Integrally combined current carrier circulation chamber and frame for use in unipolar electrochemical devices
11814741 · 2023-11-14
Assignee
Inventors
- ANDREW T. B. STUART (RAVENNA, CA)
- RAYNALD G. LACHANCE (LEVIS, CA)
- EDWARD D. B. STUART (RAVENNA, CA)
- Samantha E. L. Stuart (Toronto, CA)
- JAIDEEP S. SPAL (BRAMPTON, CA)
Cpc classification
C25B9/65
CHEMISTRY; METALLURGY
C25B1/34
CHEMISTRY; METALLURGY
Y02E60/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E60/36
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
C25B15/08
CHEMISTRY; METALLURGY
International classification
C25B1/34
CHEMISTRY; METALLURGY
C25B9/65
CHEMISTRY; METALLURGY
Abstract
Disclosed is an integrally combined electrical current carrier, circulation chamber and frame (CCF) formed as a single or double part (CCF) for use in unipolar electrochemical devices, such as a filter press electrolyser apparatus. The CCF is structured to define an internal circulation chamber for circulation of electrolyte, products, and reactants as well as apertures which form flow passageways when the filter press device is assembled. Affixed on opposed surfaces of the CCFs are electrically conductive planar electroactive structures which are in electrical contact with the CCF. The circulation chamber is formed by the depth of the CCF itself between opposing electroactive structures. Multiple CCFs are assembled and compressed together to form the filter press electrolyser apparatus. The flow passageway apertures within the assembled filter press electrolyser are aligned to form flow pathways, located above and below the circulation chambers. Reactants and electrolyte are input along the bottom flow pathways. When power is applied to the CCFs and electroactive structures, the reactants, once they flow into the circulation chamber with the electrolyte, undergo redox reactions to produce the products which are then collected and exit the electrolyser in the upper flow pathways.
Claims
1. A combined electrically conductive current carrier, circulation chamber, and rigid support frame for use in a unipolar electrochemical apparatus, comprising: a one-piece, integrally formed, rigid support frame configured to support a pair of opposed, spaced apart, electroactive structures disposed in a unipolar arrangement, the rigid support frame being electrically conductive and capable of carrying current to the pair of electroactive structures, the rigid support frame having: first and second opposed faces defining a thickness of the rigid support frame sufficient to accommodate a circulation chamber extending therebetween, spaced apart opposed first and second side arms and first and second lateral cross members extending between the first and second side arms, one of the first and second side arms is configured to receive power from a power source; a first inner frame member attached to at least one of the second and first side arms and the second lateral cross member, the first inner frame member cooperating with the at least one of the second and first side arms and the second lateral cross member to define a first channel defining aperture; a second channel defining aperture disposed near the second lateral cross member and between the first and second side arms; a second inner frame member attached to at least one of the first and second side arms and the first lateral cross member, the second inner frame member cooperating with the at least one of the first and second side arms and the first lateral cross member to define a third channel defining aperture; a fourth channel defining aperture disposed near the first lateral cross member and between the first and second side arms; a circulation chamber integrally formed within the rigid support frame for the circulation of electrolyte, products, and reactants, the circulation chamber extending between the first and second faces of the rigid support frame, the first and second inner frame members and inner edges of the first and second side arms, one or more intermediate lateral cross members extending between the first and second side arms, the one or more intermediate lateral cross members being in physical and electrical contact with the first and second side arms and being releasably detachable from the first and second side arms; the pair of electroactive structures comprising a first electroactive structure and a second electroactive structure, the first electroactive structure affixed to the rigid support frame adjacent to the first face thereof, the first electroactive structure extending between the first and second inner frame members and the first and second side arms, the second electroactive structure affixed to the rigid support frame adjacent to the second face thereof, the second electroactive structure extending between the first and second inner frame members and the first and second side arms, each electroactive structure having apertures formed therein to allow liquid and gases to pass through the electroactive structure from one side to the other; when the combined current carrier, circulation chamber, and rigid support frame is operatively connected to the unipolar electrochemical apparatus and power is applied, the first and second electroactive structures are of the same polarity.
2. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, wherein: the first inner frame member is a first generally L-shaped member having first and second arm portions joined to each other; the first arm portion of the first generally L-shaped member being attached to one of the second and first side arms and the second arm portion of the first generally L-shaped member being attached to the second lateral cross member; the second inner frame is a second generally L-shaped member having first and second arms portions joined to each other; the first arm portion of the second generally L-shaped member being attached to one of the first and second side arms and the second arm portion of the second generally L-shaped member being attached to the first lateral cross member; the circulation chamber extends between the first and second faces of the rigid support frame, the first arm portions of the first and second generally L-shaped members and inner edges of the first and second side arms.
3. The combined current carrier, circulation chamber, and rigid support frame according to claim 2, wherein: the first arm portion of the first generally L-shaped member is attached to the second side arm; and the first arm portion of the second generally L-shaped member is attached to the first side arm.
4. The combined current carrier, circulation chamber, and rigid support frame according to claim 2, wherein: the first arm portion of the first generally L-shaped member is attached to the first side arm; and the first arm portion of the second generally L-shaped member is attached to the first side arm.
5. The combined current carrier, circulation chamber, and rigid support frame according to claim 2, further comprising: the first electroactive structure extending between the first arm portions of the first and second generally L-shaped members and the first and second side arms; and the second electroactive structure extending between the first arm portions of the first and second generally L-shaped members and the first and second side arms.
6. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, wherein the one or more intermediate lateral cross members each have opposed ends shaped and configured to be insertable into complementary shaped and configured receptacles in the first and second side arms.
7. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, wherein the one or more intermediate lateral cross members each having a thickness that is substantially the same as the thickness of the rigid support frame.
8. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, wherein the one or more intermediate lateral cross members are configured to allow electrolytes, products and reactants to pass between the one or more intermediate lateral cross members and one of the electroactive structures, when the combined current carrier, circulation chamber, and rigid support frame is operational within the unipolar electrochemical apparatus.
9. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, wherein each electroactive structure is a structure selected from the group consisting of: (a) a plate provided with any of slots and holes; (b) an expanded metal screen structure; and (c) a woven mesh structure.
10. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, further comprising one or more recesses in each of the first and second side arms around the circulation chamber to allow the electroactive structures to be positioned at least partially within the depth of the circulation chamber.
11. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, wherein portions of the first and second faces are recessed along margins of the first and second side arms adjacent the circulation chamber to allow the pair of electroactive structures to be positioned at least partially within the circulation chamber.
12. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, the one of the first and second side arms having electrically conductive tabs extending outwardly from said side arm to which electrical power conductors are attachable.
13. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, the one of the first and second side arms having holes defined in one of the first and second side arms for hosting an external electrical connection mechanism.
14. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, wherein the rigid support frame has a generally rectangular shape, a height and a width; the height of the rigid support frame being greater than the width thereof.
15. The combined current carrier, circulation chamber, and rigid support frame according to claim 1, further comprising a plurality of tie rod holes defined in at least one of the first and second side arms, the tie rod holes of the plurality configured to receive therethrough tie rods therethrough to facilitate alignment of the rigid support frame with other rigid support frames in the unipolar electrochemical apparatus.
16. An electrochemical cell for a unipolar filter press electrolyser apparatus, the electrochemical cell comprising: a plurality of combined current carrier, circulation chamber, and rigid support frames arranged to form a stack of rigid support frames of alternating polarity and being aligned such that the channel defining apertures in each rigid support frame of the plurality align with each other; the plurality of rigid support frames including: a pair of end rigid support frames, one end rigid support frame being disposed at one end of the stack and the other end rigid support frame being disposed at the other end of the stack; each end rigid support frame having at least one electroactive structure affixed thereto adjacent one of its first and second faces, the at least one electroactive structure being disposed to face the opposite end of the stack; at least one intermediate rigid support frame according to claim 1 being disposed between the pair of end rigid support frames; a plurality of separators, each separator being mounted between a pair of adjacent rigid support frames to separate the circulation chamber of one of the adjacent rigid support frames from the circulation chamber of the other of the adjacent rigid support frames; a plurality of sealing and electrically insulating gaskets having substantially the same configuration as that of the plurality of rigid support frames, each sealing and electrically insulating gasket having defined therein channel defining apertures; and a plurality of masking frames, each masking frame being placed in the channel defining aperture defined in one of the sealing and electrically insulating gaskets or in one of the rigid support frames; the channel defining apertures in each of the rigid support frames and first and second apertures in the gaskets being aligned with each other to form flow passageways through the stack.
17. The electrochemical cell according to claim 16 wherein each end rigid support frame has two electroactive structures with one electroactive structure being affixed to the end rigid support frame adjacent to its first face and the other electroactive structure being affixed to the end rigid support frame adjacent to its second face.
18. The electrochemical cell according to claim 16, wherein: the first inner frame member of the at least one intermediate rigid support frame is a first generally L-shaped member having first and second arm portions joined to each other; the first arm portion of the first generally L-shaped member being attached to the second side arm and the second arm portion of the first generally L-shaped member being attached to the second lateral cross member; the second inner frame of the at least one intermediate rigid support frame is a second generally L-shaped member having first and second arms portions joined to each other; the first arm portion of the second generally L-shaped member being attached to the first side arm and the second arm portion of the second generally L-shaped member being attached to the first lateral cross member; the circulation chamber of the at least one intermediate rigid support frame extends between the first and second faces of the at least one intermediate rigid support frame, the first arm portions of the first and second generally L-shaped members associated with the at least one intermediate rigid support frame and inner edges of the first and second side arms of the at least one intermediate rigid support frame.
19. The electrochemical cell according to claim 16, wherein the one or more intermediate lateral cross members each have opposed ends shaped and configured to be insertable into complementary shaped and configured receptacles in the first and second side arms of the at least one intermediate support frames.
20. The electrochemical cell according to claim 16, wherein the one or more intermediate lateral cross members each having a thickness that is substantially the same as the thickness of the at least one intermediate rigid support frame associated therewith.
21. The electrochemical cell according to claim 16, wherein the one or more intermediate lateral cross members are configured to allow electrolytes, products and reactants to pass between the one or more intermediate lateral cross members and one of the electroactive structures, when the electrochemical cell is operational.
22. The electrochemical cell according to claim 16, wherein each electroactive structure is a structure selected from the group consisting of: (a) a plate provided with any of slots and holes; (b) an expanded metal screen structure; and (c) a woven mesh structure.
23. The electrochemical cell according to claim 16, wherein the at least one intermediate rigid support frame has one or more recesses in each of the first and second side arms around the circulation chamber to allow the electroactive structures associated with the at least one intermediate rigid support frame to be positioned at least partially within the depth of the circulation chamber.
24. The electrochemical cell according to claim 16, wherein the at least one intermediate rigid support frame has portions of the first and second faces that are recessed along margins of the first and second side arms adjacent the circulation chamber to allow the pair of electroactive structures to be positioned at least partially within the circulation chamber.
25. The electrochemical cell according to claim 16, wherein one of the first and second side arms of the at least one intermediate support frame has electrically conductive tabs extending outwardly from said side arm to which electrical power conductors are attachable.
26. The electrochemical cell according to claim 16, wherein one of the first and second side arms of the at least one intermediate support frame has holes defined in one of the first and second side arms for hosting an external electrical connection mechanism.
27. The electrochemical cell according to claim 16, wherein each rigid support frame of the plurality has a generally rectangular shape, a height and a width; the height of each rigid support frame being greater than the width thereof.
28. The electrochemical cell according to claim 16, wherein the at least one intermediate rigid support frame includes a plurality of tie rod holes defined in at least one of the first and second side arms of each of the at least one intermediate rigid support frames, the plurality of tie rod holes configured to receive therethrough tie rods therethrough to facilitate alignment of the at least one intermediate rigid support frame with other rigid support frames in the electrochemical cell.
29. A unipolar filter press electrolyser apparatus, comprising: a plurality of combined current carrier, circulation chamber, and rigid support frames arranged to form a stack of rigid support frames of alternating polarity and being aligned such that the channel defining apertures in each rigid support frame of the plurality align with each other; the plurality of rigid support frames including: a pair of end rigid support frames, one end rigid support frame being disposed at one end of the stack and the other end rigid support frame being disposed at the other end of the stack; each end rigid support frame having at least one electroactive structure affixed thereto adjacent one of its first and second faces, the at least one electroactive structure being disposed to face the opposite end of the stack; at least one intermediate rigid support frame according to claim 1 being disposed between the pair of end rigid support frame; a plurality of separators, each separator being mounted between a pair of adjacent rigid support frames to separate the circulation chamber of one of the adjacent rigid support frames from the circulation chamber of the other of the adjacent rigid support frames; a plurality of sealing and electrically insulating gaskets having substantially the same configuration as that of the plurality of rigid support frames, each sealing and electrically insulating gasket having defined therein channel defining apertures; a plurality of masking frames, each masking frame being placed in one of the channel defining aperture defined in one of the sealing and electrically insulating gaskets, the intermediate rigid support frame and the end rigid support frames; a pair of end clamping plates for clamping the plurality of end rigid support frames and the intermediate rigid support frame together, each end clamping plate being associated with and disposed adjacent to one of the end rigid support frames, each end clamping plate including a first port for feeding liquids and/or gases into the stack and a second port for extracting liquids and/or gases from the stack; a pair of gaskets, each gasket located between each end clamping plate and its associated end rigid frame for insulating each end clamping plate from its associated end rigid support frame, each gasket including first and second apertures defined therein to align with the first and second ports in each end clamping plate; and the channel defining apertures in each of the rigid support frame and first and second apertures in the gaskets being aligned with each other to form flow passageways through the stack, the flow passageways being aligned with the first and second ports in each end clamping plate.
30. The unipolar filter press electrolyser apparatus according to claim 29, wherein the unipolar filter press electrolyser apparatus is configured for one of alkaline water electrolysis and chlor-alkali electrolysis.
31. The unipolar filter press electrolyser apparatus according to claim 29, wherein each end rigid support frame has two electroactive structures with one electroactive structure being affixed to the end rigid support frame adjacent to its first face and the other electroactive structure being affixed to the end rigid support frame adjacent to its second face.
32. The unipolar filter press electrolyser apparatus according to claim 29, wherein: the first inner frame member of the at least one intermediate rigid support frame is a first generally L-shaped member having first and second arm portions joined to each other; the first arm portion of the first generally L-shaped member being attached to the second side arm and the second arm portion of the first generally L-shaped member being attached to the second lateral cross member; the second inner frame of the at least one intermediate rigid support frame is a second generally L-shaped member having first and second arms portions joined to each other; the first arm portion of the second generally L-shaped member being attached to the first side arm and the second arm portion of the second generally L-shaped member being attached to the first lateral cross member; the circulation chamber of the at least one intermediate rigid support frame extends between the first and second faces of the at least one intermediate rigid support frame, the first arm portions of the first and second generally L-shaped members associated with the at least one intermediate rigid support frame and inner edges of the first and second side arms of the at least one intermediate rigid support frames.
33. The unipolar filter press electrolyser apparatus according to claim 29, wherein the one or more intermediate lateral cross members each have opposed ends shaped and configured to be insertable into complementary shaped and configured receptacles in the first and second side arms of the at least one intermediate rigid support frames.
34. The unipolar filter press electrolyser apparatus according to claim 29, wherein the one or more intermediate lateral cross members each having a thickness that is substantially the same as the thickness of the at least one intermediate rigid support frame associated therewith.
35. The unipolar filter press electrolyser apparatus according to claim 29, wherein the one or more intermediate lateral cross members are configured to allow electrolytes, products and reactants to pass between the one or more intermediate lateral cross members and one of the electroactive structures, when the unipolar filter press electrolyser apparatus is operational.
36. The unipolar filter press electrolyser apparatus according to claim 29, wherein each electroactive structure is a structure selected from the group consisting of: (a) a plate provided with any of slots and holes; (b) an expanded metal screen structure; and (c) a woven mesh structure.
37. The unipolar filter press electrolyser apparatus according to claim 29, wherein the at least one intermediate rigid support frame has one or more recesses in each of the first and second side arms around the circulation chamber to allow the electroactive structures associated with the at least one intermediate rigid support frame to be positioned at least partially within the depth of the circulation chamber.
38. The unipolar filter press electrolyser apparatus according to claim 29, wherein the at least one intermediate rigid support frame has portions of the first and second faces that are recessed along margins of the first and second side arms adjacent the circulation chamber to allow the pair of electroactive structures to be positioned at least partially within the circulation chamber.
39. The unipolar filter press electrolyser apparatus according to claim 29, wherein one of the first and second side arms of the at least one intermediate support frame has electrically conductive tabs extending outwardly from said side arm to which electrical power conductors are attachable.
40. The unipolar filter press electrolyser apparatus according to claim 29, wherein one of the first and second side arms of the at least one intermediate support frame has holes defined in one of the first and second side arms for hosting an external electrical connection mechanism.
41. The unipolar filter press electrolyser apparatus according to claim 29, wherein each rigid support frame of the plurality has a generally rectangular shape, a height and a width; the height of each rigid support frame being greater than the width thereof.
42. The unipolar filter press electrolyser apparatus according to claim 29, wherein the at least one intermediate rigid support frame includes a plurality of tie rod holes defined in at least one of the first and second side arms of each of the at least one intermediate rigid support frames, the plurality of tie rod holes configured to receive therethrough tie rods therethrough to facilitate alignment of the at least one intermediate rigid support frame with other rigid support frames in the unipolar filter press electrolyser apparatus.
43. A unipolar filter press electrolyser apparatus, comprising: a plurality of combined current carrier, circulation chamber, and rigid support frames according to claim 1 arranged to form a stack of rigid support frames of alternating polarity and being aligned such that the channel defining apertures in each rigid support frame of the plurality align with each other, the plurality of rigid support frames including: a pair of end rigid support frame, one end rigid support frame being disposed at one end of the stack and the other end rigid support frame being disposed at the other end of the stack; each end rigid support frame having at least one electroactive structure affixed thereto adjacent one of its first and second faces, the at least one electroactive structure being disposed to face the opposite end of the stack; at least one intermediate rigid support frame being disposed between the pair of end rigid support frames; a plurality of separators, each separator being mounted between a pair of adjacent rigid support frames to separate the circulation chamber of one of the adjacent rigid support frames from the circulation chamber of the other of the adjacent rigid support frames; a plurality of sealing and electrically insulating gaskets having substantially the same configuration as that of the plurality of rigid support frames, each sealing and electrically insulating gasket having defined therein channel defining apertures; a plurality of masking frames, each masking frame being placed in one of the channel defining aperture defined in one of the sealing and electrically insulating gaskets, the intermediate rigid support frame and the end rigid support frames; a pair of end clamping plates for clamping the plurality of end rigid support frames and the intermediate rigid support frame together, each end clamping plate being associated with and disposed adjacent to one of the end rigid support frames, each end clamping plate including a first port for feeding liquids and/or gases into the stack and a second port for extracting liquids and/or gases from the stack; a pair of gaskets, each gasket located between each end clamping plate and its associated end rigid support frames for insulating each end clamping plate from its associated end rigid support frames, each gasket including first and second apertures defined therein to align with the first and second ports in each end clamping plate; and the channel defining apertures in each of the rigid support frames and first and second apertures in the gaskets being aligned with each other to form flow passageways through the stack, the flow passageways being aligned with the first and second ports in each end clamping plate and being configured to accommodate the flow of gases and/or liquids to and from the circulation chamber of each rigid support frame via the channel defining gasket support member associated with each rigid support frame.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1) Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:
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DETAILED DESCRIPTION
(39) Various embodiments and aspects of the disclosure will be described with reference to details discussed below. The following description and drawings are illustrative of the disclosure and are not to be construed as limiting the disclosure. The figures are not to scale. Numerous specific details are described to provide a thorough understanding of various embodiments of the present disclosure. However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present disclosure.
(40) As used herein, the terms, “comprises” and “comprising” are to be construed as being inclusive and open ended, and not exclusive. Specifically, when used in the specification and claims, the terms “comprises” and “comprising” and variations thereof mean the specified features, steps or components are included. These terms are not to be interpreted to exclude the presence of other features, steps or components.
(41) As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not be construed as preferred or advantageous over other configurations disclosed herein.
(42) As used herein, the terms “about” and “approximately” are meant to cover variations that may exist in the upper and lower limits of the ranges of values, such as variations in properties, parameters, and dimensions. In one non-limiting example, the terms “about” and “approximately” mean plus or minus 10 percent or less.
(43) As used herein, the terms “generally” and “essentially” are meant to refer to the general overall physical and geometric appearance of a feature and should not be construed as preferred or advantageous over other configurations disclosed herein.
(44) As used herein, the terms “stack” or “filter press stack” or “filter press” is meant to refer to, but not exclusively, the general configuration of the assembled unipolar electrochemical device in a filter press configuration.
(45) As used herein, the phrase “electroactive structures” or “electroactive surfaces” refers to conductive screens, expanded metal and perforated plates, essentially flat and thin in shape which may or may not be coated with a catalyst, depending on the electroactive material and electrochemical reaction it is intended for in the particular stack.
(46) As used herein, the phrase “sealing profile” refers to the profile along the longitudinal axis of a filter press electrolyser, defined by the outer boundaries of all components within said filter press electrolyser which serve a function of forming an external seal that prevents fluids leaking from the interior of the filter press to the external atmosphere, said components including but not limited to gasketing and masking components.
(47) As used herein, the phrase “generally L-shaped” includes shapes that are not strictly “L-shaped.” For example, a “generally L-shaped” member may be formed as a passageway defining structure, such that adjacent passageways are formed complementary to each other in a filter press stack.
PARTS LIST
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(52) All of the unipolar electrochemical device embodiments presented in this disclosure (for example 10 in
(53) In alkaline water electrolysis, (whose reactions are well known to those skilled in the art), the starting electrolyte is comprised of a highly basic sodium hydroxide or potassium hydroxide solution. The anode product created is oxygen gas, and the cathode product created is hydrogen gas. Catholyte and any additional reactants required are fed into the cathodic end of the filter press stack, and anolyte and any additional reactants required are fed into the anodic end of the stack such that target concentrations are achieved.
(54) In chlorine electrolysis, the starting electrolyte is comprised of sodium chloride in water, referred to as “brine.” The anode product is gaseous chlorine, and the cathode products are hydrogen gas and sodium hydroxide. In sodium chlorate production processes, chlorine electrolysis is completed without a separator (i.e. embodiments identical to those presented herein however without a separator 28 as described later), such that the chlorine and sodium hydroxide are not separated. When chlorine and sodium hydroxide are not separated (referred to as “sodium chlorate electrolysis”) the chlorine anode product reacts with the sodium hydroxide cathode products giving sodium hypochlorite (NaOCl) which gets removed and reacted to produce sodium chlorate NaClO.sub.3.
(55) When a separator is applied in a chlorine cell (referred to as the “chlor alkali process”) and said separator is often provided as a cation-exchange membrane, this cation exchange membrane separates the anolyte and catholyte. Brine is fed into the anode plate, and sodium ions and water molecules migrate through the membrane into the catholyte. Chloride ions are prevented from moving into the catholyte by the membrane. The anode product is still gaseous chlorine, and the cathode products are still hydrogen gas and sodium hydroxide. A separator diaphragm may be applied in place of a membrane in older chlorine cells, where the anolyte is physically separated from the catholyte through a mass-transport process rather than an ion-transport process, and there is a bulk flow of anolyte through the diaphragm to the catholyte.
(56) In membrane chlorine electrolysis processes, brine that has been reduced in concentration (“depleted brine”) is removed from the anode plate, resaturated with salt to ensure the required salt concentration is maintained, and fed back into the cell. At the cathode, water is electrolyzed to form hydrogen and hydroxyl ions to form caustic soda when combined with sodium ions. Gas liquid separation of products and the recirculation and resaturation of anolyte can be achieved outside of the electrolytic cell, or inside the electrolytic cell depending on the constraints of the cell design and application. The chlor alkali process and the sodium chlorate production process are well known to those skilled in the art of electrolysis, as their chemical products (chlorine, hydrogen, caustic soda) are sold into a wide array of chemical industries to create well known products such as bleach (made from chlorine), hydrochloric acid, and hydrogen peroxide (made from hydrogen).
(57) The growing momentum of the Hydrogen Economy in recent years further reinforces the need for scalable economic industrial electrolysis processes such as alkaline water electrolysis to be applied in the production of hydrogen for both traditional and emerging applications. The unipolar electrochemical devices presented herein are particularly preferred when applied to large scale alkaline water electrolysis.
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(59) An important clarification to make in describing unipolar filter press stacks based on CCF technology is the definition of a single electrochemical cell. The unipolar filter press stack 10 (and 410 described later) each represent one (1) electrochemical cell, configured electrically in parallel. To increase the surface area for product generation within one unipolar electrochemical cell, additional anodic and cathodic CCFs are simply added to the filter press stack longitudinally. All cathodic CCFs provided are connected externally in parallel, and similarly all anodic CCFs provided are connected externally in parallel. Even after the provision of additional CCFs longitudinally within a unipolar filter press stack, the stack remains as one electrochemical cell, now with increased surface area per cell.
(60) This contrasts the analogous situation in bipolar filter presses which are configured electrically in series. In bipolar filter presses, with each longitudinal addition of a bipolar electrode assembly (such as that shown in
(61) Increasing the surface area per electrochemical cell is highly desired in the field of large-scale alkaline water electrolysis, so to increase the product output and overall efficiency of an electrolyser design. With increases in surface area per electrochemical cell, greater amperage per cell is enabled, consequently allowing greater hydrogen product generation according to the well-known Faraday's Law of Electrolysis. This makes unipolar filter press technology based on CCF's particularly desirable for the application of large-scale alkaline water electrolysis where large increases in surface area per electrochemical cell are required to efficiently scale product generation.
(62) Unipolar filter press assemblies wherein two unipolar filter press stacks (creating proportionally two electrochemical cells) are provided within the same filter press assembly (310 and 510) are described later. Such filter press assemblies as 310 and 510 can also be scaled longitudinally by providing additional CCF's within each filter press stack to increase surface area per cell, as described later and shown in
(63) The features of the unipolar filter press stack 10 shown in
(64) Within the stack 10, two unipolar positive and two monopolar negative electrochemical reaction regions are electrically configured in parallel, creating a total of four electrochemically active regions. For ease of comprehension but not limiting other possibilities, CCF 20 described further below is construed as being of positive polarity and CCF's 21 are construed as being of negative polarity. Unipolar CCF 20 provides two electrochemical reaction regions of the same polarity (as defined in
(65) The negative electrochemical reaction regions are localized between the electroactive surface of structure 26 (negative) of monopolar CCFs 21 and the separators 28, all as shown adjacent to end gaskets 14. Electrically in parallel to both negative electrochemical reaction regions, two positive electrochemical reaction regions are localized at unipolar CCF 20, as defined by the two electroactive structures 102 (positive) of unipolar CCF 20.
(66) A conductive chamber for product circulation (“circulation chamber”) 103 within each electrochemical reaction region is provided by the thickness (“depth”) of CCFs 20 and 21 themselves, the depth being indicated in
(67) For ease of comprehension, the assembly in
(68) As well, those familiar with the electrochemical domain will understand that monopolar CCF 21 as illustrated in
(69) Those skilled in the design of electrolysers will further comprehend that the terminal (or “end-most”) monopolar CCFs 21 shown in
(70) For ease of comprehension, the parts that must be employed to incorporate more CCFs longitudinally in the filter press assembly of 10 are described below.
(71) In one embodiment, a unipolar CCF 21 could be substituted to the second monopolar CCF 21 illustrated in
(72) To scale this assembly further, insertions in the 10's or 100's of alternating unipolar CCFs 21 (negative) and 20 (positive) and their corresponding non-limiting masks (22, 24), gaskets 30, and separators 28 may be inserted into the stack centre before the terminal monopolar CCF 21. The quantity of electrochemically active regions (surface area) within a singular unipolar filter press stack will scale with the addition of each CCF, overall providing a proportionally scaled single unipolar cell within a filter press assembly, electrically configured in parallel.
(73) The electrolyser device embodiment 10 in
(74) In this disclosure,
(75) To help in the comprehension of the functional arrangement of the assembled electrolyser 10, the parts of which are shown detached in
(76) While all these parts are shown separated from each other, in the assembled unipolar filter press electrolyser 10 the two (2) electroactive structures 102 located on either side of CCF 20 are electrically connected to either side of CCF 20. The electroactive structures 26 adjacent to the two outer CCF's 21 are similarly connected to their respective CCF.
(77) As discussed, electrolyser 10 includes two preferably rigid end clamping plates 12 and 34. First and second full faced gaskets 14 each have two (2) apertures extending therethrough at diagonal corners of the gasket. First gasket 14 is “sandwiched” between end clamping plate 12 and first monopolar CCF 21. Second gasket 14 is sandwiched between end clamping plate 34 and second monopolar CCF 21. The apertures in first gasket 14 (apertures 110 and 111) align with the ports in end clamping plate 12 (49 and 59). Similarly, the apertures in second gasket 14 (apertures 94 and 109) align with the ports in end clamping plate 34 (48 and 57). Gaskets 14 are additionally in alignment with channel defining pathways for product and reactants in the respective CCFs 21, to be described later.
(78) The pathways for products and reactants, or transfer channels 116, 117, 118, 119 are better visualized when described as explained below.
(79) Reading from right to left on
(80) Similarly, reading from right to left on
(81) Reading from left to right on
(82) Reading from left to right on
(83) The height of the apertures that define product transfer passageways 116, 117, 118, and 119 (along with the product transfer passageways of any of the other electrolyser embodiments described herein) may be further adjusted as required by the underlying electrochemical process, and application of the filter press stack.
(84) Moving left to right in
(85) First gasket 30 is positioned against the right hand face of CCF 21 followed by first electroactive structure 102 on the left hand face of CCF 20. A second electroactive structure 102 on the right hand face of CCF 20, a second separator 28, and second set of channel defining gasket support pieces 56 to complete apertures 52 and 80 in first CCF 20, follow. The second set of channel defining gasket support pieces 56 support the structural integrity of the corresponding apertures 106 and 107 in second gasket 30 when the system is clamped, such that transfer channels 116 and 117 are reinforced and products and reactants are controlled within their corresponding transfer channel. Gasket support pieces 56 further control product and reactant passage into and out of apertures 52 and 80 in second CCF 20 through the provision of channels of a defined size. A second set of masking frames 22 and 24 is inserted within corresponding channel defining apertures 54 and 78 of CCF 20. A second gasket 30 is positioned against the right hand face of CCF 20.
(86) A second electroactive structure 26 is positioned between second gasket 30 and the left hand face of second CCF 21. A third set of masking frames 22 and 24 is inserted within corresponding channel defining apertures 98 and 101 of CCF 21, and a third set of channel defining gasket support pieces 56 are inserted to complete apertures 100 and 99 in second CCF 21. The third set of channel defining gasket support pieces support the structural integrity of the corresponding apertures 90 and 108 in second gasket 30 when the system is clamped, such that transfer channels 118 and 119 are reinforced, and products and reactants are controlled within their corresponding transfer channel. Gasket support pieces 56 further control product and reactant passage into and out of apertures 100 and 99 in second CCF 21 through the provision of channels of a defined size. A second full faced gasket 14 is sandwiched between second CCF 21 and the second end clamping plate 34.
(87) The function of masks 22 and 24 is dual fold: for load distribution when the electrolyser is clamped, and to prevent the electrically charged fluids of one polarity from being in contact with the metallic CCF of the opposite polarity, in order to prevent undesired electrolytic reactions within the four transfer channels 116, 117, 118 and 119. Adjacent first and third channels are electrically insulated by mask 22, for example placed in third aperture 54 of CCF 20. Similarly, for providing electrical insulation between adjacent second and fourth channels, mask 24 is placed in fourth aperture 78 of CCF 20.
(88) The purpose of gaskets 30 is to provide a means for sealing the periphery of the circulation chamber 103 and that of the four adjacent apertures between the internal pressure of system 10 and external atmospheric pressure. Gaskets 30 are also required to distribute load within the filter press stack. In an alternate embodiment, said masking frames (22, 24) are placed within the apertures of the sealing and electrically insulating gaskets 30, such that they align with their corresponding product transfer passageways, rather than being placed in the apertures of the CCF itself.
(89) When the system is clamped, full faced gaskets 14 distribute pressure across the stack to seal gaskets 30 and masks 22, 24. The purpose of gaskets 14 is also to provide a terminal seal between the internal fluids and the external atmosphere and to provide electrical isolation between first CCF 21 and first clamping plate 12 at one end of the filter press assembly and between second CCF 21 and second clamping plate 34 at the other end of the assembled system 10. The purpose of gaskets 14 is also to provide a means for sealing the periphery of chamber 103 and channel defining apertures 98, 99, 100 and 101 of CCF's 21 against the inner face of rigid plates 12 and 34.
(90) Those skilled in the art will realize that the gaskets and masks as shown are non-limiting, and that additional masking may be provided to assist with material stability, engineering requirements, and protection from corrosion. Gaskets (14, 30) and masks (22, 24) should be provided from a material that is electrically insulating, such as an elastomer, fluoropolymer, or thermoplastic, or combination thereof. In particular they may be provided from a high-performance thermoplastic elastomer (such as Santoprene™), from EPDM (ethylene propylene diene monomer) rubber, from a polytetrafluoroethylene compound (such as Teflon™), polypropylene, polyethylene, or from a synthetic rubber and fluoropolymer elastomer compound (such as Viton® rubber).
(91) To elaborate further on gaskets 30, such gaskets do not provide any current carrying capabilities, or depth to the cell for product circulation. For example, the ratio of CCF (20 or 21) depth 103A to the depth of gasket 30 can be preferred as low as 1:1, however designs may preferably increase CCF depth 103A to ratios in the range of 10:1 (where CCF depth is 10 times the gasket depth), or to any ratio greater than this as best suited to the engineering requirements of the electrochemical process.
(92) Further, achieving depth for product circulation as part of the CCF (a low-cost metal conductor) is preferred economically to providing depth through an insulating gasket material, particularly if the metal of the CCF has a lower cost than the insulating gasket material. It would further not be functional for insulating gaskets 30 to be increased in depth for the purpose of creating space for product circulation; as the created circulation space would be located between an electroactive structure (26 or 102) and separator 28, which would negatively disrupt the hydrodynamics of product circulation. Therefore, a large ratio between CCF depth 103A and the depth of gaskets 30 is preferred as described above, but non-limiting in view of other ratios which may be used.
(93) The function of separators 28 is to divide the positive and negative electrochemical reaction regions, thereby separating the anolyte and catholyte in all of the unipolar filter press stacks presently described. Separators 28 also provide a barrier which prevents or minimizes gases produced on the anodic electroactive structures and the cathodic electroactive structures to mix, while at the same time allowing for ions in solution to pass through it. Separators 28 may be provided from a diaphragm-type or membrane-type separator material as appropriate for the underlying electrochemical process. As non-limiting examples, separator 28 may be provided from felt, porous polysulphone, polyphenyl sulphide, or another type of cation exchange or anion exchange membrane.
(94) The purpose of the clamping plates 12 and 34 (as well as the equivalent plates 312, 334, 412, 434, and 512, 534 shown in other figures) is to provide strong and rigid mechanical structures for applying the required sealing pressure on the gaskets and masks (14, 30, 22, 24) to seal the periphery of the apertures, by means of an external filter press clamping device.
(95) The purpose of electroactive structures 102 (positive, anodic in the case of electrolysis) is to provide an interface for electrons and reactants to electrochemically react on the conductive surface and for the product to leave from the conductive surface. The purpose of electroactive structures 26 (negative, cathodic in the case of electrolysis) is to provide an interface for electrons and reactants to electrochemically react on the conductive surface and for the product to leave from the conductive surface.
(96) The separators 28 and electroactive structures 26 and 102 have approximately the same size and shape. The CCF's 20 and 21, the frame gaskets 30, and gaskets 14 have approximately the same rectangular dimensions. When assembled, the outer peripheral edges of all these components are generally aligned. Electroactive structures 26 and 102 and separators 28 are shorter than 20, 21, 30 and 14 so they do not encroach on any of the CCF apertures (52, 54, 80, and 24) which connect to transfer passageways.
(97) Those skilled in the art of electrolysis will understand the circularity of the apertures in gaskets 14 and end plates 12 and 34 is non-limiting, and apertures of a variety of other generally rectangular, ovular, or polyhedral shapes may be alternately employed. Further, the apertures in the CCFs presently described are depicted as rectangular in the Figures, however those skilled in the art of electrolysis will understand they could be provided in other shapes such as: square, ellipsoidal, oval, or another polygon. The apertures may further have their corners substantially rounded to avoid the creating stagnant flow regions which may cause corrosion or lower the throughput of gas product at sharp crevices.
(98) The purpose of outwardly extending tabs 64 (
(99) The tabs for electrical connection 64 are preferably equidistantly spaced, and are of a width approximately proportional to the CCF depth. Tabs 64 bring current linearly across the whole CCF, and provide sufficient electrical contact between the CCF and the busbar connecting to the external power supply (one type of electrical connection). The dimensions of the tabs for electrical connection 64 are non-limiting in this disclosure.
(100) In the case of the filter press stack 10, the electrical connection is made by connecting one polarity of a power supply (generally DC current) and tabs 64 on one side of the filter press stack. The tabs 64 on the other side of the filter press stack are attached to the opposite polarity of the power supply. The power supply polarities provided to the tabs 64 define the polarities of the entire system (i.e. the positive and negative symbols shown in
(101) To create an electrolysis system that connects two filter press stacks 10, the second filter press stack 10 would be located adjacent to the first in a manner such that their tabs for electrical connection 64 were approximately aligned facing each other, and that an electrical connection between the two sets of tabs is made. The electrical connection between the two sets of tabs 64 may be provided through a variety of methods, including but not limited to conductive bus bars and conductive wires. In this manner, the unipolar filter presses are connected in series with each other, together creating an electrolysis system of two filter press stacks. Additional filter press stacks 10 may continue to be added in this way to laterally expand the system.
(102) The paragraphs following this relate to provisions for reactant and product circulation in a unipolar filter press electrolyser based on CCF's. Particularly the unipolar filter press assembly 10 shown in
(103) In one configuration, alkaline water electrolysis, the preferred orientation of the filter press has tall vertically oriented CCF's which allow electrolytically produced hydrogen and oxygen gases to rise vertically within the circulation chamber 103. Oxygen generated on the anodically polarized CCF's electroactive surfaces structures (as indicated by 102 in
(104) The cathodically polarized electroactive structures 26 will generate hydrogen gas. The hydrogen gas will provide a lifting means to move the catholyte and hydrogen mixture up through the CCF's 21 through pathways defined by gasket support pieces 56, and then via third transfer passageway 118 to a location where gas liquid separation and electrolyte recirculation into transfer passageway 119 can occur in end plate 12.
(105) In an embodiment where it is preferable for internal gas/liquid circulation to be provided in between end plates 12 and 34, two additional CCFs with no electroactive structures may be employed at any point in the stack; one to connect corresponding catholyte output/input passageways, and one to connect corresponding anolyte output/input passageways. These additional frames are referred to as “downward circulation frames,” as they circulate reacted electrolyte downwards within the stack from the output to the input product transfer passageway.
(106) For example, a cathodic downward circulation frame may be applied in
(107) In place of using CCFs without electroactive structures as downward circulation frames, any other part that allows equivalent provisions for downward circulation may be employed as downward circulation frames. Discharge and feed channels may further be provided at other locations within the filter press stack, with suitable equivalent product/reactant feed/removal ports inserted therein.
(108) Those skilled in the art will understand methods of adding feed water, cooling water, returning electrolyte from the external capture devices, provisions for gas liquid separation, and the creation of mixing zones of the anolyte and catholyte to ensure the overall electrolyte has minimal differential electrolyte concentration gradients. These non-limiting methods may be applied to provide internal or external circulation.
(109) Those skilled in the art will further understand methods of maintaining elevated absolute pressure within the mechanical capacity of the filter press to withstand, as well as methods of controlling levels of catholyte and the anolyte in the circulation system and differential pressures in the circulation system.
(110) To provide further information on particularly useful features of the CCF in the optimization of filter press efficiency to its target application, some additional details are provided. In summary, the CCF width (as represented by members 53, or 57, or 353 described later on), the height (as represented by members 51, or 55), and the depth (provided at circulation chamber, 103A) of all CCF embodiments presently described are parameters which can be selectively engineered, such that a given CCF embodiment is tailored to suit the engineering targets of its application. In particular, the width, height, and depth parameters can be tailored to meet a given cost target, an electroactive surface area target (for product generation space), a pressurization target, and/or an overall efficiency target. The ability to tailor these parameters to the application's targets without technology-imposed constraints or substantial incremental costs is a core advantage of the CCF design, as applied to create a unipolar filter press electrochemical cell.
(111) For example, pressure characteristics are best optimized by the embodiments of
(112) In addition to the conducting struts enhancing mechanical strength, because they are made of the electrically conducting material of the frame itself, these struts also improve current conduction to the electroactive surfaces through direct connection. In the preferred embodiment of
(113) It is particularly of interest that the conducting features' height, width, and depth can be precisely adapted to further optimize current conduction for a given CCF application. For example, by increasing the depth of a conducting feature 69, 76 or 58 (achieved by increasing CCF depth) while maintaining a fixed height and width of the feature, the cross-sectional area of the feature is increased. Increased cross sectional area of the conducting feature consequently improves current conduction to the electroactive structure. It is possible to increase the cross-sectional area of a conducting feature by increasing its height or width as well, however, this comes with the efficiency and cost trade-off of subtracting space from the available electroactive surface area for product generation (i.e. total area of the electroactive structure−surface area in direct contact via conducting feature=practical available surface area for product generation). By increasing the CCF depth to improve conduction, rather than increasing the height and width of the conducting features, improvements to conduction are achieved without subtracting any excess practical surface area for product generation.
(114) The presence of additional conductive features within a CCF further enables the use of thinner electroactive structures, as compared to a CCF embodiment without any additional conductive features. The use of thinner (and consequently less costly) electroactive structures is enabled as the added conductive features support a portion of the lateral current, conducting across the CCF over the electroactive structures. Because the additional conductive features support lateral current conduction, they further allow for a CCF laterally wider than shown to be designed, such that the length of lateral cross members 53, 57 is increased. It can be desirable to achieve a laterally wider CCF design to increase the practical product generating surface area of the CCF, as the electroactive structure applied to the widened CCF is proportionally wide. Therefore, a CCF with additional conductive features may advantageously be modified in lateral width to achieve large surface area targets at low incremental cost. Customization of electroactive surface area can further be provided by adjusting the vertical height of the CCF. The CCF design being substantially rectangular, vertical height expansion allows for an efficient use of plant area. Preferably, the rectangular geometry of the CCF comprises a height to width ratio in the range of 2:1 to 6:1, however this feature is non-limiting and may be adjusted to best suit the engineering requirements for the application of the device.
(115) Finally, variations in electrolyte volume, gas and liquid velocity, as well as the void fraction of electrolytic gases within circulation chamber 103 of any CCF embodiments presented in this disclosure can be controlled in part by adjusting the CCF's depth.
(116) Referring to
(117) Each of CCF's 20 and 21 includes an electronically conductive frame 50 having two side members 51 and 55 and two lateral cross members 53. Frame 50 is made from a conductive material suitable for the intended application of CCF 20 and CCF 21 and may be made of carbon steel, nickel plated steel, titanium, nickel, carbon, and alloys. They may also be provided with coatings known to those in the art that are resistant to the corrosive effects of the environment in which the CCF 20 and CCF 21 are to be placed. Non-limiting example environments in which CCF 20 and CCF 21 may be placed include, but are not limited to, sodium chloride, sodium hydroxide, potassium hydroxide, chlorine, hydrogen, oxygen, sodium hypochlorite, sodium chlorate and sulphuric acid. All of the CCF embodiments discussed in this disclosure may be provided from the same group of materials listed above.
(118) Frame 50 and other variations of it are designed particularly to minimize the impact of corrosion. Crevices and stagnant areas where corrosion may occur are avoided where possible in the design. In this and in all CCF embodiments presently disclosed, the presence of notches 66 and 67 along the inner surface of the long frame members 51 and 55 is an optional beneficial provision to maximize the vertical length of the circulation chamber (103) while defining the lateral width of their adjacent aperture (52 or 80) consequently defining the lateral width of the product transfer passageway that passes through said aperture (52 or 80). For example, the lateral width provided for product transfer passageways 116 and 118 in
(119) All CCFs presently disclosed are provided as one integral part, which may be manufactured through a variety of methods. These manufacturing methods are non-limiting and may include any one or combination of: laser cutting, plasma cutting, water jet cutting, machining, sand or investment casting, or any other applicable manufacturing technology.
(120) In an embodiment, any of the single CCFs presently described may be provided with an additional channel in strut (or “arm”) 115 (or equivalently struts 360 and 315 for a double CCF, which bound catholyte and anolyte input passageways) such that anolyte and catholyte mixing may occur between the associated transfer passageways feeding into circulation chambers 103, to favourably adjust the concentration gradient within the electrolyte. In embodiments where an aperture for anolyte and catholyte mixing upon input into the filter press is inserted (“mixing aperture”) in strut 115 (or equivalent struts bounding catholyte/anolyte input passageways), an additional gasket support piece 56 with channels may be provided to fit within the bounds of the mixing aperture. As described later, such a gasket support may be provided to be friction fit in the mixing aperture, or in an alternate embodiment a gasket support may be provided integrally of the CCF, with additional through-channels provided to allow mixing.
(121)
(122) All electroactive structures presently described are obviously perforated or otherwise “openworked” to permit the transport of the products or reactants between the separator 28 and the circulation chamber 103 as shown in
(123) The diamond shaped apertures shown of electroactive structures 26 and 102 of
(124) While any of the electrode structures 40 to 45 may be employed in any of the embodiments of the present disclosure, thick, mechanically robust embodiments of electroactive structures 40 to 45 are preferred with CCF embodiments such as frame 50 in
(125) Electroactive structures may be attached through a variety of manufacturing methods. These manufacturing methods are non-limiting and may include any one or combination of: press-fitting, spot welding, thermal welding, ultrasonic welding, electron beam welding, laser beam welding, tungsten inert gas welding, or any other applicable technology.
(126) Generally, in order to attach the electroactive structure to the CCF, welds would be performed on some or all the planar surfaces surrounding the chamber 103, particularly on the sides of the frame. In embodiments described later on (
(127) If metallic wool were to be used as an electroactive structure, the manufacturing method of press-fitting would be the preferred method of its attachment to the CCF. In a press fit, one may only need attachment at a few (or no) uniquely dedicated locations, thus reducing the precision required in assembly and the total assembly costs. In the “press-fit” embodiment using a CCF with lateral struts or conductive structures (such as
(128) Frame 50 when used in CCF 20 is constructed such that it defines a circulation chamber 103 that is hydraulically connected to the channel defining apertures 52 and 80 via channel defining gasket support pieces 56 seen in
(129) The gasket support pieces 56 can be used interchangeably with any of the CCF embodiments described in the figures. Gasket support pieces 56 (or 120, 121, or 122) are preferably made from a metallic material, and may be made of carbon steel, nickel plated steel, titanium, nickel, carbon, and alloys or coatings on substrates known to those in the art that are resistant to the corrosive effects of the environment in which the CCF 20 and CCF 21 are to be placed. Gasket support pieces 56 may alternatively be provided from polymeric, ceramic materials, or a combination of metallic, polymeric and ceramic materials that fulfil the equivalent purposes.
(130) Gasket support piece 122 shows an embodiment in which a plurality of holes are drilled through the member for liquid flow from chamber 103 up to the upper passageway. Gasket support member 121 is produced as a wavy structure while gasket support 120 has two slots located therein rather than a plurality of holes.
(131) In one embodiment, gasket support pieces 56 may be provided from the same unitary part as the CCF itself as shown in 56B in
(132) Alternative embodiments of integrally provided non-removable gasket support pieces with one or more through-channels configured to allow products and reactants to pass through it in operation, specifically such that gases and liquids may pass in a controlled manner between circulation chamber 103 and a product transfer passageway (such as 116-120) are shown in
(133) Those skilled in the art of electrolysis will further comprehend that gasket support pieces applied at opposite ends of the CCF may be different in size or structure.
(134) In another embodiment, only one gasket support piece 56 is provided, between apertures 52 and 54 as shown in
(135) In another embodiment, shown in
(136) For example, in another embodiment a CCF cathode is made substantially equivalent to frame 21 or 50, however additionally its arm 114 being positioned closer to frame member 55 than frame member 51, such that aperture 52 (and its associated product transfer passageway) is consequently increased in lateral width while aperture 54 (and its associated product transfer passageway) and arm 63 are reduced in lateral width. In
(137) Such embodiments are particularly useful where the gas/liquid separation of one product (either anodic or cathodic) is achieved more readily than the other. For example, experimental data for alkaline water electrolysis has suggested the gas liquid separation of oxygen from the anolyte is provided more readily than the gas liquid separation of hydrogen from the catholyte. Therefore, it may be beneficial to increase the size of the cathodic product transfer passageway such that the hydrogen gas is allowed greater space in its transfer passageway.
(138) To assemble a full filter press stack around CCF cathodes and anodes wherein the gas off-take transfer passageways are provided of different sizes; all of the same parts (gaskets, masks, separators, gasket supports) as previously described in
(139) Slight modifications to the CCF may be optionally provided when required to improve the sealing of the assembly. The perimeter of circulation chamber 103 may be slightly recessed on one or more faces in order to ensure the electroactive structures are substantially flush to the surface of the CCF. Further, one or more continuous negative grooves may additionally be cut from both planar faces of any of the CCF embodiments presently described. The negative grooves when applied are preferred around the periphery of all apertures in the frame, such that gasket and mask components in the assembly are ensured to be flush to the surface of the CCF.
(140) To provide further information on the applications for the CCF embodiments shown in
(141) As there are no additional conducting features provided in this embodiment, the majority of the current carrying occurs across the electrode structure alone, beginning on the left side adjacent to tabs 64, then moving to the right (i.e. “parallel” to the electrode structure as is shown in
(142) This low-cost embodiment of
(143) Large surface area per CCF (such that the lateral cross members 53, 57 are approximately between 8 inches to 56 inches in length) is a preferred embodiment for an electrolyser applied to large scale alkaline water electrolysis. Preferred CCF embodiments with additional conductive features such as in
(144)
(145) In another embodiment, after manufacturing the cross members 69 such that holes 70 are provided therein and cross members 69 are inserted into CCF 68, cross members 69 are welded or otherwise electrically joined to frame member 55, which contains the tabs 64 for electrical connection, thus improving the robustness of the electrical connection provided to cross members 69. Similarly, in a double CCF embodiment of
(146)
(147)
(148) In another embodiment, to improve the circulation of liquid electrolytes in chamber 103, one or more through-channels may be provided in the spears 76 (or 76A described later). Preferably, the one or more channels are provided adjacent to frame member 55, the side the spears are provided from, allowing improved circulation of electrolyte in these regions. Similarly, in a double CCF embodiment of
(149) In an alternate embodiment, one or more spears 76 or 76A may extend across circulation chamber 103 to meet outer frame members 51, thereby forming an embodiment with both spears and one or more “conductive struts.” Said one or more conductive struts may be provided in an the upward-pointing diagonal configuration of the spears, or in another shape. In one embodiment the conductive strut may be substantially arcuate in shape, a beneficial shape to improve hydrodynamics in chamber 103 discussed later. Said one or more conductive struts are beneficial for improving the mechanical rigidity of this embodiment. Said one or more conductive struts further comprise one or more through channels therein, or they may be thinner than depth 103A, or have other means provided to support the circulation of gas and liquids within chamber 103 towards off-take apertures while additionally supporting the mechanical rigidity of the frame. Additionally, in any embodiment of a CCF with spears 76 (or 76A) the spears' dimensions may be different from one another within the same CCF, such that a hydrodynamically beneficial gradient is created. Similarly, the double CCF embodiments described later on may employ any of the presently described features to create equivalent double CCF embodiments.
(150) The embodiment of the CCF in
(151) The preferred embodiment of
(152)
(153)
(154) In another embodiment, additional holes or “cut-outs” 79 of metal may be provided from frame members 55, or 51 (or 332 of single or double CCFs described later) where metal is not strictly required for current conduction and mechanical support. Providing such cut-outs 79 enable a reduction in part mass, increase scrap metal value, and support an increase in lateral width of frame members 55 and 51 while minimizing part mass. Extending the lateral width of frame members 55 and 51 allows the CCF to beneficially protrude externally to a filter press when configured in a filter press electrolyser assembly embodiment such that the frame is air-cooled where it protrudes externally. Parts of the CCF protruding from a filter press sealing profile with sites 79 in particular protruding to additionally support air-cooling improves filter press heat removal capabilities. For the sole purposes of air-cooling, however, cut-outs 79 are optional, and an embodiment of the CCF may be provided wherein parts of the CCF protrude from the filter press sealing profile for air-cooling without any cut-outs 79. CCFs may be adapted to increase heat removal from conduction, convection, or radiation. In another embodiment, lateral frame members 53 and 57 may additionally be increased in height with optional cut-outs provided for purposes of air cooling the electrolyser, among other benefits. Cut-outs 79 and/or protrusions for air-cooling may be further provided in any other CCF embodiment presently described. In an alternative embodiment, cut-outs 79 may additionally be provided in other geometric shapes.
(155) In another embodiment, outer frame members of the CCF may be adjusted in shape to further improve heat removal capabilities, for example being castellated, or otherwise bent or waved to create additional surface area and protrusions for air-cooling from the filter press. Additionally, coatings to further improve heat removal capabilities may be applied to any CCF, discussed in detail later.
(156) In another embodiment, central frame member 332 may be expanded in lateral width, such that additional material cut-outs 79 may be provided, said cut-outs reducing part weight and increasing scrap metal value, and further creating further beneficial sites for air-cooling.
(157)
(158) In operation, gas rises through struts 58 via channels 60 formed by the gaps between rectangular prisms (or equivalently “shapes”) 62 provided from the material of struts 58. The channels 60 provide space for the circulation of electrochemical reactants and products within circulation chamber 103. While shapes 62 are shown for example as substantially rectangular prisms in
(159) The shapes 62 on conductive struts 58 serve as attachment or contacting points to electroactive structures (such as 26 and 102 from
(160) The method to obtain the effect of a shapes 62 and the channels 60 from strut 58 could be via subtracting material from strut 58 through machining, stamping or another technique known to those skilled in the art of fabrication. While the channels 60 are shown as generally rectangular in
(161) Alternately, in place of subtracting material to create the effect of shapes 62, another embodiment possesses struts 58 which are entirely thinner in depth relative to the CCF sides 51, 55, 57 and 53 (“a thin conductive strut”), similar to how the strut 58 as shown in the Figures would appear if the entire strut was reduced to the dimensions of 60 shown in
(162) Said thin conductive struts (or “thin lateral cross members”) may be formed integrally of CCF 85, having their thickness subtracted by means of manufacturing. Alternatively, thin conductive struts may be originally provided from a section of another plate having a thickness less than a thickness of said CCF sides (51, 55, 57, and 53), but of the same material as CCF frame 85, and consequently be joined between said first and second side arms 51, 55 by means of a welding method such that an electrical connection between the strut and the side frame members 55, 51 is formed. The resulting embodiment of CCF 85 comprising thin conductive struts is substantially equivalent when produced by either method described.
(163) An alternate embodiment to this may have material added to the thin conductive struts to create the effect of raised shapes 62 and channels 60.
(164)
(165) In an alternate embodiment, when one or more electroactive structures 44 are provided on a single or double CCF embodiment comprising thin conductive struts, said electroactive structures may be further provided with “indented inward-facing dimples” positioned directly facing and over top of the thin conductive struts, to allow for an electrical connection to be made to the thin conductive struts, and to define channels substantially parallel to frame members 55 and 51 (or 51 and 332 in a double CCF with thin conductive struts) in the remaining lateral space between the thin conductive struts and the non-dimpled regions of the electroactive structure. These embodiments provide advantages in reducing the complexity and cost of manufacturing CCF 85. In another embodiment, where recesses surrounding chamber 103 are additionally provided as previously described, appropriate engineering adjustments are made to allow the dimpled electroactive surface to be ultimately substantially flush to the surfaces of the CCF it is applied to.
(166)
(167) The electrolyser device 310 comprises two unipolar filter press cells; the first unipolar filter press cell is provided with four product transfer passageways 316, 317, 318, and 319. The second unipolar filter press cell is provided also with four product transfer passageways, 320, 321, 322, and 323. The products and reactants of the first and second unipolar filter press cells are physically separated and do not mix within any of the end plates 312 and 334. The current generated by the power input provided at tabs 64 of the single CCFs travels across the chambers of double CCF 350, as will be described later in
(168) Moving from left to right, transfer passageway 316 is created by the channel-forming combination of port 355 in first end clamping plate 312, and apertures 110, 54, 106, (as previously described) and aperture 352 in double CCF 350. The side of CCF 350 which is joined to transfer passageway 316 is anodically polarized as indicated by the positive sign in
(169) Reading again from left to right, transfer passageway 317 is created by the channel-forming combination of port 356 in first end plate 312 (obscured by first right-hand gasket 14), and apertures 111, 78, 107, and aperture 380 in the anodically polarized side of CCF 350. The anodic product circulation chamber 103 of double CCF 350 is fed with anolyte liquid through aperture 380 and its corresponding gasket support piece. Anolyte reactant liquid is initially fed into passageway 317 through obscured port 356 in first end plate 312. The anolyte liquid input into transfer passageway 317 may be virgin electrolyte, or it may be recycled anolyte that has been removed from passageway 316 or 322 and externally processed.
(170) Reading from right to left, transfer passageway 318 is created by the channel-forming combination of port 351 in first end plate 334, and apertures 94, 52, 90, 354 of double CCF 350, 90 and 52. The cathodically polarized CCFs 50 feed gaseous cathodic product through a gasket support piece 56 and into aperture 52 which then feeds into transfer passageway 318. As noted equivalently for the anodic gaseous product, depending on the provisions employed for gas/liquid separation in the filter press stack some catholyte liquid may enter passageway 318 with the gaseous cathodic product. The product and any residual catholyte is removed at port 351.
(171) Reading from right to left, transfer passageway 319 is created by the channel-forming combination of port 353 in first end clamping plate 334, and apertures 109, 80, 108, 378, 108, 80. The cathodic product circulation chambers 103 of CCFs 50 are fed with catholyte liquid through apertures 80 and their corresponding gasket support pieces. Catholyte reactant liquid is initially fed into passageway 319 through port 353 in first end plate 334. The catholyte liquid input into transfer passageway 319 may be water, or it may be recycled catholyte that has been removed from passageway 318 or 320 and externally processed.
(172) Reading from right to left, transfer passageway 320 is created by the channel-forming combination of port 348 connecting to second end plate 334, and apertures 94 (not shown due to cutaway), 54, 90, 356 of double CCF 350. The cathodically polarized portion of double CCF 350 feeds gaseous cathodic product from its cathodic chamber 103 up through a gasket support piece 56 into aperture 356 which then feeds into transfer passageway 320. Depending on the provisions employed for gas/liquid separation in the filter press stack some catholyte liquid may enter passageway 320 with the gaseous cathodic product. The gaseous cathode product and any residual catholyte is removed at port 348.
(173) Reading from right to left, transfer passageway 321 is created by the channel-forming combination of port 357 in second end plate 334, and apertures 109, 78, 108, and 381. The cathodic product circulation chamber 103 of CCF 350 is fed with catholyte liquid through apertures 381 and its corresponding gasket support piece. Catholyte reactant liquid is initially fed into passageway 321 through port 357 in second end plate 334. The catholyte liquid input into transfer passageway 321 may be water, or it may be recycled catholyte that has been removed from passageway 320 or 318 and externally processed.
(174) Reading from left to right, transfer passageway 322 is created by the channel-forming combination of port 349 in second end plate 312, and aperture 110, 52, 106, 355 in double CCF 350, 106, and terminates at second aperture 52. The CCFs 50 joined to transfer passageway 322 are anodically polarized. Transfer passageway 322 is fed with anodic gaseous product that arises from the circulation chamber 103 of anodic CCFs 50 through gasket support pieces 56 and into apertures 52, which then feed into passageway 322. Depending on the provisions applied for gas/liquid separation anolyte liquid may also enter transfer passageway 322 with the anodic gas product. This anodic product gas and anolyte liquid is removed from 322 for further processing through port 349 in second end plate 312.
(175) Reading from left to right, transfer passageway 323 is created by the channel-forming combination of port 359 in second end plate 312, and apertures 111, 80, 107, 379, 107, and 80. The anodic product circulation chamber 103 of single CCFs 50 is fed with anolyte liquid through aperture 80 and its corresponding gasket support piece. Anolyte reactant liquid is initially fed into passageway 323 through port 359 in second end plate 312. The anolyte liquid input into transfer passageway 323 may be virgin electrolyte, or it may be recycled anolyte that has been removed from passageway 316 or 322 and externally processed.
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(177) This double plate CCF 350, where one half is the anode of one unipolar filter press cell stack, and one half is a cathode in the adjacent unipolar filter press cell stack. By eliminating the need for a bus bar between adjacent unipolar filter press cell stacks, the metallic resistive losses between the stacks are reduced, and the unipolar stacks can approach the low resistive losses achieved by state-of-the-art bipolar filter press stacks. The reduced current path length is a result of the ability for the double CCF to act as an improved inter-cell electrical connection (improving over an inter-cell bus bar) between two unipolar filter press stacks. The improvement comes from the feature of the double CCF that current travels only laterally between the adjacent cells, rather than both laterally and vertically as required on single CCFs with tabs 64. It can also be more efficient in manufacturing to cut one large component rather than two small components to accomplish the same task.
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(183) Further, in another embodiment, a coating to improve heat removal capabilities may be additionally applied to frame members of the double CCF, preferably to central frame member 332. The coating to improve heat removal capabilities may be comprised of but is not limited to: high emissivity paint, ceramic-based or silicone-ceramic-based coatings, black pigmented coating, for example Aremco's 840-MS. In alternative embodiments, coatings to improve heat removal capabilities of a CCF may be applied to any CCF embodiment presently described.
(184) Further, in another embodiment additional material shapes may be provided to CCF frame members to increase the frame surface area protruding from the filter press such that heat transfer is improved. Such additional protruding material shapes may preferably be provided as fins, or another heat transferable shape.
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(187) While single CCFs 450 are shown to have a bare product circulation chamber 103 analogous to single CCFs 50, their product circulation chamber 103 may be configured in preferred embodiments that include the conductive features of previously described single CCFs 68, 74, or 85, such that the CCFs of
(188) The unipolar electrochemical device in 410 is comprised of one unipolar filter press cell, with six product transfer passageways 416, 417, 418, 419, 420, 421.
(189) Moving from left to right, transfer passageway 416 is created by the channel-forming combination of port 449 in end clamping plate 412, and apertures 494 in gasket 414, 493 in CCF 450, 460 in gasket 430, 488 in CCF 450, 460, and 493. The CCFs 450 which physically join to transfer passageway 416 are anodically polarized as indicated by the positive sign in
(190) Moving from left to right, transfer passageway 417 is created by the channel-forming combination of port 459 in end plate 412, and apertures 495, 480, 461, 478, 461, 480. The anodic product circulation chamber 103 of CCFs 450 which physically join to transfer passageway 417 is fed with anolyte liquid through aperture 480 and its corresponding gasket support piece. Anolyte reactant liquid is initially fed into passageway 417 through port 459 in end plate 412. The anolyte liquid input into transfer passageway 417 may be virgin electrolyte, or it may be recycled anolyte that has been removed from passageway 418 and externally processed.
(191) Reading from left to right, transfer passageway 418 is created by the channel-forming combination of port 452 in end plate 412, and apertures 496, 492, 462, 489, 462, and 492. The anodic product circulation chamber 103 of CCFs 450 which physically join to transfer passageway 418 is originally fed with anolyte liquid from transfer passageway 417 up through aperture 480 and its corresponding gasket support piece. Anodic gaseous product is generated in product circulation chamber 103 and flows into aperture 493 to enter transfer passageway 416. Surplus reacted liquid anolyte additionally flows into aperture 493, however then passes through channel 483 into adjacent aperture 492 (as shown in
(192) Reading from right to left, transfer passageway 419 is created by the channel-forming combination of port 457 in end plate 434, and apertures 495, 478, 463, 480, 463, 480. The cathodic product circulation chamber 103 of CCF 450, indicated by the negative sign, which physically joins to transfer passageway 419 is fed with catholyte liquid through aperture 480 and its corresponding gasket support piece. Catholyte reactant liquid is initially fed into passageway 419 through port 457 in end plate 434. The catholyte liquid input into transfer passageway 419 may be virgin electrolyte, water, or recycled catholyte that has been removed from passageway 420 and externally processed.
(193) Reading from right to left, transfer passageway 420 is created by the channel-forming combination of port 451 in end plate 434, 496, 489, 464, and 492. The cathodic product circulation chamber 103 of CCF 450 that physically joins to transfer passageway 420 is originally fed with catholyte liquid from transfer passageway 419 up through aperture 480 and its corresponding gasket support piece. Cathodic gaseous product is generated in product circulation chamber 103 and flows into aperture 493 to enter transfer passageway 421. Surplus reacted liquid catholyte additionally flows into aperture 493, however then passes through channel 483 into adjacent aperture 492 (as shown in
(194) Reading from right to left, transfer passageway 421 is created by the channel-forming combination of port 448 in end clamping plate 434, and apertures 494, 488, 465, 493. The CCF 450 which physically joins to transfer passageway 421 is cathodically polarized as indicated by the negative sign in
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(198) The electrolyser device 510 comprises two unipolar filter press cells; the first unipolar filter press cell is provided with six product transfer passageways 516, 517, 518, 519, 520, 521. The second unipolar filter press cell is provided also with six product transfer passageways, 522, 523, 524, 525, 526, and 527. The products and reactants of the first and second unipolar filter press cells are physically separated and do not mix within any of end plates 512 and 534. The current generated by the power input provided at tabs 64 of the single CCFs travels across the chambers of double CCF 550, as will be described later in
(199) Moving from left to right, transfer passageway 516 is created by the channel-forming combination of port 549 in first end clamping plate 512, and apertures 494, 488, 460, 593 in double CCF 550. The side of CCF 550 in which is joined to transfer passageway 516 is anodically polarized as indicated by the positive sign in
(200) Reading from left to right, transfer passageway 517 is created by the channel-forming combination of port 559 in first end plate 512 (obscured by first right-hand gasket 414), 495, 478, 461 (obscured by electroactive structure), and 580 in the anodically polarized side of CCF 550. The anodic product circulation chamber 103 of double CCF 550 is fed with anolyte liquid through aperture 580 and its corresponding gasket support piece. Anolyte reactant liquid is initially fed into passageway 517 through obscured port 559 in first end plate 512. The anolyte liquid input into transfer passageway 517 may be virgin electrolyte, or it may be recycled anolyte that has been removed from passageway 518 or 526 and externally processed.
(201) Reading from left to right, transfer passageway 518 is created by the channel-forming combination of port 555 in first end plate 512, and apertures 496, 489, 462, 592. The anodic product circulation chamber 103 of CCFs 550 which physically joins to transfer passageway 518 is originally fed with anolyte liquid from transfer passageway 517 up through aperture 580 and its corresponding gasket support piece. Anodic gaseous product is generated in product circulation chamber 103 and flows into aperture 593 to enter transfer passageway 516. Surplus reacted liquid anolyte additionally flows into aperture 593, however then passes through channel 583 into adjacent aperture 592 (as shown in
(202) Reading from right to left, transfer passageway 519 is created by the channel-forming combination of port 553 in first end plate 534, obscured aperture 495 in gasket 414, 480, 463, 578, 463, and 480. The cathodic product circulation chambers 103 of cathodic single CCFs 450 are fed with catholyte liquid through apertures 480 and their corresponding gasket support pieces. Catholyte reactant liquid is initially fed into passageway 519 through port 553 in first end plate 534. The catholyte liquid input into transfer passageway 519 may be water, or it may be recycled catholyte that has been removed from passageway 520 or 524 and externally processed.
(203) Reading from right to left, transfer passageway 520 is created by the channel-forming combination of port 554 in first end plate 534, 496, 492, 464, 589, 464, 492. The cathodic product circulation chamber 103 of single CCFs 450 that physically join to transfer passageway 520 is originally fed with catholyte liquid from transfer passageway 519 up through aperture 480 and its corresponding gasket support piece. Cathodic gaseous product is generated in product circulation chamber 103 and flows into aperture 493 to enter transfer passageway 521. Surplus reacted liquid catholyte additionally flows into aperture 493, however then passes through channel 483 into adjacent aperture 492 (as shown in FIG. 13A) ultimately entering product transfer passageway 520, where it will be removed at port 554 in first end plate 534. The reacted catholyte removed from port 554 may be processed externally as a final product, or recirculated back into the system through passageway 519 or 523.
(204) Reading from right to left transfer passageway 521 is created by the channel-forming combination of port 552 in first end plate 534, and apertures 494, 493, 465, 588, 465, and 493. The cathodically polarized CCFs 450 feed gaseous cathodic product through a gasket support piece 56 and into aperture 493 which then feeds into transfer passageway 521. The product and residual catholyte (if any) is removed at port 552.
(205) Reading from right to left, transfer passageway 522 is created by the channel-forming combination of port 548 in second end plate 534, and apertures 494, 488, 465, and 573. The cathodically polarized portion of double CCF 550 feeds gaseous cathodic product from its cathodic chamber 103 up through a gasket support piece 56 into aperture 573 which then feeds into transfer passageway 522. The gaseous cathode product and any residual catholyte (if any) is removed at port 548.
(206) Reading from right to left, transfer passageway 523 is created by the channel-forming combination of port 557 in second end plate 534, and apertures 495, 478, 463, and 560. The cathodic product circulation chamber 103 of the cathodic portion of double CCF 550 is fed with catholyte liquid through aperture 560 and the corresponding gasket support piece. Catholyte reactant liquid is initially fed into passageway 523 through port 557 in second end plate 534. The catholyte liquid input into transfer passageway 523 may be water, or it may be recycled catholyte that has been removed from passageway 520 or 524 and externally processed.
(207) Reading from right to left, transfer passageway 524 is created by the channel-forming combination of port 551 in second end plate 534, and apertures 496, 489, 464, and 572. The cathodic product circulation chamber 103 of double CCF 550 that physically joins to transfer passageway 524 is originally fed with catholyte liquid from transfer passageway 523 up through aperture 560 and its corresponding gasket support piece. Cathodic gaseous product is generated in product circulation chamber 103 and flows into aperture 573 to enter transfer passageway 522. Surplus reacted liquid catholyte additionally flows into aperture 573, however then passes through channel 563 into adjacent aperture 572 (as shown in
(208) Reading from left to right, transfer passageway 525 is created by the channel-forming combination of port 556 in second end plate 512, and apertures 495, 480, 461, 558, 461, 480. The anodic product circulation chambers 103 of anodic single CCFs 450 are fed with anolyte liquid through apertures 480 and their corresponding gasket support pieces. Anolyte reactant liquid is initially fed into passageway 525 through port 556 in second end plate 512. The catholyte liquid input into transfer passageway 525 may be virgin electrolyte or it may be recycled anolyte that has been removed from passageway 526 or 518 and externally processed.
(209) Reading from left to right, transfer passageway 526 is created by the channel-forming combination of port 546 in second end plate 512, 496, 492, 462, 569, 462, and 492. The anodic product circulation chamber 103 of single CCFs 450 which physically join to transfer passageway 526 is originally fed with anolyte liquid from transfer passageway 525 up through aperture 480 and its corresponding gasket support piece. Anodic gaseous product is generated in product circulation chamber 103 and flows into aperture 493 to enter transfer passageway 527. Surplus reacted liquid anolyte additionally flows into aperture 493, however then passes through channel 483 into adjacent aperture 492 (as shown in
(210) Reading left to right, transfer passageway 527 is created by the channel forming combination of port 547 in second end clamping plate 512, and apertures 494, 493, 460, 568, 460, 493. The single CCFs 450 which are joined to transfer passageway 527 are anodically polarized. Transfer passageway 527 is fed with anodic product (a gaseous product in the case of the electrolysis of water or chlorine electrolysis) arising from the circulation chamber 103 of single CCFs 450, through a gasket support piece 56 into aperture 493 which feeds into passageway 526. This anodic product gas and residual anolyte liquid (if any) is removed from 527 for further processing through tubular port 547 in second end plate 512.
(211) The embodiments of
(212) The embodiments of
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(214) In other embodiments of CCFs with additional transfer passageways (i.e. greater than the 4 transfer passageways per unipolar electrochemical cell press shown in
(215) For example, one embodiment comprises a single CCF similar to
(216) Similarly, another exemplary embodiment comprises a double CCF similar to
(217) It is noted that any embodiments of any of the conductive features presently described (conductive struts, spears, thin conductive struts, arcuate conductive struts, etc.) may be combined within the circulation chamber of one CCF. For example, one CCF (either single or double) may be provided with both spears and a conductive strut, or multiple conductive struts and one spear. Any other combination of the conductive features presently described may be further employed. Further, any such embodiments may include: any form of one or more through-channels within said conductive features to allow the passage of fluids, said conductive features may be reduced in thickness as compared to depth 103A at any position on the feature to allow the passage of fluids, said conductive feature may be angled upwards or downwards or adjusted otherwise at any beneficial orientation or shape for hydrodynamic flow, or provided in an embodiment with any combination of the above. The ability to achieve low-incremental cost customization of features to suit the conditions of the environment of the CCF is a key aspect of the present disclosure.
(218) Additionally, CCFs employed within a given filter press need not be identical. For example, a given filter press stack of CCFs may include CCF embodiments provided with no features in their circulation chamber, spears, or conductive struts, or combinations thereof, all present within the same stack. Further, the shape of the CCF frame may be adjusted such that corners of the external frame and/or apertures therein are rounded, or otherwise adjusted in shape.
(219) Beyond the preferred applications of alkaline water electrolysis and chlorine electrolysis, there are many other possible electrochemical processes for which a unipolar filter press electrochemical device based on the various CCF embodiments disclosed herein could be employed.
(220) While the present CCFs can be used to create an electrochemical device based on entirely CCF-type current carriers and frames, as discussed throughout the present disclosure, a CCF may also be adapted to suit other electrochemical devices which require replacement parts.
(221) Combined Single-Double CCF System Expanded to Scale
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(226) The assembly of
(227) Additionally, as discussed previously, the CCFs that are positioned adjacent to end assemblies are provided in a monopolar configuration with one inner electroactive structure (as shown in
(228) Thus it can be seen that the single and double CCF embodiments presently disclosed are very useful and advantageous for being able to scale the resulting unipolar filter press cell blocks.
(229) This description is exemplary and should not be interpreted as limiting the invention or its applications. Specific parts or part numbers mentioned in the description may be substituted by functional equivalents.