type mode and the cell is designed to hold a specific quantity of electrolyte. In some embodiment the cell is used in a continuous flow mode and the cell is optimized in consideration of the mass transport of electrolyte through the cell. Other aspects that can affect cell design are product buildup and removal, electrode composition, position and size, and requirements specific to the application.

[0045] In one embodiment of the presently disclosed invention, the intercalation membrane is used to separate the anode and cathode of a micro flow cell as schematically represented in FIG. 2. This cell has the basic components described for FIG. 1, except there are two ports on the anolyte chamber, one for introducing anolyte to the chamber 9 and one for removing anolyte from the chamber 10. Similarly, there are two ports on the catholyte chamber, one for introducing the catholyte 12 and one for removing the catholyte 11. The flow of the electrolytes into and out of the electrochemical cell shown in FIG. 2 can be controlled using pumps or other fluid transport means which can cause the electrolyte medium to flow. This type of cell allows the distance between the electrodes and intercalation membrane to be small while still processing high volumes of material. In such a cell the products of the reactions occurring at the anode and cathode are carried away by the flow of the electrolyte, while fresh reactant is constantly delivered to the electrode surface. This type of flow cell is beneficial for electrochemical reactions in which the electrolyte is liquid or gaseous.

[0046] In one embodiment the electrolytes are cycled between the electrochemical cell and a reservoir (not shown) for each of the anolyte and catholyte allowing the electrochemical reaction to occur until a specific quantity of charge has passed. In some embodiments the electrolyte can pass through multiple reservoirs before cycling back into the electrochemical cell. The reservoirs can be used to collect different components of the electrolyte, conduct separate chemical reactions or to change the properties of the electrolyte, for example heating or cooling the electrolyte. In another embodiment the electrolytes are passed through the electrochemical cell in a single pass, without any dedicated reservoirs for the electrochemical process. It is within the scope of the disclosed invention to provide multiple electrochemical cells arrange in series and or parallel in which the electrolyte flows through in either a single pass or until a specific quantity of charge has passed, otherwise in continuous or batch mode. It should be clear to those skilled in the art that the disclosed invention is not dependent on the method of electrolyte flow or storage.

[0047] The intercalation membrane disclosed in the present invention is a dense material in which at least one component is an intercalation compound. Accordingly the intercalation compound is a compound that has a reversible uptake of ions, either cations or anions at low temperatures while the structure of the host lattice is conserved. In some embodiments the intercalation compound is chosen from the dichalcogenides, graphite, oxides, phosphates, Chevrel phase, perovskites and silicates. Some non-limiting examples of intercalation compounds with and without the guest ion are MoS.sub.2, MoSe.sub.2, MoTe.sub.2, WS.sub.2, WSe.sub.2, Mo.sub.6S.sub.8, Mo.sub.6Se.sub.8, Mo.sub.6Te.sub.8, Li.sub.xCoO.sub.2, Li.sub.xMn.sub.2O.sub.4, Li.sub.xV.sub.3O.sub.8, Li.sub.xNiO.sub.2 or Li.sub.xMnO.sub.2, Li.sub.xFePO.sub.4, VOPO.sub.4, Na.sub.xFeFe(CN).sub.6, Na.sub.xCrO.sub.2, P2-Na.sub.x[Fe.sub.1/2Mn.sub.1/2]O.sub.2, O3-Na[Ni.sub.1/3Fe.sub.1/3Mn.sub.1/3]O.sub.2, Na.sub.xFePO.sub.4CO.sub.3, Na.sub.xV.sub.2O.sub.2(PO.sub.4).sub.2F, Mg.sub.1.03Mn.sub.0.97SiO.sub.4, MgFeSiO.sub.4, MgCoSiO.sub.4, CaSi.sub.2, and RuO.sub.2. The value of “x” identified in the foregoing compounds is different, but for the purpose of providing a general, but non-limiting parameter, x is typically in the range from 0 to 3. The choice of intercalation compound for the membrane depends on the ion that needs to be transferred for the electrochemical reactions being conducted by the cell and the stability of the intercalation compound to the media it is exposed to on both surfaces of the membrane. Other factors can also be taken into account for the selection of the intercalation compounds, such as physical properties, ion and electron conductivity, cost of production and ease of fabrication.

[0048] In one embodiment the intercalation compound is chosen to transport Li-ions across the intercalation membrane. Compounds known to intercalate Li-ions from the extensive work on Li-ion batteries can be used. Some non-limiting examples are Li.sub.xCoO.sub.2, Li.sub.xMn.sub.2O.sub.4, Li.sub.xV.sub.3O.sub.8, Li.sub.xNiO.sub.2 or Li.sub.xMnO.sub.2, and Li.sub.xFePO.sub.4. In another embodiment the intercalation compound is chosen to transport Na-ions across the intercalation membrane. Compounds known to intercalate Na-ions are used. Some non-limiting examples are VOPO.sub.4, Na.sub.xFeFe(CN).sub.6, Na.sub.xCrO.sub.2, P2-Na.sub.x[Fe.sub.1/2Mn.sub.1/2]O.sub.2, O3-Na[Ni.sub.1/3Fe.sub.1/3Mn.sub.1/3]O.sub.2, Na.sub.xFePO.sub.4CO.sub.3, and Na.sub.xV.sub.2O.sub.2(PO.sub.4).sub.2F. In another embodiment the intercalation compound is chosen to transport Mg-ions across the intercalation membrane. Compound known to intercalate Mg-ions are used. Some non-limiting examples include Mg.sub.1.03Mn.sub.0.97SiO.sub.4, MgFeSiO.sub.4, and MgCoSiO.sub.4. In the above mentioned embodiments specific ions were targeted for transport across the membrane.

[0049] Yet in other embodiments, the intercalation compound is chosen to transport numerous metal or alkali metal ions across the membrane, including, but not limited to, ions of Li, Na, K, Mg, Pb, Zn, Y, and Cs. In one embodiment an intercalation compound like Mo.sub.6S.sub.8 is used to conduct multiple cations. In one embodiment the electrochemical cell is operated in a method that transports the ions without preference to a specific ion, in another embodiment the electrochemical cell is operated that preferentially transports certain ions over other ions. Further still, in another embodiment multiple cells or compartments within a single cell are used to separate different ions being transferred through the intercalation membrane.

[0050] According to the disclosed invention the intercalation membrane is composed of at least one intercalation compound. In one embodiment the membrane is composed of a single material, which is the intercalation compound. In such an embodiment the intercalation membrane can be formed with or without the guest species present. For a non-limiting example, the membrane can be made using LiMn.sub.2O.sub.4, or Mn.sub.2O.sub.4. In another embodiment the membrane is composed of solely Mo.sub.6S.sub.8 and is formed as Cu.sub.2Mo.sub.6S.sub.8 or as Mo.sub.6S.sub.8. In either of these examples the guest species can be removed either chemically or electrochemically once the membrane is formed, or prior to forming the membrane. The formation of the single material intercalation membrane can be performed using standard solid state processing techniques which will depend on the intercalation material being implemented. To fully exploit the benefits of using an intercalation membrane the membrane is fabricated in a manner that produces a membrane with a density of at least 90% or more preferably at least 98%. In this context membrane density describes the amount of void space or lack of void space present in the membrane. A membrane density of 100% would have no void space present in the membrane.

[0051] In another embodiment the intercalation membrane is composed of an intercalation compound and at least one additional compound. The additional compounds can be inorganic or organic and can in themselves be able to transport ions through macro/nano-scopic pores or through their crystal structure or grain boundaries. In one embodiment at least one of the additional compounds is also an intercalation compound. In another embodiment at least one of the additional compounds is not able to transport ions. In one embodiment the additional compounds are added to improve the mechanical, chemical, thermal, transport or electrical properties of the membrane specific for the application it is being used. The addition compounds can also be added to improve the production of the membrane by reducing processing difficulties, permitting forms that cannot be obtained with the intercalation material, and by reducing the cost of producing the intercalation membrane.

[0052] In one embodiment, the intercalation membrane is between 10 and 5000 microns thick, or more preferably between 10 and 200 microns thick, or even more preferably the membrane is between 50 and 100 microns thick. In one embodiment, the membrane is in planar form as a rectangle, disk, or other planar geometries that conform to the electrochemical cell design. In other embodiment, the membrane is in the form of a cylinder or cube. The geometry of the intercalation membrane can thus be modified for electrochemical cells with a variety of configurations. For non-limiting examples the intercalation membrane can be designed to be used in parallel plate electrochemical cells or in tubular electrochemical cells. It should be clear to one skilled in the art, the process and intercalation membrane can be applied in a variety of cell designs.

[0053] In one embodiment the intercalation membrane 3 is fabricated with a support structure. The support can be fabricated out of ceramic, plastic, or other materials chosen specifically for their mechanical and chemical stability. The support structure can be made out of a solid material in a form with void spaces that permits flow, or the support structure can be a porous material. The intercalation membrane can be fabricated in a manner that makes it amendable to be assembled with the support structure after the membrane has been fabricated. In another embodiment the intercalation membrane is formed directly on the support structure for example through the any of the different thin films processing techniques. The intercalation membrane and support structure can be combined at any point of the fabrication process based on the process required to form both components. In another embodiment, the intercalation membrane can be formed such that there are microchannels within the macrostructure of the membrane.

[0054] The anode 1 can comprise of any suitable material that allows oxidation reactions to occur in the anolyte compartment when an electrical field is applied between the anode and cathode. Some non-limiting examples of anode materials include, but are not limited to, platinum, titanium, nickel, cobalt, iron, stainless steel, lead dioxide, metal alloys, combination thereof, and other known or novel anode materials. In one embodiment, the anode may comprise iron-nickel alloys such as KOVAR® or INVAR®. In other embodiments, the anode may comprise carbon based electrodes such as boron doped diamond, glassy carbon and synthetic carbon. Additionally, in some embodiments the anode comprises a dimensionally stable anode (DSA), which may include, but is not limited to, rhenium dioxide and tantalum pentoxide on a titanium substrate.

[0055] The cathode 2 may also be fabricated of any suitable cathode material that allows the reduction reaction to occur without any significant degradation. The cathode may comprise the same or different materials used for the anode. Some non-limiting examples of suitable cathode materials include without limitation, nickel, stainless steel, graphite, and any other suitable cathode materials that is known or novel.

[0056] In one embodiment, the electrodes have a smooth morphology such as a foil or thin film. In another embodiment, the anode and cathode have a high surface area morphology, for examples but not limited to, a foam, grit, or other porous structure. In one embodiment, the anode and cathode have the same morphology, while in another embodiment, electrodes have a different morphology. The distance between the intercalation membrane and the electrodes is optimized for the reactions and cell type. In some embodiments the electrodes are in physical contact with the intercalation membrane, in some cases the electrodes can be formed directly on the membrane.

[0057] In one embodiment the electrolyte medium is gas or steam. In some embodiments the electrolyte medium may be a super critical gas, such as super critical steam or supercritical CO.sub.2. In another embodiment one side of the intercalation membrane is in direct contact with a molten metal such as molten sodium. In another embodiment the electrolyte medium comprises one or more molten salts. Yet in another embodiment the electrolyte medium is an ionic liquid that is liquid between 0-250° C. In some embodiments the electrolyte medium is a conventional solvent compatible with the electrochemical cell components and which is liquid between −25-125° C.

[0058] In one embodiment the anolyte and catholyte medium are the same and are maintained at similar conditions, such as temperature and pressure. Yet in another embodiment the medium of the anolyte and catholyte are different and or the conditions of the electrolytes are different. This is possible because the intercalation membrane isolates the compartments from each other in every way besides the conduction of ions. Thus, the anolyte and catholyte may be separately selected specifically for the reactions that occur in each compartment and/or the solubility of the chemicals required for the specific reactions. It should be clear to one skilled in the art, that the electrolyte composition is application specific. It is a parameter that may be optimized for electrochemical cell reactions, but the electrolyte composition does not enable any particular aspect of the ion transfer across the intercalation membrane.

[0059] The electrolyte medium may comprise a liquid solvent or a mixture of solvents. In one embodiment the mixture contains at least one organic solvent. In another embodiment at least one solvent is water. At least one component of the solvent is a polar solvent and some non-limiting examples include with-out limitation, water, methanol, ethanol, isopropanol, n-propanol, acetone, acetonitrile, dioxane, butanol, DMSO, CS.sub.2, diethyl carbonate, ethylene carbonate, glycerol, and ionic liquids. In some embodiments at least one component of the anolyte is a non-polar solvent for some non-limiting examples are, hexane, cyclohexane, pentadecane, petroleum ethers, and dodecane. The solvent or solvent mixture will depend on the application of the electrochemical cell, solubility of the reactants and products of the electrochemical reaction occurring at the electrodes, physical properties such as melting and boiling point, conductivity, and compatibility with electrodes and intercalation membrane.

[0060] In on embodiment the catholyte and anolyte are comprised of water and a salt of a metal, alkali metal or a rare earth metal. The salt concentration is between 0.1-50% by weight, or more preferably between 5-25% by weight, or most preferably between 7-15% by weight. Another embodiment the anolyte is comprised of waste water, a natural source of water, or another system from which the removal of ions is desired. In such an embodiment the anolyte salt concentration will be determined by the source of the water. In another embodiment the salt concentration of the anolyte is adjusted from the concentration found in the source using specific, non-toxic salts to improve the conductivity of the electrolyte.

[0061] When an electric potential is applied across the electrochemical cell an oxidation reaction occurs at the anode and a reduction reaction occurs at the cathode. One non-limiting examples is the oxidation and reduction of water producing H.sub.3O.sup.+ and O.sub.2 at the anode and H.sub.2 and OH.sup.− at the cathode. As the electrons flow through the external circuit from the oxidation reaction to the reduction reaction, cations are transported from the anode to the cathode to maintain charge balance. In the disclosed invention, the cations travel through the anolyte to the intercalation membrane where they are transferred to the catholyte, after which they travel to the cathode. Using the non-limiting example of splitting water, the cations then combine with the OH.sup.− and form hydroxides.

[0062] Several examples will be given to demonstrate the technical feasibility of using an intercalation membrane to separate the reactions that are occurring at the electrodes of an electrochemical cell. These examples demonstrate the advantage of using a membrane based on intercalation materials over porous polymer membranes, dense ceramic ion conducting membranes and electrochemical transfer walls/junctions. These are given by way of example only, and it is understood that the following examples are not comprehensive or exhaustive of the many types of embodiments of the present invention that can be prepared in accordance with the present invention.

EXAMPLES

[0063] The examples disclosed herein, used an experimental setup which consisted of a micro flow cell similar to the structure shown in FIG. 2, allowing both the anolyte and catholyte to be pumped through the cell while minimizing the distance between the electrodes and the membrane. The membranes used in the examples consisted of 2.54 cm diameter disks less than 1 mm thickness that were housed on scaffolds in the center of the cells. The disks were made by creating a slurry of Cu.sub.2Mo.sub.6S.sub.8 (NIPPON) and BUTVAR® (Eastman) with a 50 vol % ratio of each and casting the slurry using a doctor blade. Following the casting, the slurry was allowed to dry overnight creating polymer composite intercalation membranes. As the scaffold and membrane physically separate the anode and cathode compartments, there was a separate reservoir and temperature controlled hotplate for the anolyte and catholyte. This allowed the chemistry and conditions of each electrolyte to be optimized for the respective electrode reactions. The anode consisted of platinum foil and the cathode consisted of nickel foil, each surface area significantly larger than that of the membrane. A multiple-head peristaltic pump was used to pump both electrolytes into the electrolysis cell. The tubing between the cell, pump, and reservoir was insulated for temperature sensitive electrolytes.

[0064] The anolyte that contained the sulfate salt of the different cations tested, and were made by dissolving at least 10% of the salt into deionized (DI) water. The catholyte was made in the same fashion as the anolyte and inductively coupled plasma (ICP) analysis was used to determine the pre and post electrolysis ion concentrations.

[0065] A power supply was connected and a current density between 10 and 100 mA/cm.sup.2 was applied. During electrolysis, the voltage and current were monitored using a Data Acquisition Unit (Agilent 3490A) controlled by LabVIEW software. The applied current density caused oxidation to occur at the anode (smooth platinum) and reduction to occur at the cathode (nickel), with each electrode having a surface area of 11 cm.sup.2. As the power supply transported electrons from the anode to the cathode, a charge balance was be maintained across the cell by the diffusion of positively charged ions. Given the dense nature of the intercalation membrane, the metallic or alkali earth ions are the only species that can provide this balance.

[0066] The ICP data and the quantity of charged passed during the electrolysis were used to determine the transfer efficiency for the different systems describe in the following examples. Details pertaining to the specific examples will be given below.

Example 1

[0067] An intercalation membrane was used to transfer ions from a first medium to a second medium. Na-ions were transferred from an aqueous solution of sodium sulfate in contact with the anode through an intercalation membrane and to an aqueous solution also containing sodium sulfate. The electrolytes were both made to contain 10 wt % Na.sub.2SO.sub.4 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 110 mA/cm.sup.2 for the duration of the experiment. The current 13, 15 and potential 14, 16 transients of these experiments can be seen in FIGS. 3 and 4. It can be seen in FIG. 4 that during the step test the cell potential increased from 4 to 8 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 110 mA/cm.sup.2 shown in FIG. 3 the cell potential started at 12 V and slowly decreased to 9 V during the 3 h duration of the experiment. Following the experiment the pH of the anolyte was 2 and the pH of the catholyte was 12. These solutions were allowed to cycle in the electrochemical cell for 12 h, after which the pH was measured and found to be unchanged. Comparing the charge transferred according to the number of coulombs passed during the experiment to the change in Na-ion concentration of the anolyte and catholyte, determined by ICP analysis, a Coulombic efficiency of over 90% was obtained.

Example 2

[0068] An intercalation membrane was used to transfer ions from a first medium to a second medium. Li-ions were transferred from an aqueous solution of lithium sulfate in contact with the anode through an intercalation membrane and to an aqueous solution also containing lithium sulfate. The electrolytes were both made to contain 10 wt % Li.sub.2SO.sub.4 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 110 mA/cm.sup.2 for the duration of the experiment. The current 17, 19 and potential 18, 20 transients of these experiments can be seen in FIGS. 5 and 6. It can be seen in FIG. 6 that during the step test the cell potential increased from 2 to 15 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 110 mA/cm.sup.2 shown in FIG. 5 the cell potential started at 10 V and slowly decreased to 8 V during the 4 h duration of the experiment. Comparing the charge transferred according to the number of coulombs passed during the experiment to the change in Li-ion concentration of the anolyte and catholyte, determined by ICP analysis, a Coulombic efficiency of over 92% was obtained.

Example 3

[0069] An intercalation membrane was used to transfer ions from a first medium to a second medium. Mg-ions were transferred from an aqueous solution of magnesium sulfate in contact with the anode through an intercalation membrane and to an aqueous solution also containing magnesium sulfate. The electrolytes were both made to contain 10 wt % MgSO.sub.4 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 110 mA/cm.sup.2 for the duration of the experiment. The current 21, 23 and potential 22, 24 transients of these experiments can be seen in FIGS. 7 and 8. It can be seen in FIG. 8 that during the step test the cell potential increased from 3 to 18 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 110 mA/cm.sup.2 shown in FIG. 7 the cell potential started at 12 V and slowly decreased to 8 V during the 4 h duration of the experiment. Comparing the charge transferred according to the number of coulombs passed during the experiment to the change in Mg-ion concentration of the anolyte and catholyte, determined by ICP analysis, a Coulombic efficiency of over 91% was obtained.

Example 4

[0070] An intercalation membrane was used to transfer ions from a first medium to a second medium. K-ions were transferred from an aqueous solution of potassium sulfate in contact with the anode through an intercalation membrane and to an aqueous solution also containing potassium sulfate. The electrolytes were both made to contain 10 wt % K.sub.2SO.sub.4 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 110 mA/cm.sup.2 for the duration of the experiment. The current 25, 27 and potential 26, 28 transients of these experiments can be seen in FIGS. 9 and 10. It can be seen in FIG. 10 that during the step test the cell potential increased from 4 to 15 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 110 mA/cm.sup.2 shown in FIG. 9 the cell potential started at 9 V and slowly decreased to 5.5 V during the 4 h duration of the experiment. Comparing the charge transferred according to the number of coulombs passed during the experiment to the change in K-ion concentration of the anolyte and catholyte, determined by ICP analysis, a Coulombic efficiency of over 98% was obtained.

Example 5

[0071] An intercalation membrane was used to transfer ions from a first medium to a second medium. Zn-ions were transferred from an aqueous solution of zinc nitrate in contact with the anode through an intercalation membrane and to an aqueous solution also containing zinc nitrate. The electrolytes were both made to contain 10 wt % Zn(NO.sub.3).sub.2 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 35 mA/cm.sup.2 for the duration of the experiment. The current 29, 31 and potential 30, 32 transients of these experiments can be seen in FIGS. 11 and 12. It can be seen in FIG. 12 that during the step test the cell potential increased from 2 to 20 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 35 mA/cm.sup.2 shown in FIG. 11 the cell potential started at 20 V and slowly decreased to 15 V during the 1.5 h duration of the experiment. Comparing the charge transferred according to the number of coulombs passed during the experiment to the change in Zn-ion concentration of the anolyte and catholyte, determined by ICP analysis, a Coulombic efficiency of over 80% was obtained.

Example 6

[0072] An intercalation membrane was used to transfer ions from a first medium to a second medium. Pb-ions were transferred from an aqueous solution of lead nitrate in contact with the anode through an intercalation membrane and to an aqueous solution also containing lead nitrate. The electrolytes were both made to contain 10 wt % Pb(NO.sub.3).sub.2 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 35 mA/cm.sup.2 for the duration of the experiment. The current 33, 35 and potential 34, 36 transients of these experiments can be seen in FIGS. 13 and 14. It can be seen in FIG. 14 that during the step test the cell potential increased from 3 to 10 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 35 mA/cm.sup.2 shown in FIG. 13 the cell potential started at 6 V and maintained this potential during the 2 h duration of the experiment.

Example 7

[0073] An intercalation membrane was used to transfer ions from a first medium to a second medium. Ce-ions were transferred from an aqueous solution of cerium nitrate in contact with the anode through an intercalation membrane and to an aqueous solution also containing cerium nitrate. The electrolytes were both made to contain 10 wt % Ce(NO.sub.3).sub.3 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 35 mA/cm.sup.2 for the duration of the experiment. The current 37, 39 and potential 38, 40 transients of these experiments can be seen in FIGS. 15 and 16. It can be seen in FIG. 16 that during the step test the cell potential increased from 2 to 22 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 35 mA/cm.sup.2 shown in FIG. 15 the cell potential started at 9 V and dramatically increased to 30V during the 18 min of the experiment.

Example 8

[0074] An intercalation membrane was used to transfer ions from a first medium to a second medium. Y-ions were transferred from an aqueous solution of yttrium nitrate in contact with the anode through an intercalation membrane and to an aqueous solution also containing yttrium nitrate. The electrolytes were both made to contain 10 wt % Y(NO.sub.3).sub.3 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 35 mA/cm.sup.2 for the duration of the experiment. The current 41, 43 and potential 42, 44 transients of these experiments can be seen in FIGS. 17 and 18. It can be seen in FIG. 18 that during the step test the cell potential increased from 3 to 26 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 35 mA/cm.sup.2 shown in FIG. 17 the cell potential started at 6 V and slowly decreased to 27 V during the 45 min duration of the experiment.

Example 9

[0075] An intercalation membrane was used to transfer ions from a first medium to a second medium. Both Na-ions and K-ions were transferred from an aqueous solution of sodium and potassium sulfate in contact with the anode through an intercalation membrane and to an aqueous solution also containing sodium and potassium sulfate. The electrolytes were both made to contain 10 wt % Na.sub.2SO.sub.4 and K.sub.2SO.sub.4 making an aqueous solution with a pH between 9 and 10. The temperature of the electrolytes was unchanged, remaining at room temperature for the duration of the experiments. Two different experiments were conducted with the system. The first consisted of a current density step experiment, where the current density was stepped up starting at 0.5 mA/cm.sup.2 to 250 mA/cm.sup.2 holding each step for 60 s. The second experiment was a bulk electrolysis experiment, in which the current density was maintained at 110 mA/cm.sup.2 for the duration of the experiment. The current 45, 47 and potential 46, 48 transients of these experiments can be seen in FIGS. 19 and 20. It can be seen in FIG. 20 that during the step test the cell potential increased from 2 to 14 V as the current density was increased from 0.5 to 250 mA/cm.sup.2. During the bulk electrolysis at 110 mA/cm.sup.2 shown in FIG. 19 the cell potential started at 10 V and slowly decreased to 8 V during the 3 h duration of the experiment. Comparing the charge transferred according to the number of coulombs passed during the experiment to the change in Na-ion concentration and K-ion concentration of the anolyte and catholyte, determined by ICP analysis, a Coulombic efficiency of over 90% was obtained for the sodium and 90% for the potassium.

[0076] While specific embodiments and examples of the present invention have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims.