System energy demand reduction by fluid manipulation to overcome capillary forces formed by bubbles on reactive surfaces

Abstract

A fluid associated with a desired chemical or electrochemical reaction continuously flows or cyclically pulsates across the reactive surface at a flow rate or frequency consistent with the average time required for a desired proportion of bubbles to grow to a particular diameter as part of the reaction. The fluid flow rate used is sufficient to disrupt the capillary force of the bubbles on the reactive surface at the specific diameter. If pulsatile, the fluid does not flow or is at a sufficiently low flow rate to allow sufficient reaction kinetics during a period of time between periodic fluid flow or pulsations. Bending the reactive surface and the fluid flow channel may also reduce the surface tension of the bubbles, reduce the fluid flow force required to remove the bubbles at an optimal size, thereby reducing the energy demand for pumping the fluid.

Description

[0001] Citation of Related Applications

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 392,059, filed on July 25, 2022, and U.S. Provisional Patent Application No. 63 / 397,942, filed on August 15, 2022. The contents and disclosures of each of these applications are incorporated herein by reference in their entirety. Background Art

[0003] The present invention relates to gas-forming chemical or electrochemical reactions occurring at the contact area between a fluid solution (such as an electrolyte) and a reactive surface (such as an electrode or catalytic material), and wherein the same chemical or electrochemical reaction is unlikely to occur at the contact area between a gas (such as the gas produced during the above reaction) and the same reactive surface. Summary of the invention

[0004] Climate change is one of the greatest threats facing the world today. Extreme weather events such as floods, hurricanes, fires and heat waves are becoming more common as the atmosphere continues to be polluted with greenhouse gases from burning fossil fuels. Therefore, alternatives to polluting energy sources must be provided to the planet, and countries with high emissions must transition away from the use of polluting fossil fuels.

[0005] Achieving net-zero emissions by the mid- to late-21st century is of utmost importance for both developing and developed countries. An integral part of these ambitious goals is carbon-free fuels and energy. Renewable energy sources such as solar and wind can provide green electricity, however, the electricity generated cannot always be stored and available when consumers need it, and these energy sources alone cannot quickly, efficiently, and cost-effectively replace fossil fuels.

[0006] Hydrogen is a fuel that has the ability to store energy for later use. Hydrogen has many advantages, such as not producing any pollution (its byproduct is water), its ability to be compressed into an energy-dense fuel, and its potential to democratize energy availability in the world. In addition, hydrogen can store energy as an alternative to large-scale batteries or other methods of storing electricity. The development of a strong hydrogen economy would free up fossil fuels for countries that currently rely on others, and if combined with renewable energy, would greatly reduce the carbon footprint of any country that utilizes the fuel.

[0007] During a chemical or electrochemical reaction involving the formation of bubbles on a surface, a gas formation reaction typically occurs at the contact area of ​​a reacting fluid solution (such as an electrolyte) with a surface of interest (such as an electrode). As bubbles grow on the reactive surface, when the buoyancy and / or other forces on the bubbles exceed the capillary force, they are eventually removed with a probabilistically distributed size. However, when bubbles are formed on the surface of interest, a reaction is no longer possible at the contact area between the gas produced during the above-mentioned reaction and the surface of interest. In addition, if the reacting fluid solution does not contact the surface of interest for a duration sufficient to allow the reaction kinetics to occur (such as if the solution flows over the surface at a high flow rate, this is the case), the gas will not form or may be produced suboptimally.

[0008] When the main buoyancy force (F B ), gas momentum force (F M ) and capillary shear force (F s ) overcomes the main capillary force acting downward (F σ ) and resistance (F d ) and inertial force (F i ), the bubbles will detach from the reactive surface.

[0009] It is known that the steady flow of system electrolyte has an effect on the efficiency of the electrolysis system. During electrolysis involving the formation of hydrogen and oxygen bubbles at the surfaces of two different electrodes, the formation of bubbles will block the reaction kinetics on the electrode surfaces until the bubbles naturally break the capillary forces or are removed by the flow of electrolyte across the electrodes. Conversely, a high flow of electrolyte will reduce the available reaction time and significantly reduce the efficiency of the system.

[0010] Not addressed in known studies are the distribution of bubble sizes when removed during electrochemical reactions, fluid inefficiencies, the relationship between bubble growth rate and fluid pressure, the effects of capillary forces between bubbles and electrodes, and especially any periodicity in the flow of the fluid solution, the adverse effects of reaction kinetics on the flow rates used, or considerations of the ratio of bubble size to available reactive surface area.

[0011] Fluid pressure affects the growth rate of bubbles. As pressure increases, the bubble growth rate decreases proportionally, which provides a greater likelihood of successfully timing the removal of bubbles of optimal size with a pulsating fluid flow.

[0012] A fluid flowing in a curved channel will experience a higher fluid velocity on the inner curve of the channel relative to the fluid velocity on the outer curve of the channel; and therefore, a curved channel experiences a lower fluid pressure on the inner curve of the channel relative to the fluid pressure on the outer curve. This pressure difference has been formulated as:

[0013]

[0014] Where R is the curve radius, V is the fluid velocity, and ρ is the fluid viscosity.

[0015] As a bubble grows in this tortuous fluid flow environment, a pressure differential is created across the bubble. This causes buoyancy forces to be directed from high pressure to low pressure, which can reduce the requirement for additional forces to break the capillary forces needed to remove the bubble from its reactive surface.

[0016] The present invention includes a new method for reducing system energy requirements by controlling the formation of bubbles on reactive surfaces. A fluid associated with a desired chemical or electrochemical reaction is periodically flowed or pulsed across the reactive surface at a flow rate or frequency consistent with the average time required for a desired proportion of bubbles to grow to a specific diameter and be at a specific fluid pressure as part of the reaction. The fluid flow rate used is sufficient to disrupt the capillary forces of the bubbles on the reactive surface of the above-mentioned specific diameter. During the time periods between periodic fluid flows or pulsations, the fluid is not flowing or is at a sufficiently low flow rate to allow sufficient reaction kinetics.

[0017] Systems and methods are described herein for targeting optimal flow rates, pulsation frequencies and durations, and fluid channel design properties of a flowing fluid to reduce the energy required to support gaseous product reactions for any given fluid pressure and viscosity. Optimization of these properties can be determined in whole or in part by calculation of the reaction kinetics of gaseous products forming bubbles on a surface, systematic experimentation to isolate the effect of adjusting each property on energy input versus output, and systematic control of adjusting dynamically controllable input properties to optimize the response of energy output to energy input.

[0018] In some embodiments, at least one of the fluid pressure or fluid viscosity is determined. For example, one or more sensors placed within the fluid can provide measurements from which the pressure and / or viscosity of the fluid can be determined. A probability distribution of bubble sizes is then selected, and based on the determined pressure and / or viscosity, an optimal flow rate across the surface of the fluid required to remove bubbles from the reactive surface under the probability distribution of the selected bubble sizes is calculated. The flow rate of the fluid across the reactive surface is then adjusted to the optimal flow rate. In some cases, the flow rate of the fluid is adjusted in response to optimizing the energy output measured relative to the measured energy input.

[0019] In some embodiments, the reactive surface on which the bubbles are formed can be a concave surface. The fluid can be continuously pumped in a cavity or fluid channel that is close to and parallel to the curvature of the concave surface. The cavity or fluid channel can have sufficient cross-sectional space to allow the fluid to flow in a direction parallel to the curved surface area, so that the fluid flows faster in the area of ​​the cavity or fluid channel that is not closest to the reactive surface.

[0020] In some embodiments, adjusting the flow rate includes periodically pulsating the fluid across the reactive surface at an optimal flow rate. Between periodic pulsations, the rate of the fluid flow rate is at or near zero velocity. As the fluid pressure at the reactive surface increases, the periodicity of the pulsating fluid can increase to coincide with or compensate for the reduced growth rate of the bubbles within the increased fluid pressure.

[0021] In some embodiments, pulsation of the fluid is accomplished using a piston pump, a valve actuated fluid channel, a peristaltic pump, or other system capable of periodically pulsating a fluid.

[0022] In some embodiments, the velocity of the fluid is monitored by a flow meter at one or both of the inlet and / or outlet of the system.

[0023] In some embodiments, the timing of the pulsation frequency is controlled by monitoring the energy consumption of the system in the form of electrical energy (volts, current, and watts) and thermal energy (kelvins) which is proportional to the fluid pressure of the reaction. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The above and other objects and advantages of the present disclosure will become apparent by considering the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts throughout, and wherein:

[0025] Figure 1 shows bubbles increasing in size as they are removed from a reactive surface;

[0026] Figure 2 is a cross-section of a fluid-enclosed compartment containing a reactive surface for chemically or electrochemically generating bubbles and a fluid flow for generating shear forces according to some embodiments of the present disclosure;

[0027] Figure 3 is a cross-section of a fluid-enclosed compartment containing a concave curved reactive surface that chemically or electrochemically generates gas bubbles and a fluid flow that generates both shear forces and additional buoyancy forces according to some embodiments of the present disclosure;

[0028] Figure 4 shows design considerations for a curved electrolyser according to some embodiments of the present disclosure;

[0029] Figure 5 is an exemplary electrolyzer design showing fluid channels and curved reactive surface areas according to some embodiments of the present disclosure;

[0030] Figure 6 An example of an apparatus for producing gas from an electrolytic process according to some embodiments of the present disclosure is shown;

[0031] Figure 7is a flow chart representing an illustrative process for optimizing fluid flow rate across a reactive surface by monitoring energy input and energy content of generated gas, according to some embodiments of the present disclosure; and

[0032] Figure 8 is a flow chart representing an illustrative process for optimizing fluid pulsation frequency according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0033] The present disclosure relates to a fluid-enclosed compartment comprising a reactive surface, which produces bubbles chemically or electrochemically on the surface. Enclosed fluid is required and contributes to chemical or electrochemical reactions, such as electrolytic fluids. The reactive surface can be composed of a catalyst that reacts chemically with the fluid, or the reactive surface can be an anode or cathode with a voltage and current specifically applied with or without heat, radiation or other related energy sources present in the electromagnetic spectrum of the reaction at the reactive surface that need to be applied to the system and that are required for the electrochemical reaction of the enclosed fluid.

[0034] refer to Figure 1 , images showing bubble formation and removal from a reactive surface are shown in the same scale. From left to right, 100 shows bubbles grown under conditions requiring relatively lower energy consumption than 102, which in turn shows bubbles grown under conditions requiring relatively lower energy consumption than 104. As can be observed in 100, bubbles grown on the reactive surface are removed at a size smaller than 102, which in turn shows bubbles grown on the reactive surface are removed at a size smaller than 104. Figure 1 The images in demonstrate the energy consumption benefits of smaller bubble sizes grown on reactive surfaces.

[0035] Reference now Figure 2 , shows a cross section of a fluid-enclosed compartment containing a reactive surface that chemically or electrochemically produces bubbles typical of a reaction chamber. Bubbles 200 are shown to be formed on reactive surface 202. All areas outside the bubble and above the reactive surface are composed of fluids (such as electrolytes 203) required to support chemical or electrochemical reactions. Chemical or electrochemical reactions occur at the contact points between the bubble 200, reactive surface 202, and fluid 203. A representation of the flow of fluid 206 from right to left is also shown. There are several forces on the bubble that affect the conditions under which the bubble 200 will be removed from the reactive surface 202.

[0036] Capillary force (F σ) 218 ​​holds the bubble on the surface at the contact point between the bubble 200, the reactive surface 202 and the fluid 203 required to support the reaction. This is sometimes referred to as surface tension. Two downward forces 218 are shown to indicate the combined capillary forces that hold the bubble on the reactive surface. This is affected by the composition of the reactive surface, the composition of the gas of the bubble and the properties of the fluid.

[0037] If the bubble is to start moving upward in the direction of buoyancy, it needs to overcome the inertial force (F i ) 214. This is the downward force.

[0038] If the bubble is to start moving in the fluid 203, it needs to overcome the resistance (F d ) 216. This is the downward force and is primarily affected by the viscosity of the fluid.

[0039] Buoyancy (F B ) 210 is an upward force proportional to the volume of the bubble 200 in the denser fluid 203 minus the weight of the bubble. It is based on the sum of the hydrostatic forces distributed across the entire surface of the bubble from top to bottom, where this fluid-based pressure at the top of the bubble is slightly lower than the hydrostatic force at the bottom, resulting in a net upward force vector.

[0040] Gas momentum force (F M ) 212 is generated as the bubble grows and is based on the velocity of the gas and its associated momentum as the bubble 200 expands. The faster the bubble grows, the greater the force. When the bubble is anchored on a surface, the gas momentum force is generally in a direction away from the reactive surface. A net vector force in the upward direction is shown.

[0041] Shear forces (F) exist when a bubble is exposed to lateral forces exerted by the unidirectional flow of the surrounding fluid. S ) 208. When the lateral force pushes on one side of the bubble, it creates a fulcrum scenario that provides an upward force. This force increases as the velocity of the fluid increases.

[0042] Fluid stream 206 is shown traveling from right to left across the reactive surface, starting at the wavy line, providing the necessary fluid to support the reaction at the reactive surface, providing the aforementioned shear forces to the growing bubbles, and circulating through a pipe, tube, or other to a reservoir, tank, or other 204, and then circulating back to the reactive surface. While the fluid is within the reservoir, tank, or other 204, the chemical properties of the fluid can be analyzed, and appropriate chemicals, treatment agents, or other can be added to the fluid.

[0043] The goal is to provide sufficient shear, and in some embodiments additional buoyancy, to remove air bubbles with optimal system efficiency by manipulating fluid flow.

[0044] In some embodiments, the reactive surface and the fluid channel above the reactive surface are tightly concavely curved in one dimension, wherein the fluid flows across the reactive surface in the same direction of the concave curve in the fluid channel, the fluid channel having a height upward from the surface of the reactive surface that is at least 2.5 times the diameter of the calculated bubble size, the height being consistent with a continuous flow rate for an optimal energy output to input ratio determined by the above process. The purpose is to provide a greater pressure differential between the bottom of the bubble at the reactive surface and the top of the bubble due to the higher flow rate at the top of the channel. This greater pressure differential contributes more to buoyancy, thereby requiring a smaller net fluid velocity across the reactive surface to remove the bubble, and therefore requiring less external energy to operate the fluid pump.

[0045] In a similar manner, now refer to Figure 3 , shows a cross section of a fluid-enclosed compartment containing a curved reactive surface that chemically or electrochemically produces a bubble typical of a reaction chamber. Bubble 300 is shown as being formed on reactive surface 302. All areas outside the bubble and above the reactive surface are composed of fluid (such as electrolyte 303) required to support the chemical or electrochemical reaction. The chemical or electrochemical reaction occurs at the contact point between bubble 300, reactive surface 302 and fluid 303. A representation of the flow of fluid 306 from right to left is also shown. There are several forces on the bubble that affect the conditions at which point the bubble 300 will be removed from the curved reactive surface 302. These forces are determined by Figure 2 The same force components as shown in , but with one addition (320).

[0046] Capillary force (F σ ) 318 holds the bubble on the surface at the contact points between the bubble 300, the reactive surface 302 and the fluid 303 required to support the reaction. This is sometimes referred to as surface tension. Two downward forces 318 are shown to indicate the combined capillary forces that hold the bubble on the reactive surface. This is affected by the composition of the reactive surface, the gas of the bubble and the properties of the fluid.

[0047] If the bubble is to start moving upward in the direction of buoyancy, it needs to overcome the inertial force (F i )314. This is the downward force.

[0048] If the bubble is to start moving in the fluid 303, it needs to overcome the resistance (F d ) 316. This is the downward force and is primarily affected by the viscosity of the fluid.

[0049] Buoyancy (F B) 310 is an upward force proportional to the volume of the bubble 300 in the denser fluid 303 minus the weight of the bubble. It is based on the sum of the hydrostatic forces distributed across the entire surface of the bubble from top to bottom, where this fluid-based pressure at the top of the bubble is slightly lower than the hydrostatic force at the bottom, resulting in a net upward force vector.

[0050] The additional buoyancy (F) caused by the curvature of the fluid C ) 320 is the upward force caused by the fluid flow being directed to follow the curved reactive surface 302 with decreasing radius from bottom to top, with a calculated decreasing fluid pressure from bottom to top following Equation 1 above, where R is the radius of the fluid curve at a point in the fluid flow channel, V is the fluid 306 velocity, and p is the fluid 306 viscosity. This creates an additional fluid pressure differential between the bottom and top of the bubble that would not exist if the fluid channel had no radius.

[0051] Gas momentum force (F M ) 312 is generated as the bubble grows and is based on the velocity of the gas and its associated momentum as the bubble 300 expands. The faster the bubble grows, the greater the force. When the bubble is anchored on a surface, the gas momentum force is generally in a direction away from the reactive surface. A net vector force in the upward direction is shown.

[0052] Shear forces (F) exist when a bubble is exposed to lateral forces exerted by the unidirectional flow of the surrounding fluid. S ) 308. When the lateral force pushes on one side of the bubble, it creates a fulcrum scenario that provides an upward force. This force increases as the velocity of the fluid increases.

[0053] Fluid stream 306 is shown traveling from right to left across the curved reactive surface, starting at the wavy line, providing the necessary fluid to support the reaction at the reactive surface, providing the aforementioned shear forces to the growing bubbles, and circulating through a pipe, tube, or other to a reservoir, tank, or other 304, and then circulating back to the reactive surface. While the fluid is within the reservoir, tank, or other 304, the chemical properties of the fluid can be analyzed and appropriate chemicals, treatments, or other can be added to the fluid.

[0054] Reference now Figure 4 , shows design considerations for an electrochemically driven system that produces bubbles growing on reactive surfaces within a fluid. A cross section of a curved system design is shown, where a membrane 404 separates two electrodes at 402 and 406, and where an electrolytic fluid flows 410 across one of the electrodes 402.

[0055] Interface design considerations are also shown at cross-sectional end 400, which shows structure 416 supporting electrical connections from the outside of the fluid chamber to the inside at 418 and 420, where the same electrical connections are treated with a non-reactive surface coating at 412 and 414 for use inside the fluid chamber and further electrically connected to the electrodes at 406 and 402. To support the electrochemical system reactions, and to help ensure fluid and / or gas separation between the two reactive surfaces of the electrodes, at 406 and 402, the membrane 404 has seals 422 between the support structure 406 and either side of the membrane 404 to further ensure fluid and / or gas separation between the two reactive surfaces of the electrodes.

[0056] Looking down at the reactive surface, design considerations for fluid flow entering the reaction chamber of system 408 are also shown as being directed and distributed 428 by support structure 426 relative to electrode 424. The fluid is distributed 428 from a single channel inlet and bifurcates several times to present the fluid across the entire bottom edge of electrode 424 at nearly the same pressure and flow rate in this representation, traversing the reactive surface of electrode 424 from bottom to top.

[0057] Reference now Figure 5 , and an example electrolyzer is represented as a three-dimensional view showing a curved support structure 500 having a curved fluid channel contained therein, with a reactive surface or electrode 502 placed between one curved structure 500 and another identical curved structure 504. It should be understood that Figure 5 The three-dimensional representation shown in is merely an illustrative example of a curved fluid channel in an electrolyzer. Other designs are possible, including changes in support structures, dimensions, curve radii, etc., and all such changes are contemplated by the present disclosure and fall within the scope of the present disclosure.

[0058] Reference now Figure 6 , shows a single-cell electrolyzer with various system controllers, measuring instruments, fluid and gas flows, and a system support process without a supporting structure. The center of the electrolyzer is a combination of an anode, a cathode, and a membrane separator 600. The anode and cathode are connected to a potentiostat 601, which provides electrical energy to support the electrochemical reaction of the electrolyzer and also measures the electrical energy consumed by the electrolyzer. In this representation, the electrolytic fluid 602 is exposed to the anode or pumped across the anode from the bottom to the top. In order to support or enhance the electrochemical reaction, the fluid and the electrolyzer can be heated 604, and a thermometer 613 can be used to facilitate the control of the heater 604 and / or measure the exothermic heat generated by the electrolyzer at the anode. In order to support or enhance the electrochemical reaction, the fluid 602 can be radiated by an electromagnetic energy source 606 that is excited, controlled, and monitored by a device 608. During the electrochemical reaction, the anode produces a gaseous byproduct that is solely or primarily oxygen, which bubbles or dissolves into the fluid 602.

[0059] The cathode produces primarily hydrogen, which is captured as gas 603, or bubbles or dissolves into the fluid. To support or enhance the electrochemical reaction, the gas, fluid, or electrolyzer 605 may be heated, and a thermometer 614 may be used to facilitate control of the heater 605 and / or measure the exotherm produced by the electrolyzer at the cathode. To support or enhance the electrochemical reaction, the gas or fluid 603 may be radiated by an electromagnetic energy source 607 that is stimulated, controlled, and monitored by a device 608.

[0060] The electrolytic fluid is stored in a reservoir, tank or other device 609 where the chemical properties of the fluid can be analyzed and appropriate chemicals, treatments or other devices can be added to the fluid. The electrolytic fluid is pumped from the reservoir 609 using a pump 611 such as a piston pump, a valve actuated pressurization system, a peristaltic pump or other system capable of periodically pulsating the fluid. The flow rate 611 and pressure 612 of the electrolytic fluid entering the electrolyzer are monitored and controlled.

[0061] The flow rate 616 and pressure 615 of the electrolytic fluid 602 leaving the anode side of the electrolyzer are monitored and controlled before the gas and liquid are separated 617. The electrolytic fluid separated from the gas is then sent to a reservoir 609. The separated gas (primarily oxygen) is exhausted 622 or used elsewhere after being monitored and controlled by a back pressure regulator 621. A portion of the separated gas, primarily oxygen, is sent through a mass flow controller 623 before being analyzed by a gas chromatograph or similar system 627.

[0062] The flow rate 619 and pressure 618 of the gas 603 or fluid present on the cathode side of the electrolyzer are monitored and controlled before the gas and liquid are separated 620. The separated gas (primarily hydrogen) is stored 625 or transported elsewhere after being monitored and controlled by a back pressure regulator 624. A portion of the separated gas, primarily hydrogen, is sent through a mass flow controller 626 before being analyzed by a gas chromatograph or similar system 627.

[0063] The system controller 628 monitors and controls all inputs used by the electrolyzer, including the potentiostat 601, the electrolytic fluid reservoir 609, the pump 611, the flow rate 611 and the pressure 12 of the electrolytic fluid entering the electrolytic fluid, the anode heating 604, the cathode heating 605, and the consumption used by other electromagnetic radiation sources (606, 607) controlled and monitored 608. The system controller 628 can be based on any suitable processing circuit, and includes a control circuit and a memory circuit, which can be set on a single integrated circuit or can be a discrete component. As mentioned herein, the processing circuit should be understood to mean a circuit based on one or more microprocessors, microcontrollers, digital signal processors, programmable logic devices, field programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), etc., and can include multi-core processors (e.g., dual-core, quad-core, hexa-core, or any suitable number of cores). In some embodiments, the processing circuit can be distributed on multiple separate processors or processing units, for example, multiple processing units of the same type (e.g., two Intel Core i7 processors) or multiple different processors (e.g., Intel Core i5 processors and Intel Core i7 processors). The system controller 628 regulates the inputs based on the above input measurements and outputs measurements of power consumption 601, outbound gas and fluid flow rates (616, 619), outbound gas and fluid pressures (615, 618), and gas chromatograph 627 measurements of all gases analyzed. The system controller 628 may receive these measurements via a wired or wireless connection. For example, the system controller 628 may include a transceiver or data bus for communicating with various sensors via any suitable wired or wireless data protocol (e.g., Ethernet, USB, Wi-Fi, Bluetooth, etc.).

[0064] Minimum and maximum thresholds are set within the system controller 628 based on predefined limits on pressure, flow rate, temperature, and energy consumption of components and equipment used within the system. Given different fluid pressures for the gaseous product reactions targeted by the system, the controller logic uses the following combination Figure 7 The process experiments discussed are baselined from the fluid flow rates derived therefrom. During normal operation, the controller logic includes the same process. If a pulsating fluid strategy is targeted for system operation, the controller logic is baselined using the fluid pulsation frequency, which is determined by combining the following Figure 8 The process of discussion is to conduct experiments and combine Figure 8 The process discussed is derived. During normal operation, the controller logic includes the same process.

[0065] Reference now Figure 7, the system requires a predetermined calculation for energy input as a baseline for system efficiency, such as voltage, current, heat, radiation, or other relevant energy source present in the electromagnetic spectrum that needs to be applied to the system to support the chemical or electrochemical reaction at the reactive surface. This calculation may need to consider the effect of fluid pressure on the energy input requirement - especially if slowing bubble growth is a system goal. It is also necessary to calculate the reaction fluid consumption rate based on the net area of ​​the reactive surface and convert it into a minimum fluid flow rate into the system to ensure that the reaction is not starved.

[0066] A chemical or electrochemical reaction is started 702 in a reaction chamber using an energy input expected for the reaction, wherein the fluid flow rate matches the fluid flow rate expected to be consumed by the reaction. A sufficient fluid 704 is monitored for the reactive surface by a level gauge, a capacitive sensor tuned for level measurement, or by monitoring a thermal anomaly 704 emitted from the reactive surface (which will indicate a lack of fluid for the reaction). If there is not enough fluid supplied to the reactive surface ("No" at 704), then at 706, the flow rate is increased. If there is enough fluid supplied to the reactive surface ("Yes" at 704), then all energy inputs are monitored relative to the output in terms of the energy content of the produced gas, which can be derived 708 from the volume and pressure of the produced gas. If the energy input and output are unstable ("No" at 708), then in some embodiments, a waiting period can be applied, otherwise the above-mentioned monitoring at 704 and 708 continues.

[0067] If the energy input and output are stable ("yes" at 708), a baseline ratio of energy output to energy input is recorded, the fluid flow rate is increased at 710, and the stability of the energy input and output is monitored 712 after the flow rate is increased. If the consumption of energy input relative to energy output is not stable ("no" at 712), then in some embodiments, a waiting period may be applied. Once the consumption of energy input relative to energy output is stable ("yes" at 712), the ratio of energy output to input is compared to the previous record 714 as the flow rate is increased. If the energy ratio has improved ("improved" at 714), the fluid flow rate is increased 710 and monitoring continues. If the energy ratio has deteriorated ("deteriorated" at 714), the fluid flow rate is reduced 716, and the reactive surface is monitored for sufficient fluid 704 before continuing the above process. If the ratio has not changed ("no change" at 714), then in some embodiments, a waiting period may be applied.

[0068] In some embodiments, the reaction system process is initiated by pulsating the fluid at a very high flow rate at a frequency for a period of time that matches the calculated bubble growth time that is consistent with the continuous flow rate for the optimal energy output to input ratio determined by the above process. The duration of the pulsation is determined experimentally by monitoring the flow rate leaving the reactive surface or reaction chamber prior to recirculation and setting the optimal continuous flow rate previously determined as the end of the fluid pulsation period. Due to the inertial delay of the fluid between the end of the pulsation and the measurement of the end flow rate, the duration of the pulsation may have to be reduced until the observed fluid flow rate leaving the reactive surface matches the optimal continuous flow rate for the system. Figure 8 is a flow chart showing an illustrative process for optimizing the frequency of a fluid pulsating across a reactive surface, which follows Figure 7 Same process, except in some processes instead of increasing or decreasing the flow rate, the frequency of the high flow rate pulses is increased or decreased.

[0069] In some embodiments, as above and Figure 8 As described in the previous section, the pulsation of the fluid provides Figure 7 The starting conditions in terms of pulsating the fluid at a fixed frequency and duration, and by following Figure 7 The remaining process within is used to optimize the flow rate of each pulse.

Claims

1. A method for optimizing a gas forming chemical or electrochemical reaction, comprising: determining at least one of a pressure of a fluid and a viscosity of the fluid; Choose a probability distribution for bubble size; calculating, based on the determining, an optimal flow rate of a fluid across the reactive surface required to remove bubbles from the reactive surface at a selected probability distribution of bubble sizes; as well as adjusting the flow rate of the fluid across the reactive surface to the optimal flow rate, in: During the gas forming chemical or electrochemical reaction, gas bubbles will form on the reactive surface; and The fluid is required for the gas to form a chemical or electrochemical reaction.

2. The method according to claim 1, further comprising: Optimize the measured energy output relative to the measured energy input, Wherein adjustment of the flow rate of the fluid across the reactive surface is performed in response to optimizing the energy output.

3. The method of claim 1, wherein the reactive surface is a concave surface, the method further comprising: The fluid is continuously pumped within a cavity or fluid channel, which is close to and parallel to the curvature of the concave surface, and the cavity or fluid channel is also concave and has sufficient cross-sectional space to allow the fluid to flow in a direction parallel to the curved reactive surface area, so that the fluid flows faster in the area of ​​the cavity or fluid channel that is not closest to the reactive surface.

4. The method of claim 1 , wherein adjusting the flow rate of the fluid comprises: The fluid is periodically pulsed across the bubble forming reactive surface at the optimal flow rate to remove bubbles from the reactive surface, and wherein the flow rate between the periodic pulsations is at or near zero velocity.

5. The method of claim 4, wherein the periodicity of the pulsating fluid increases as the fluid pressure at the reactive surface increases to coincide with a reduced growth rate of bubbles within the increased fluid pressure.

6. The method of claim 4, wherein the pulsation of the fluid is accomplished using a piston pump.

7. The method of claim 4, wherein the pulsating of the fluid is accomplished using a valve-actuated fluid channel.

8. The method of claim 4, wherein the pulsation of the fluid is accomplished using a peristaltic pump.

9. The method according to claim 4, further comprising: The periodicity of the pulsation of the fluid is controlled by monitoring the energy consumption in the form of electrical and thermal energy proportional to the pressure of the fluid.

10. The method according to claim 1, further comprising: monitoring the velocity of the fluid, Wherein, the velocity of the fluid is monitored by at least one of a fluid inlet and a fluid outlet and a flow meter.

11. A system for optimizing a gas-forming chemical or electrochemical reaction, comprising: a reactive surface on which bubbles will form during the gas-forming chemical or electrochemical reaction; The gas forms a fluid required for a chemical or electrochemical reaction; as well as A control circuit, the control circuit being configured to: determining at least one of a pressure of a fluid and a viscosity of the fluid; Choose a probability distribution for bubble size; calculating, based on the determining, an optimal flow rate of a fluid across the reactive surface required to remove bubbles from the reactive surface at a selected probability distribution of bubble sizes; as well as The flow rate of the fluid across the reactive surface is adjusted to the optimal flow rate.

12. The system of claim 11, wherein the control circuit is further configured to: Optimize the measured energy output relative to the measured energy input, Wherein the control circuit is configured to adjust a flow rate of the fluid across the reactive surface in response to optimizing the energy output.

13. The system of claim 11, wherein the reactive surface is a concave surface, and wherein the control circuit is further configured to: The fluid is continuously pumped within a cavity or fluid channel, which is close to and parallel to the curvature of the concave surface, and the cavity or fluid channel is also concave and has sufficient cross-sectional space to allow the fluid to flow in a direction parallel to the curved reactive surface area, so that the fluid flows faster in the area of ​​the cavity or fluid channel that is not closest to the reactive surface.

14. The system of claim 11, wherein the control circuit configured to adjust the flow rate of the fluid is further configured to periodically pulse the fluid across the bubble forming reactive surface at the optimal flow rate to remove bubbles from the reactive surface, and wherein the flow rate between the periodic pulsations is at or near zero velocity.

15. The system of claim 14, wherein the control circuit is further configured to increase the periodicity of the pulsating fluid as the fluid pressure at the reactive surface increases to coincide with a reduced growth rate of bubbles within the increased fluid pressure.

16. The system of claim 14, wherein the pulsation of the fluid is accomplished using a piston pump.

17. The system of claim 14, wherein the pulsation of the fluid is accomplished using valve-actuated fluid passages.

18. The system of claim 14, wherein the pulsation of the fluid is accomplished using a peristaltic pump.

19. The system of claim 14, wherein the control circuit is further configured to control the periodicity of the pulsation of the fluid by monitoring energy consumption in the form of electrical energy and thermal energy proportional to the pressure of the fluid.

20. The system of claim 11, wherein the control circuit is further configured to: monitoring the velocity of the fluid, in, The control circuit monitors the velocity of the fluid using a flow meter at at least one of a fluid inlet and a fluid outlet.

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