A device for production of green hydrogen

Abstract

A Green HYDROGEN production apparatus is provided having a modular reactor vessel. The reaction is managed to safely drive the reaction to completion to maximize HYDROGEN production. A HYDROGEN outlet provides for the collection of the generated HYDROGEN from the reactor vessel (e.g. 1)

Description

FIELD OF INVENTION

[0001] The present disclosure is related generally to the production of Green Hydrogen, Metal Hydroxides and Oxides, and more particularly, in various embodiments of the described principles, to systems and methods for safe and reliable production with high purity at scale. BACKGROUND OF INVENTION

[0002] Green Hydrogen As the effects of climate change becomes an increasingly real concern, the burning of fossil fuels is coming to be seen as a detriment to the environment, and to human health more generally. Based on such concerns and the unreliable availability and pricing of fossil fuels, a need for renewable and clean energy sources and energy storage media has arisen. While there have been attempts to provide Green HYDROGEN (Hydrogen produced from renewable energy intensive sources, hereinafter “HYDROGEN”) in many ways, e.g., electrolysis, steam reformation, etc., there is not yet a simple, clean, scalable solution that can provide large quantities of HYDROGEN to supplement and replace fossil fuels.

[0003] For example, with respect to reacting metals to produce HYDROGEN, prior attempts have presented a risk of becoming uncontrollably exothermic and / or resulted in unreacted metal. One reason for this latter failure, as observed by the inventors, appears to be the formation of an oxide layer that shields the metal and prevents complete reaction.

[0004] Metal Hydroxides and Oxides Hydroxides such as Sodium Aluminate, ATH (alumina trihydrate), Magnesium Hydroxide, Zinc Hydroxide and metal oxides such as Zinc Oxides are produced using traditional manufacturing processes and used for various applications.

[0005] Sodium Aluminate Sodium Aluminate (NaA102) is used as a concrete additive and in water treatment to coagulate impurities while producing potable water. It is produced by reacting Gibbsite (aluminum hydroxide) with caustic soda. An embodiment of the described methods provides a novel process for modular production of Sodium Aluminate at water treatment sites whilst minimizing impact on environment.

[0006] Alumina Trihydrate (ATH) ATH (Al(0H)3) is used as a fire retardant in plastics and as an additive for paints. ATH is produced using the Bayer process, which employs mined bauxite and produces a toxic residue called Red Mud. An embodiment of the described methods provides a novel process for environmentally safe production of ATH without generating hazardous Red Mud.

[0007] Magnesium Hydroxide Magnesium Hydroxide (Mg(0H)2) is used as a fire retardant in plastics and construction applications. Magnesium Hydroxide is produced by calcinating mined magnesite at high temperatures to produce magnesium oxide which is then reacted with water. The embodiment of the described methods provides a novel process for modular production of Magnesium Hydroxide with low energy consumption.

[0008] Zinc Hydroxide Zinc Hydroxide (Zn(OH)2) is used for industrial applications such as water treatment and as a flame retardant additive in plastics and construction materials. Zinc Hydroxide is produced by reacting zinc salts with catalysts. An embodiment of the described methods provides a novel process for modular production of Zinc Hydroxide.

[0009] Zinc Oxides Metal oxides such as Zinc Oxide (ZnO) are produced using traditional manufacturing processes and used for consumer and industrial applications. Zinc Oxide is used for consumer applications such as sunscreen creams, UV absorbent textiles, and other industrial applications, e.g., rubbers and plastics. Zinc Oxide is produced by vaporizing zinc metal at very high temperatures in furnaces, reacting the vapor with oxygen and then cooling the result to a useable form. This is known as the indirect French vapor deposition process. High energy consumption and the hazards of the vapor deposition process make the process difficult to manage with respect to environmental issues, in part because of environmental and worker safety regulations. Most manufacturers have exited the North American and European regions, with Asia now supplying a majority of the market. An embodiment of the described methods provides a novel process for safer, low energy, and reliable production of Zinc Oxide, while protecting the environment and worker health.

[0010] Before proceeding, it should be appreciated that while the present disclosure is directed to a system that may address many or all of the shortcomings listed or implicit in this Background section, any such benefit is not a limitation on the scope of the disclosed principles, or of the attached claims, except to the extent expressly noted in the claims.

[0011] Additionally, the discussion of technology in this Background section is reflective of the inventors’ own observations, considerations, and thoughts, and is in no way intended to accurately catalog or comprehensively summarize any prior art reference or practice. As such, the inventors expressly disclaim this section as admitted or assumed prior art. Moreover, the identification herein of one or more desirable courses of action reflects the inventors’ own observations and ideas and should not be assumed to indicate an art-recognized desirability. OBJECTIVES OF THE INVENTION

[0012] It is an objective of the present invention to provide for a novel approach for managing the reaction of metals such as Aluminum, Magnesium and Zinc in the presence of a catalyzing agent to produce HYDROGEN, Sodium Aluminate, Alumina Trihydrate, Magnesium Hydroxide, Zinc Hydroxide, and Zinc Oxide. The disclosed techniques overcome obstacles to large scale use of this reaction to generate commercial quantities of high purity HYDROGEN and Metal Hydroxides and Oxides. The novel process manages the reaction between a metal and hydroxyl group in the presence of a catalyst within a reactor. The innovation provides a unique approach to managing this reaction through the manipulation of temperature, pressure, pH, molality, and reaction time.

[0013] Another objective of the present invention is to provide a novel process for modular production of Sodium Aluminate at water treatment sites whilst minimizing impact on environment.

[0014] Yet another objective of the present invention is to provide a novel process for environmentally safe production of ATH without generating hazardous Red Mud.

[0015] A further objective of the present invention is to provide for a novel process for modular production of Magnesium Hydroxide with low energy consumption.

[0016] Another objective of the present invention is to provide for a novel process for modular production of Zinc Hydroxide.

[0017] Yet another objective of the present invention is to provide for a novel process for safer, low energy, and reliable production of Zinc Oxide, while protecting the environment and worker health. SUMMARY OF THE INVENTION

[0018] The present invention relates to a HYDROGEN (Green Hydrogen) production apparatus comprising: a reactor vessel having: a catalyst containing a hydroxyl group; at least one fuel loading inlet configured to introduce a metallic fuel into the reactor vessel without depressurizing the reactor vessel, wherein the metallic fuel is selected from a group of a virgin or recycled transition and post-transition metals; a HYDROGEN outlet configured to release HYDROGEN from the reactor vessel; and characterized in that a managed reaction of the metallic fuel in the presence of a catalyzing agent is carried out in the reactor vessel to produce HYDROGEN by managing temperature in the range of 25°C-100°C, pressure in the range of 1-10 ATM and molality in the range of pH 8-15 so as to allow the fuel to completely react, finishing the reaction and maximizing the amount of HYDROGEN produced. 5

[0019] In an embodiment of the present invention, the fuel loading inlet configured in the HYDROGEN production apparatus comprises a two-valve pressure lock that prevents depressurizing of the reactor vessel.

[0020] In another embodiment of the present invention, the fuel loading inlet of the HYDROGEN production apparatus further comprises a scale configured to weigh each 10 incoming fuel piece.

[0021] In yet another embodiment of the present invention, the catalyst used the HYDROGEN production apparatus is an alkali ionic hydroxide.

[0022] In a further embodiment of the present invention, the alkali ionic hydroxide catalyst includes at least one of calcium hydroxide, aluminum hydroxide, potassium 15 hydroxide, and sodium hydroxide.

[0023] In another embodiment of the present invention, the HYDROGEN production apparatus further comprises a catalyst recirculation loop having therein a pump and one or more modules configured to modify one or more properties of the catalyst solution to treat and refresh the catalyst.

[0024] In yet another embodiment of the present invention, wherein each of the one or more modules comprises a molarity module configured to control the catalyst solution molarity.

[0025] In a further embodiment of the present invention, wherein each of the one or more modules comprises a heat exchange module configured to control the catalyst solution temperature.

[0026] The present invention also relates to A HYDROGEN production apparatus comprising: a reactor vessel for reacting a metallic fuel with a catalyst to produce HYDROGEN; a catalyst solution within the reactor vessel; a fuel loading inlet configured to introduce a metallic fuel into the reactor vessel; a HYDROGEN outlet configured to release HYDROGEN from the reactor vessel; and a reaction manager configured to automatically manage one or more attributes of the catalyst solution to avoid formation of an oxide shield on the fuel, so as to allow complete reaction of the metallic fuel with the catalyst.

[0027] In an embodiment of the present invention, the reaction manager of the HYDROGEN production apparatus is further configured to provide continuous or semi-continuous operations without shutdown, start-up, or steady state loss.

[0028] In another embodiment of the present invention, the reaction of the metallic fuel with the catalyst is controlled by design of the metal fuel and / or catalyst introduction.

[0029] In yet another embodiment of the present invention, the reaction of the metallic fuel with the catalyst is controlled by introduction of the catalyst into the reaction vessel.

[0030] In a further embodiment of the present invention, the reaction temperature is controlled by vessel design and material process control.

[0031] In a still further embodiment of the present invention, the reaction manager is configured to provide a substantially constant reaction rate.

[0032] Other features and aspects of the disclosed principles of the HYDROGEN production apparatus will be apparent from the detailed description taken in conjunction with the included Figures 1, 2 and 3. BRIEF DESCRIPTION OF DRAWINGS

[0033] While the appended claims set forth the features of the present techniques with particularity, these techniques, together with their objects and advantages, may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:

[0034] FIG. 1 illustrates a schematic representation of a HYDROGEN generator reaction vessel in accordance with an embodiment of the disclosed principle;

[0035] FIG. 2 illustrates a chart showing HYDROGEN generation rates using an embodiment of the disclosed principles and structures.

[0036] FIG. 3 illustrates a schematic representation of a HYDROGEN production process in accordance with an embodiment of the disclosed principles. DETAILED DESCRIPTION OF INVENTION

[0037] This patent describes the subject matter for patenting with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope cf this patent. The principles described herein may be embodied in many different forms.

[0038] As noted above, there is a long-felt need for renewable and clean energy sources and energy storage media, and yet the known attempts to provide HYDROGEN to date have not provided a simple, clean, scalable solution to provide the large quantities of HYDROGEN needed to supplement and replace fossil fuels. However, in various embodiments of the disclosed principles, a HYDROGEN generation solution is provided employing a managed reaction of metals in the presence of a catalyzing agent to safely produce HYDROGEN in large quantities, with other useful byproducts being produced as well. The disclosed techniques provide a unique approach to managing this reaction through the manipulation of temperature, pressure, pH, molality, and reaction time.

[0039] With this overview in mind, we turn now to a more detailed discussion of the disclosed principles in conjunction with the attached figures. Turning more specifically to the figures, FIG. 1 is a schematic representation of a HYDROGEN generator reaction vessel in accordance with an embodiment of the disclosed principles. The illustrated configuration includes vessel 101, having at least one fuel inlet 103 and at least one HYDROGEN outlet 105, wherein metallic fuel 107 is provided to the vessel at the fuel inlet 103 and HYDROGEN 109 is emitted from the vessel 101 at the HYDROGEN outlet 105.

[0040] As the reaction progresses and produces HYDROGEN, the HYDROGEN rises into the head space of vessel 101, creating a higher-than atmospheric HYDROGEN pressure. It will be appreciated that the opening of the fuel inlet 103 is intermittent, to allow the generation of the excess head pressure, and this pressure is ultimately limited by the flow rate out of the HYDROGEN outlet 105. Under the influence of this pressure, the generated HYDROGEN eventually exits vessel 101 via the HYDROGEN outlet 105. At that point, the HYDROGEN may be used, or stored at ambient pressure, or compressed and stored, or implemented in any other applications, as the user desires. The use of the generated HYDROGEN, whether immediate or delayed, may include and is not limited to burning as a fuel, use as a reactant in another process, use in a reverse electrolysis reaction to produce electricity via fuel cell or other such processes and so on as required by the user.

[0041] Complementing FIG. 1, FIG. 2 and FIG. 3 shows, respectively, a chart of HYDROGEN generation rates using embodiments of the disclosed principles and structures and a schematic representation of a HYDROGEN production process in accordance with an embodiment of the disclosed principles. Further with respect to FIG. 2, this figure illustratively demonstrates achieved production rates of 1 to 3 kg of HYDROGEN per hour. Higher rates can be achieved by minor changes to design of vessel and / or process.

[0042] As shown in FIG. 3, the disclosed principles include a unique fuel introduction pipeline, wherein the metallic fuel pieces are weighed and then introduced to the vessel, all without releasing the vessel’s pressure.

[0043] It will be appreciated that this method maintains the reactor HYDROGEN boundary, minimizes loss of HYDROGEN, which aids both safety and efficiency, and allows for continuous operation of the reactor.

[0044] As noted above, in traditional systems, the unmanaged or poorly managed reaction of a metal and catalyst may create a runaway (uncontrollably exothermic) reaction and may paradoxically also end with unreacted metallic fuel being trapped under an oxide layer, preventing completion of the reaction. In embodiments of the disclosed principles, the reaction of all metallic fuel will go to full completion or negligible oxide residue in vessel 101. The factors used to optimize the reaction are the fuel type, associated surface area, loading mechanism, catalyst pH and molality, vessel temperature and pressure.

[0045] Regarding the fuel type, in an embodiment, the fuel comprises at least one of virgin or recycled transition and post-transition metals such as aluminum, magnesium, zinc or other metals. The fuel can bear any shape, e.g., pieces, strips or wires. It will be appreciated that other shapes may be used instead or in addition, e.g., pyramids, cubes, ingots etc. While a nonsymmetrical form factor may be used for the fuel, symmetry can be beneficial.

[0046] In addition to the fuel loading system and managing dwell time in the vessel 101, the process also, in an embodiment, manages temperature (e.g., over the range 25°C-100°C), pressure (e.g., over the range 1-10 ATM) and molality (e.g., over the range pH 8-15). This allows the fuel to completely react, finishing the reaction and maximizing the amount of HYDROGEN produced.

[0047] A recirculation loop 117 containing one or more filters 119 and pumps 121 is connected to the vessel 101. The recirculation loop 117 is used to treat and refresh the catalyst. This recirculation loop 117 also contains a heat exchanger 123 and fresh catalyst feed input 125.

[0048] Additional safety systems may be included, e.g., one or more overpressure relief valves and the capacity to rapidly release the catalyst to a safety vessel to quench the reaction.

[0049] As used herein, the phrase "at least one of" preceding a series of items, with the term "and" or "or" to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase "at least one of" does not require selection of at least one of each item listed; rather, the phrase allows a meaning that includes at least one of any one of the items, and / or at least one of any combination of the items, and / or at least one of each of the items. By way of example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" each refer to only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

[0050] The predicate words "configured to", “such that,” and "operable to" do not imply any particular tangible or intangible modification of a subject, but, rather, are intended to be used interchangeably. A phrase such as "an aspect" does not imply that such aspect is essential to the subject technology or that such aspect applies to all configurations of the subject technology. A disclosure relating to an aspect may apply to all configurations, or one or more configurations. An aspect may provide one or more examples of the disclosure. A phrase such as an "aspect" may refer to one or more aspects and vice versa. A phrase such as an "embodiment" does not imply that such embodiment is essential to the subject technology or that such embodiment applies to all configurations of the subject technology.

[0051] A disclosure relating to an embodiment may apply to all embodiments, or one or more embodiments. An embodiment may provide one or more examples of the disclosure. A phrase such an "embodiment" may refer to one or more embodiments and vice versa. A phrase such as a "configuration" does not imply that such configuration is essential to the subject technology or that such configuration applies to all configurations of the subject technology. A disclosure relating to a configuration may apply to all configurations, or one or more configurations. A configuration may provide one or more examples of the disclosure. A phrase such as a "configuration" may refer to one or more configurations and vice versa.

[0052] The words "exemplary,” “exemplify,” and “example” are used herein to mean "serving as an example, instance, or illustration." Any embodiment described herein as "exemplary" or as an "example" is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, to the extent that the term "include," "have," or the like is used in the description or the claims, such term is intended to be inclusive in a manner similar to the term "comprise" as "comprise" is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term "include," "have," or the like is used in the description or the claims, such term is intended to be inclusive in a manner similar to the term "comprise" as "comprise" is interpreted when employed as a transitional word in a claim.

[0053] All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112, sixth paragraph, unless the element is expressly recited using the phrase "means for" or, in the case of a method claim, the element is recited using the phrase "step for."

[0054] Reference to an element in the singular is not intended to mean "one and only one" unless specifically so stated, but rather "one or more." Unless specifically stated otherwise, the term "some" refers to one or more. Pronouns in the masculine (e.g., his) include the feminine and neuter gender (e.g., her and its) and vice versa. Headings and subheadings, if any, are used for convenience only and do not limit the subject disclosure.

[0055] While this specification contains many specifics, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of particular implementations of the subject matter. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable sub-combination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a sub combination or variation of a sub combination.

[0056] It will be appreciated that various systems and processes have been disclosed herein. However, in view of the many possible embodiments to which the principles of the 5 present disclosure may be applied, it should be recognized that the embodiments described herein with are meant to be illustrative only and should not be taken as limiting the scope of the claims. Therefore, the techniques as described herein contemplate all such embodiments as may come within the scope of the following claims and equivalents thereof.

Claims

1. A HYDROGEN (Green Hydrogen) production apparatus comprising:a reactor vessel having:a catalyst containing a hydroxyl group;at least one fuel loading inlet configured to introduce a metallic fuel into the reactor vessel without depressurizing the reactor vessel, wherein the metallic fuel is selected from a group of a virgin or recycled transition and post-transition metals; a HYDROGEN outlet configured to release HYDROGEN from the reactor vessel; andcharacterized in that a managed reaction of the metallic fuel in the presence of a catalyzing agent is carried out in the reactor vessel to produce HYDROGEN by managing temperature in the range of 25°C-100°C, pressure in the range of 1-10 ATM and molality in the range of pH 8-15 so as to allow the fuel to completely react, finishing the reaction and maximizing the amount of HYDROGEN produced.

2. The HYDROGEN production apparatus as claimed in claim 1, wherein the fuel loading inlet configured comprises a two-valve pressure lock that prevents depressurizing of the reactor vessel.

3. The HYDROGEN production apparatus as claimed in claim 2, wherein the fuel loading inlet further comprises a scale configured to weigh each incoming fuel piece.

4. The HYDROGEN production apparatus as claimed in claim 1, wherein the metallic fuel comprises at least one of Aluminum, Magnesium and Zinc.

5. The HYDROGEN production apparatus as claimed in claim 1, wherein the catalyst is an alkali ionic hydroxide.

6. The HYDROGEN production apparatus as claimed in claim 5, wherein the alkali ionic hydroxide includes at least one of calcium hydroxide, aluminum hydroxide, potassium hydroxide, and sodium hydroxide.

7. The HYDROGEN production apparatus as claimed in claim 1, further comprising a catalyst recirculation loop having therein a pump and one or more modules configured to modify one or more properties of the catalyst solution to treat and refresh the catalyst.

8. The HYDROGEN production apparatus as claimed in claim 7, wherein each of the one or more modules comprises a molarity module configured to control the catalyst solution molarity.

9. The HYDROGEN production apparatus as claimed in claim 7, wherein each of the one or more modules comprises a heat exchange module configured to control the catalyst solution temperature.

10. A HYDROGEN production apparatus comprising:a reactor vessel for reacting a metallic fuel with a catalyst to produce HYDROGEN;a catalyst solution within the reactor vessel;a fuel loading inlet configured to introduce a metallic fuel into the reactor vessel;a HYDROGEN outlet configured to release HYDROGEN from the reactor vessel; anda reaction manager configured to automatically manage one or more attributes of thecatalyst solution to avoid formation of an oxide shield on the fuel, so as allow complete reaction of the metallic fuel with the catalyst.

11. The HYDROGEN production apparatus as claimed in claim 10, wherein the reaction manager is further configured to provide continuous or semi-continuous operations 5           without shutdown, start-up, or steady state loss.

12. The HYDROGEN production apparatus as claimed in claim 10, wherein the reaction of the metallic fuel with the catalyst is controlled by design of the metal fuel and / or catalyst introduction.

13. The HYDROGEN production apparatus as claimed in claim 10, wherein the reaction 10           of the metallic fuel with the catalyst is controlled by introduction of the catalyst intothe reaction vessel.

14. The HYDROGEN production apparatus as claimed in claim 10, wherein the reaction temperature is controlled by vessel design and material process control.

15. The HYDROGEN production apparatus as claimed in claim 10, wherein the reaction 15           manager is configured to provide a substantially constant reaction rate.

Images