Anode and / or cathode pan assemblies in electrochemical cells, and methods for using and manufacturing them.

Abstract

Provided herein are anode and / or cathode pan assemblies with unique manifold, outlet tube, and / or baffle plate configurations, electrochemical cells and / or electrolyzers including the anode and / or cathode pan assemblies, and methods of using and manufacturing the same. The anode and / or cathode pan assemblies may include an anode and / or cathode pan and a manifold positioned inside the anode and / or cathode pan, the cross-sectional area of ​​the manifold having a manifold depth that is about 0.25-0.75 of the pan depth. The pan may include one or more ribs on the inside of the pan with one or more notches, and a baffle plate with two or more slots configured to fit over the one or more notches in the one or more ribs.

Description

[Background technology]

[0001] (Cross-reference of related applications) This application is a continuation of U.S. Patent Application No. 17 / 557,421, filed on 21 December 2021, claiming the interests of U.S. Provisional Application No. 63 / 195,520, filed on 1 June 2021, each of which is fully incorporated herein by reference.

[0002] Hydrogen production plays a vital role in any industrialized society because it is required for many essential chemical processes. As of 2019, approximately 70 million tons of hydrogen could be produced worldwide annually for various uses, such as in petroleum refining, and in the production of ammonia (through the Haber process) and methanol (through the reduction of carbon monoxide), as well as as a fuel in transportation.

[0003] The majority of hydrogen (approximately 95%) can be produced from fossil fuels through steam conversion of natural gas, partial oxidation of methane, and coal gasification. Other methods of hydrogen production include biomass gasification, methane pyrolysis (which does not emit CO2), and water electrolysis. Electrolysis consists of using electricity to decompose water into hydrogen and oxygen. However, all methods and systems are generally more expensive than fossil fuel-based production methods, which damage the environment. Therefore, there is a need for cost-competitive and environmentally friendly hydrogen gas production electrolysis systems. [Overview of the project] [Means for solving the problem]

[0004] Provided herein are methods and systems relating to anode pan assembly and / or cathode pan assembly configurations used in electrochemical cells designed to perform electrolytic processes such as hydrogen gas production in ion exchange membrane (IEM) water electrolysis technology, which may enable a commercially viable alternative to fossil fuels. The anode pan assembly and / or cathode pan assembly configurations provided herein include unique manifold, outlet tube, and / or baffle plate configurations that enable operation of the electrochemical cell at high current densities. Due to production at high current densities, targeted production rates can be filled with fewer cells, thereby reducing capital costs and making the electrolytic system a viable source for hydrogen gas production.

[0005] In one aspect, an anode and / or cathode pan assembly is provided, the anode and / or cathode pan assembly comprising an anode and / or cathode pan and a manifold positioned inside the anode and / or cathode pan, the manifold having a cross-sectional area such that the depth of the manifold is approximately 0.25 to 0.75 of the depth of the pan. In some embodiments of the aforementioned aspect, the cross-sectional area of ​​the manifold is approximately 520 to 6,200 mm². 2 In some embodiments of the aforementioned aspects and embodiments, the anode and / or cathode pan assembly further comprises an outlet pipe fluidly connected to the manifold. In some embodiments of the aforementioned aspects and embodiments, the equivalent diameter of the outlet pipe is approximately 26 to 89 mm.

[0006] In one aspect, an anode and / or cathode pan assembly is provided, the anode and / or cathode pan assembly comprising an anode and / or cathode pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs.

[0007] In one aspect, an anode and / or cathode pan assembly is provided, the anode and / or cathode pan assembly comprising an anode and / or cathode pan, a manifold positioned inside the anode and / or cathode pan, the manifold having a cross-sectional area having a depth of manifold which is about 0.25 to 0.75 of the depth of the pan, and one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs.

[0008] In some embodiments of the aforementioned side view, the baffle plate is perpendicular to one or more ribs. In some embodiments of the aforementioned side view and embodiments, the baffle plate is suspended between the electrode and the anode and / or cathode pan or pan bed. In some embodiments of the aforementioned side view and embodiments, the baffle plate is parallel to the anode and / or cathode pan.

[0009] In some embodiments of the aforementioned aspects and embodiments, the width of two or more slots in the baffle plate is equal to the width of one or more ribs such that the two or more slots fit over one or more notches of one or more ribs. In some embodiments of the aforementioned aspects and embodiments, the distance between two or more slots is equal to the length of one or more notches such that the two or more slots fit over one or more notches of one or more ribs. In some embodiments of the aforementioned aspects and embodiments, the distance between two or more slots and / or the length of one or more notches is approximately 5 to 100 mm.

[0010] In some aspects and embodiments of the aforementioned features, the anode and / or cathode pan assembly further comprises one or more ribs and electrodes mounted on top of the anode and / or cathode pan.

[0011] In some embodiments of the aforementioned aspects and embodiments, the distance of the baffle plate from the electrode is approximately 5 to 15 mm. In some embodiments of the aforementioned aspects and embodiments, the baffle plate is installed at a depth of approximately 0.25 to 0.5 mm from the anode and / or cathode pan. In some embodiments of the aforementioned aspects and embodiments, the baffle plate leaves space at the top and / or bottom between the baffle plate and the anode and / or cathode pan for gas and liquid flow. In some embodiments of the aforementioned aspects and embodiments, the space between the baffle plate and the bottom of the anode and / or cathode pan is approximately 6 to 75 mm, and / or the space between the baffle plate and the top of the anode and / or cathode pan and / or manifold is approximately 6 to 150 mm.

[0012] In some embodiments of the aforementioned aspects and embodiments, the anode and / or cathode pan assembly is equipped with a high flow rate of anode fluid or cathode fluid of about 200 to 10,000 kg / hour, respectively. In some embodiments of the aforementioned aspects and embodiments, the anode and / or cathode pan assembly is equipped with a flow rate of about 300 mA / cm². 2 ~6,000mA / cm 2 It is located inside the electrochemical cell which is started at a high current density. In the aforementioned aspects and in some embodiments of the embodiments, the cross-sectional area of ​​the manifold, outlet pipe, and / or baffle plate ensures that the surface liquid velocity of the anode and / or cathode liquid is less than 0.1 m / sec.

[0013] In some embodiments of the aforementioned aspects and embodiments, the cross-sectional area of ​​the manifold, outlet pipe, and / or baffle plate is adapted to high-flow anode or cathode fluid and / or gas to prevent slug or plug flow. In some embodiments of the aforementioned aspects and embodiments, the cross-sectional area of ​​the manifold, outlet pipe, and / or baffle plate prevents pressure fluctuations due to multiphase flow within the cell to less than 0.5 psi. In some embodiments of the aforementioned aspects and embodiments, the cross-sectional area of ​​the manifold, outlet pipe, and / or baffle plate prevents film erosion and / or fatigue.

[0014] In some embodiments of the aforementioned aspects and embodiments, the baffle plate partitions the internal volume of the anode and / or cathode pan, creating a rising region between the baffle plate and the electrodes that is rich in gas, and a falling region between the baffle plate and the bottom of the pan that is rich in electrolyte. In some embodiments of the aforementioned aspects and embodiments, the electrodes are the anode (in the anode-pan assembly) and / or cathode (in the cathode-pan assembly). In some embodiments of the aforementioned aspects and embodiments, the baffle plate allows for electrolyte circulation and mixing from top to bottom, causing thermal equilibrium of the incoming electrolyte and preventing overheating of the cell.

[0015] In some embodiments of the aforementioned aspects and embodiments, the anode and / or cathode pan assembly is located inside the hydrogen gas production electrochemical cell. In some embodiments, in the hydrogen gas production electrochemical cell, hydrogen is generated at the cathode and oxygen is generated at the anode.

[0016] In the aforementioned aspects and in some embodiments of the embodiments, the anode and / or cathode pan assemblies further comprise electrolytes such as anode solution and / or cathode solution, respectively, wherein the anode solution and / or cathode solution comprises an alkaline solution.

[0017] In one aspect, an electrochemical cell is provided, the electrochemical cell comprising an anode and / or cathode pan assembly as described in any of the preceding aspects and embodiments, an anode positioned on the anode pan assembly, a cathode positioned on the cathode pan assembly, and an ion exchange membrane disposed between the anode and the cathode. In the electrochemical cell, either the aforementioned anode pan assembly (with a typical or conventional cathode assembly) or the aforementioned cathode pan assembly (with a typical or conventional anode assembly), or both the anode pan assembly and the cathode pan assembly may exist, and it should be understood that all such configurations are well within the scope of this disclosure.

[0018] In one aspect, an electrolytic apparatus is provided that comprises a large number of the aforementioned individual electrochemical cells.

[0019] In one aspect, a method is provided, the method comprising positioning a manifold inside the anode and / or cathode pan of an electrochemical cell, fluidly connecting an outlet pipe to the manifold, thereby forming an anode and / or cathode pan assembly, wherein the cross-sectional area of ​​the manifold has a depth of manifold of about 0.25 to 0.75 of the depth of the anode and / or cathode pan. In some embodiments of the aforementioned aspect, the method further comprises about 520 to 6,200 mm 2 This includes providing the cross-sectional area of ​​the manifold. In some embodiments of the aforementioned aspects and embodiments, the method further includes providing the equivalent diameter of the outlet pipe, which is about 26 to 89 mm.

[0020] In one aspect, a method is provided, the method comprising: positioning one or more ribs inside the anode and / or cathode pan of an electrochemical cell, wherein one or more ribs are provided with one or more notches; placing a baffle plate on one or more ribs, wherein the baffle plate is provided with two or more slots; and fitting two or more slots on one or more notches of one or more ribs.

[0021] In one respect, it is a method, and the method is The manifold is positioned inside the anode and / or cathode pan of the electrochemical cell, and the outlet pipe is fluidly connected to the manifold, wherein the cross-sectional area of ​​the manifold has a depth of approximately 0.25 to 0.75 times the depth of the anode and / or cathode pan. Positioning one or more ribs inside the anode and / or cathode pan of an electrochemical cell, wherein one or more ribs are provided with one or more notches, The baffle plate is installed on one or more ribs, and the baffle plate has two or more slots. A method is provided which includes fitting two or more slots onto one or more notches of one or more ribs.

[0022] In some embodiments of the aforementioned aspects and embodiments, the method further includes mounting a baffle plate perpendicular to one or more ribs. In some embodiments of the aforementioned aspects and embodiments, the method further includes mounting an electrode to one or more ribs and the top of the anode and / or cathode pan. In some embodiments of the aforementioned aspects and embodiments, the method further includes suspending a baffle plate between the electrode and the anode and / or cathode pan or pan floor. In some embodiments of the aforementioned aspects and embodiments, the method further includes leaving a space between the baffle plate and the top and / or bottom of the anode and / or cathode pan for gas and liquid flow.

[0023] In some embodiments of the aforementioned aspects and embodiments, the method further includes operating the anode and / or cathode pan assembly, respectively, under a high flow rate of anode or cathode liquid of about 200 to 10,000 kg / hour. In some embodiments of the aforementioned aspects and embodiments, the method includes positioning the anode and / or cathode pan assembly to assemble an electrochemical cell and operating it under a flow rate of about 300 mA / cm². 2 ~6,000mA / cm 2 This further includes activating the electrochemical cell at a high current density. In the aspects described above and in some embodiments of the embodiments, the electrochemical cell is a hydrogen gas production cell.

[0024] In some embodiments of the aforementioned aspects and embodiments, the method further includes ensuring that the surface liquid velocity of the anode and / or cathode fluid is less than 0.1 m / sec. In some embodiments of the aforementioned aspects and embodiments, the method further includes adapting to high flow rates of anode or cathode fluid and / or gas to prevent slag or plug flow. In some embodiments of the aforementioned aspects and embodiments, the method further includes preventing pressure fluctuations due to multiphase flow within the cell from being less than 0.5 psi. In some embodiments of the aforementioned aspects and embodiments, the method further includes preventing film erosion and / or fatigue.

[0025] In some aspects and embodiments of the aforementioned features, the method further includes partitioning the internal volume of the anode and / or cathode pan using a baffle plate, creating a gas-rich elevated region between the baffle plate and the electrode, and creating an electrolyte-rich elevated region between the baffle plate and the pan floor.

[0026] In some aspects and embodiments of the aforementioned features, the method further includes using a baffle plate to enable electrolyte circulation and mixing from top to bottom, causing thermal equilibrium of the incoming electrolyte and preventing overheating of the cell.

[0027] In one aspect, a process is provided for manufacturing an anode and / or cathode pan assembly, the process comprising: attaching a manifold inside the anode and / or cathode pan of an electrochemical cell; fluidically connecting an outlet pipe to the manifold; thereby forming an anode and / or cathode pan assembly, wherein the cross-sectional area of ​​the manifold has a depth of manifold of approximately 0.25 to 0.75 of the depth of the anode and / or cathode pan.

[0028] In one aspect, a process is provided for manufacturing an anode and / or cathode pan assembly, the process comprising: attaching one or more ribs inside the anode and / or cathode pan of an electrochemical cell, the one or more ribs having one or more notches; placing a baffle plate on the one or more ribs, the baffle plate having two or more slots; and fitting two or more slots on one or more notches of the one or more ribs.

[0029] In some embodiments of the aspects described above, the process includes metallurgically mounting a manifold inside the anode and / or cathode pan, and / or metallurgically mounting one or more ribs to the anode or cathode pan, and / or metallurgically mounting baffle plates to one or more ribs of the electrochemical cell.

[0030] In one aspect, it is a process for assembling an electrochemical cell, and the process is By joining the aforementioned anode pan assembly and a cathode assembly containing a cathode pan and a cathode together, and by attaching the anode to the anode pan assembly to form an anode assembly, an individual electrochemical cell can be assembled, or By joining the aforementioned cathode pan assembly and the anode assembly, which includes the anode pan and anode, together, and by attaching the cathode to the cathode pan assembly to form a cathode assembly, individual electrochemical cells can be assembled, or By joining the aforementioned anode pan assembly and cathode pan assembly together, attaching the anode to the anode pan assembly to form the anode assembly, and attaching the cathode to the cathode pan assembly to form the cathode assembly, individual electrochemical cells are assembled, and The anode assembly and cathode assembly are installed in parallel and separated by an ion exchange membrane, and A process is provided which includes supplying cell current and electrolytic raw materials to an electrochemical cell using a feeder.

[0031] In some embodiments of the aforementioned aspects, the electrochemical cell is a hydrogen gas production cell.

[0032] In one aspect, a process for assembling an electrolytic device is provided, the process comprising assembling the aforementioned individual electrochemical cells, arranging a plurality of assembled electrochemical cells side by side in a stack, and fixing them together to maintain electrical contact between the electrochemical cells. The present invention further provides, for example, the following: (Item 1) an anode and / or cathode pan assembly, wherein the anode and / or cathode pan assembly is Anode and / or cathode pan, The manifold located inside the anode and / or cathode pan Equipped with, An anode and / or cathode pan assembly having a manifold cross-sectional area and a depth of the manifold such that the manifold depth is approximately 0.25 to 0.75 times the depth of the pan. (Item 2) The cross-sectional area of ​​the aforementioned manifold is approximately 520 to 6,200 mm². 2 The anode and / or cathode pan assembly as described in item 1. (Item 3) The anode and / or cathode pan assembly described in item 2 further comprises an outlet pipe fluidly connected to the manifold, wherein the equivalent diameter of the outlet pipe is approximately 26 to 89 mm. (Item 4) an anode and / or cathode pan assembly, wherein the anode and / or cathode pan assembly is Anode and / or cathode pan, One or more ribs on the inside of the bread, which have one or more cuts, A baffle plate having two or more slots configured to fit onto one or more notches of one or more ribs, an anode and / or cathode pan assembly comprising (Item 5) The anode and / or cathode pan assembly as described in item 4, wherein the baffle plate is perpendicular to one or more ribs. (Item 6) The anode and / or cathode pan assembly according to item 4 or 5, wherein the width of the two or more slots in the baffle plate is equal to the width of the one or more ribs such that the two or more slots fit over the one or more notches of the one or more ribs. (Item 7) An anode and / or cathode pan assembly as described in any one of items 4-6, wherein the distance between two or more slots is equal to the length of one or more notches such that the two or more slots fit over one or more notches of one or more ribs. (Item 8) The distance between the two or more slots or the length of the one or more cuts is approximately 5 to 100 mm, as described in item 7 of the anode and / or cathode pan assembly. (Item 9) The anode and / or cathode pan assembly according to any one of items 4-8, further comprising one or more ribs and an electrode mounted on the top of the anode and / or cathode pan. (Item 10) The anode and / or cathode pan assembly according to item 9, wherein the baffle plate is suspended between the electrode and the anode and / or cathode pan. (Item 11) The anode and / or cathode pan assembly according to any one of items 4-10, wherein the baffle plate is parallel to the anode and / or cathode pan. (Item 12) The distance from the electrode to the baffle plate is approximately 5 to 15 mm, as described in any one of items 9-11 of the anode and / or cathode pan assembly. (Item 13) The anode and / or cathode pan assembly as described in any one of items 4-12, wherein the baffle plate is installed at a depth of approximately 0.25 to 0.5 of the anode and / or cathode pan. (Item 14) The anode and / or cathode pan assembly according to any one of items 4-13, wherein the baffle plate leaves space at the top and / or bottom between the baffle plate and the anode and / or cathode pan for gas and liquid flow. (Item 15) The anode and / or cathode pan assembly according to item 14, wherein the space between the baffle plate and the bottom of the anode and / or cathode pan is approximately 6 to 75 mm, and / or the space between the baffle plate and the top of the anode and / or cathode pan is approximately 6 to 150 mm. (Item 16) an anode and / or cathode pan assembly, wherein the anode and / or cathode pan assembly is Anode and / or cathode pan, A manifold positioned inside the anode and / or cathode pan, wherein the cross-sectional area of ​​the manifold has a depth of approximately 0.25 to 0.75 times the depth of the pan, One or more ribs on the inside of the bread, which have one or more cuts, A baffle plate having two or more slots configured to fit onto one or more notches of one or more ribs, an anode and / or cathode pan assembly comprising (Item 17) The anode and / or cathode pan assembly according to any one of items 1-16, wherein the anode and / or cathode pan assembly is provided with a high flow rate of anode fluid or cathode fluid of approximately 200 to 10,000 kg / hour, respectively. (Item 18) The anode and / or cathode pan assembly has a current of approximately 300 mA / cm². 2 ~6,000mA / cm 2 An anode and / or cathode pan assembly, as described in any one of items 1-17, located inside an electrochemical cell operating at a high current density. (Item 19) The cross-sectional area of ​​the manifold, the outlet pipe, and / or the baffle plate ensures that the surface liquid velocity of the anode and / or cathode fluid is less than 0.1 m / sec, as described in any one of items 1-18 of the anode and / or cathode pan assembly. (Item 20) The cross-sectional area of ​​the manifold, the outlet pipe, and / or the baffle plate is suitable for high-flow anode fluid or cathode fluid and / or gas, as described in any one of items 1-19, for an anode and / or cathode pan assembly. (Item 21) The cross-sectional area of ​​the manifold, the outlet pipe, and / or the baffle plate prevents pressure fluctuations due to multiphase flow within the cell from being less than 0.5 psi, as described in any one of items 1-20 of the anode and / or cathode pan assembly. (Item 22) The cross-sectional area of ​​the manifold, the outlet pipe, and / or the baffle plate is such that it prevents film erosion and / or fatigue, as described in any one of items 1-21 of the anode and / or cathode pan assembly. (Item 23) The anode and / or cathode pan assembly according to any one of items 4-22, wherein the baffle plate partitions the internal volume of the anode and / or cathode pan, creating a gas-rich elevated region between the baffle plate and the electrode, and an electrolyte-rich descending region between the baffle plate and the pan floor. (Item 24) The anode and / or cathode pan assembly according to any one of items 4-23, wherein the baffle plate allows for electrolyte circulation and mixing from top to bottom, causes thermal equilibrium of the incoming electrolyte, and prevents overheating of the cell. (Item 25) The anode and / or cathode pan assembly is located inside a hydrogen gas production electrochemical cell, as described in any one of items 1-24. (Item 26) The anode and / or cathode pan assembly according to item 25, further comprising an anode solution and / or cathode solution, wherein the anode solution and / or the cathode solution comprises an alkaline solution. (Item 27) An electrochemical cell comprising the anode and / or cathode pan assembly described in any one of items 1-26, an anode positioned on the anode pan assembly, a cathode positioned on the cathode pan assembly, and an ion exchange membrane disposed between the anode and the cathode. (Item 28) An electrolytic apparatus equipped with numerous individual electrochemical cells as described in item 27. (Item 29) A method comprising positioning a manifold inside the anode and / or cathode pan of an electrochemical cell, fluidly connecting an outlet pipe to the manifold, thereby forming an anode and / or cathode pan assembly, wherein the cross-sectional area of ​​the manifold is approximately 0.25 to 0.75 times the depth of the anode and / or cathode pan. (Item 30) Approximately 520~6,200mm 2 The method according to item 29, further comprising providing the cross-sectional area of ​​the manifold. (Item 31) The method of item 30, further comprising providing an equivalent diameter of the outlet pipe which is approximately 26 to 89 mm. (Item 32) A method, wherein the said method is Positioning one or more ribs inside the anode and / or cathode pan of an electrochemical cell, wherein the one or more ribs are provided with one or more notches, The baffle plate is installed on one or more of the aforementioned ribs, and the baffle plate has two or more slots. Fitting the two or more slots onto the one or more notches of the one or more ribs Methods that include... (Item 33) A method for forming an anode and / or cathode pan assembly, the method being: The method involves positioning a manifold inside the anode and / or cathode pan of an electrochemical cell, and fluidly connecting the outlet pipe to the manifold, wherein the cross-sectional area of ​​the manifold is approximately 0.25 to 0.75 times the depth of the anode and / or cathode pan. Positioning one or more ribs inside the anode and / or cathode pan of the electrochemical cell, wherein each of the one or more ribs is provided with one or more notches, The baffle plate is installed on one or more of the aforementioned ribs, and the baffle plate has two or more slots. Fitting the two or more slots onto the one or more notches of the one or more ribs Methods that include... (Item 34) The method according to item 32 or 33, further comprising installing the baffle plate perpendicular to one or more ribs. (Item 35) The method according to any one of items 32-34, further comprising attaching the electrodes to the one or more ribs and the top of the anode and / or cathode pan. (Item 36) The method according to any one of items 32-35, further comprising suspending the baffle plate between the electrode and the anode and / or the cathode pan. (Item 37) The method according to any one of items 32-36, further comprising leaving a space between the baffle plate and the top and / or bottom of the anode and / or cathode pan for gas and liquid flow. (Item 38) The method according to any one of items 29-37, further comprising operating the anode and / or the cathode pan assembly, respectively, under a high flow rate of anode fluid or cathode fluid of approximately 200-10,000 kg / hour. (Item 39) Positioning the anode and / or cathode pan assembly to assemble the electrochemical cell, Approximately 300mA / cm 2 ~6,000mA / cm 2 Operating the electrochemical cell at a high current density and The method described in any one of items 29-38, further including the method described in any one of items 29-38. (Item 40) The electrochemical cell is a hydrogen gas production cell, according to the method described in item 39. (Item 41) The method according to any one of items 29-40, further comprising ensuring that the surface liquid velocity of the anode and / or cathode is less than 0.1 m / sec. (Item 42) The method according to any one of items 29-41, further comprising adapting to high flow rates of anode or cathode fluid and / or gas to prevent slag or plug flow. (Item 43) The method according to any one of items 29-42, further comprising preventing pressure increases or decreases due to multiphase flow within the cell from being less than 0.5 psi. (Item 44) The method according to any one of items 29-43, further comprising preventing membrane erosion and / or fatigue. (Item 45) The method according to any one of items 32-44, further comprising using the baffle plate to partition the internal volume of the anode and / or the cathode pan, creating a gas-rich elevated region between the baffle plate and the electrode, and creating an electrolyte-rich descending region between the baffle plate and the bottom of the pan. (Item 46) The method according to any one of items 32-45, further comprising using the baffle plate to enable electrolyte circulation and mixing from top to bottom, causing thermal equilibrium of the incoming electrolyte and preventing overheating of the cell. (Item 47) A process for manufacturing an anode and / or cathode pan assembly, the process comprising: attaching a manifold inside the anode and / or cathode pan of an electrochemical cell; fluidically connecting an outlet pipe to the manifold; thereby forming an anode and / or cathode pan assembly. A process wherein the cross-sectional area of ​​the manifold has a depth of the manifold of approximately 0.25 to 0.75 times the depth of the anode and / or cathode pan. (Item 48) The process according to item 47, comprising metallurgically mounting the manifold inside the anode and / or cathode pan of the electrochemical cell. (Item 49) A process for manufacturing an anode and / or cathode pan assembly, wherein the process is: Attaching one or more ribs to the inside of the anode and / or cathode pan of an electrochemical cell, wherein the one or more ribs are provided with one or more notches, The baffle plate is installed on one or more of the aforementioned ribs, and the baffle plate has two or more slots. Fitting the two or more slots onto the one or more notches of the one or more ribs A process that includes this. (Item 50) A process for assembling an electrochemical cell, wherein the process is Assembling individual electrochemical cells by joining the anode pan assembly described in any one of items 1-26 together with a cathode assembly comprising a cathode pan and a cathode, attaching an anode to the anode pan assembly, and forming an anode assembly, or Assembling individual electrochemical cells by joining a cathode pan assembly described in any one of items 1-26 together with an anode assembly comprising an anode pan and an anode, attaching a cathode to the cathode pan assembly, and forming a cathode assembly, or Assembling individual electrochemical cells by joining together the anode pan assembly and the cathode pan assembly as described in any one of items 1-26, attaching the anode to the anode pan assembly to form the anode assembly, attaching the cathode to the cathode pan assembly to form the cathode assembly, and The anode assembly and the cathode assembly are installed in parallel, and they are separated by an ion exchange membrane, and The cell current and electrolytic raw materials are supplied to the electrochemical cell using a feeder. A process that includes this. (Item 51) The electrochemical cell is a hydrogen gas production cell, as described in item 50 of the process. (Item 52) A process for assembling an electrolytic device, wherein the process is Assembling the individual electrochemical cells described in item 50 or 51, Multiple of the aforementioned assembled electrochemical cells are arranged side by side in a stack, To maintain electrical contact between the electrochemical cells, and to fix them together. A process that includes this. [Brief explanation of the drawing]

[0033] Novel features of the present invention are described in detail in the appended claims. A deeper understanding of the features and advantages of the present invention can be obtained by referring to the following detailed description, which describes illustrative embodiments in which the principles of the present invention are utilized, and to the accompanying drawings.

[0034] [Figure 1] Figure 1 illustrates several embodiments relating to an anode pan assembly or cathode pan assembly comprising a manifold and an outlet pipe. The figure on the right shows a front view of the assembly, and the figure on the left shows a cross-sectional view of the assembly.

[0035] [Figure 2] Figure 2 illustrates several embodiments relating to the manifold inside the anode pan or cathode pan and the outlet pipe attached to the manifold through the nozzle, in cross-sectional and enlarged views.

[0036] [Figure 3] Figure 3 illustrates several embodiments relating to the orientation and configuration of the manifold in the anode pan or cathode pan.

[0037] [Figure 4] Figure 4 illustrates several embodiments relating to the direction of gas and liquid flow through the manifold in an anode pan assembly or cathode pan assembly.

[0038] [Figure 5] Figure 5 illustrates several embodiments relating to an anode pan assembly or cathode pan assembly, which includes a baffle plate fitted over a rib and suspended within the anode pan or cathode pan. The figure on the right shows a front view of the assembly, and the figure on the left shows a cross-sectional view of the assembly.

[0039] [Figure 6] Figure 6 illustrates several embodiments relating to a cross-sectional view of an anode or cathode pan assembly showing two or more slots in a baffle plate fitted over one or more notches in one or more ribs inside the anode or cathode pan.

[0040] [Figure 7] Figure 7 illustrates several embodiments relating to a front view of a baffle plate with slots.

[0041] [Figure 8] Figure 8 illustrates several embodiments related to electrolyte flow through half cells with and without baffle plates.

[0042] [Figure 9] Figure 9 illustrates several embodiments relating to the positioning and dimensions of the baffle plate inside the anode pan or cathode pan.

[0043] [Figure 10] Figure 10 illustrates vector plots showing simulated liquid flow distributions with and without baffle plates, as described in Example 2. [Modes for carrying out the invention]

[0044] Components, methods, and electrochemical cells related to anode pan assemblies and / or cathode pan assemblies are provided herein, the pan assemblies comprising unique manifold and / or outlet tube and / or baffle plate configurations, which are designed to perform electrolytic processes such as hydrogen gas production at high current densities in IEMs (e.g., anion exchange membrane (AEM) alkaline water electrolysis technology).

[0045] Typically, commercial alkaline water electrolysis cells have a flow rate of 100-400 mA / cm². 2 It can operate in such conditions. For example, commercial chlor-alkali electrochemical cells typically have a maximum current of approximately 500 mA / cm². 2 It can operate at current densities. However, the applicant has designed a unique electrochemical cell and its components that can dynamically operate at high current densities, allowing operators to meet their targeted production rate with fewer cells, thereby reducing capital costs. Furthermore, the range of high operating current densities of the cell provides operators with a large turndown ratio, which can enable operators to maximize production when electricity prices are low and reduce power consumption when electricity prices are high.

[0046] Before the present invention is described in more detail, it should be understood that the invention is not limited to the specific embodiments described and is therefore naturally subject to change. It should also be understood that the terminology used herein is for the purpose of describing specific embodiments only and is not intended to be limiting, as the scope of the invention will be limited only by the appended claims.

[0047] Where a range of values ​​is provided, it should be understood that, unless the context explicitly determines otherwise, each intervening value up to one-tenth of the lower limit unit between the upper and lower limits of that range, and any other stated or intervening values ​​within that stated range, are included within the invention. The upper and lower limits of these smaller ranges may independently be included within smaller ranges and are also included within the invention, according to any specifically excluded limits within the stated range. If the stated range includes one or both of the limits, the range excluding one or both of those included limits is also included within the invention.

[0048] Certain ranges presented herein by numerical value may be interpreted as “approximate” numbers. “Approximate” is intended to provide literal support for the exact number that precedes it, and for any number that is close to or approximates the preceding number. In determining whether a number is close to or approximates a specifically enumerated number, a close or approximate unenumerated number may, in the context in which it is presented, provide a substantial equivalent of the specifically enumerated number.

[0049] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art in which the invention pertains. Any methods and materials similar to or equivalent to those described herein may also be used in the practice or testing of the invention, but representative illustrative methods and materials are described herein.

[0050] All publications and patents cited herein are incorporated herein by reference to the same extent as each individual publication or patent is shown to be incorporated by specific and individual reference, and are incorporated herein by reference to disclose and explain the manner and / or materials by which the publications are cited in connection therewith. Any citation of a publication relates to its disclosure prior to the filing date and should not be construed as acknowledging that the present invention does not have prior rights to such publication by prior art. Furthermore, the dates of publications provided may differ from the actual publication dates and may need to be independently verified.

[0051] It should be noted that, as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural nouns unless the context clearly determines otherwise. It should be further noted that claims may be drafted to exclude any optional elements. Thus, these words are intended to serve as antecedents for the use of exclusive technical terms such as “simply,” “only,” or “negative” limitation relating to the enumeration of claim elements.

[0052] As will be apparent to those skilled in the art upon careful reading of this disclosure, each of the individual embodiments described and illustrated herein has discrete components and features that can be readily separated from or combined with any of the features of several other embodiments without departing from the scope or spirit of the invention. Any enumerated method may be performed in the order of the enumerated events, or in any other logically possible order.

[0053] (Anode and / or cathode pan assembly) The operation of electrochemical cells at high current densities, as described above, can present significant challenges, but are not limited to, adapting to the large gas volume produced at high current densities, large pressure fluctuations, membrane erosion or fatigue, large amounts of heat generated within the cell, and / or high electrolyte flow rates. The unique configurations of the anode and / or cathode pan assemblies within electrochemical cells provided herein can overcome one or more of these challenges, but are not limited to, avoiding large temperature fluctuations of the electrolyte along the cell height; avoiding gas covering a significant portion of the nominal active area; avoiding the formation of stagnant gas pockets that can lead to localized drying of the membrane; and / or avoiding large pressure fluctuations caused by slug or plug flow at the cell outlet.

[0054] Due to the large gas volume, static gas pockets can form on the electrodes or at the top of the cell. To counteract gas pockets, utilizing features that provide high electrolyte flow rates, induce gas lift, and produce high local shear rates can help minimize static gas pockets that form on the electrodes. However, high electrolyte flow rates, coupled with the large volume of gas production and the large volume of liquid entering and leaving the cell, present significant challenges associated with sluggish and plugged flow. Operation at high electrolyte flow rates and high current densities can lead to slugging at the cell outlet, which can be minimized by using the manifold and outlet pipe configurations provided herein.

[0055] The applicant provides herein an anode and / or cathode pan assembly that includes an effective collection system at the top of the cell to ensure that large stagnant gas pockets are not formed at the top of the cell or are minimized. The collection system comprises a manifold and outlet pipe with a large cross-sectional area that effectively provides space for gas to collect and for liquid to flow without covering the membrane and / or causing sludge and plug flow. The anode and / or cathode pan assembly provided herein ensures that this two-phase (gas / liquid) flow is effectively directed out of the cell.

[0056] Anode and / or cathode pan assemblies, including manifolds and outlet pipes, provided herein are designed to ensure uniform flow across the cell width and minimal pressure fluctuations within the cell. The flow uniformity requirement drives the need to ensure that the back pressure associated with the flow entering the manifold significantly exceeds the pressure drop along the length of the manifold. The need to maintain an essentially constant internal pressure distribution drives the requirement to avoid slug or plug flow through the manifolds and outlet pipes. Therefore, anode and / or cathode pan assemblies, including manifolds and outlet pipes as provided herein, are critical design elements enabling reliable cell operation over a wide range of electrolyte flows and high current densities.

[0057] The design of an anode and / or cathode pan assembly, including a manifold and outlet pipe as provided herein, must ensure that there are no sludge or plug flow problems with operation at high current densities, while the cross-sectional area of ​​the manifold and outlet pipe must also be optimized to prevent excessively deep cells that are ineffective for operational and economic purposes. The applicant has designed a manifold and outlet pipe configuration with cross-sectional areas that meet these needs.

[0058] As the current density increases within the cell, power dissipation can also increase dramatically. Large spatial and / or temporal temperature fluctuations can damage the membrane. The effect of internal power dissipation on the internal temperature distribution of the cell can be minimized through operating conditions such as temperature maintenance, the flow rate of the incoming electrolyte, and / or the recirculation of the incoming electrolyte. High electrolyte flow rates can help maximize convective heat transfer within the cell, thereby minimizing heat buildup and associated temperature increases within the cell that could otherwise result from increased current density. The applicant designed an internal baffle plate configuration of the anode and / or cathode pan assembly to minimize the effect of increasing and decreasing power dissipation on the internal temperature of the cell.

[0059] In an electrochemical cell, an anode pan containing the anode and anode electrolyte may be present. A cathode pan containing the cathode and cathode electrolyte may also be present, and the anode pan and cathode pan are separated by a diaphragm, a membrane electrode assembly (MEA), or one or more ion exchange membranes (IEMs). The anode pan and / or cathode pan may further include components such as a collection system (together forming the anode pan assembly or cathode pan assembly) that collects gases and liquids and allows them to flow out of the cell. The IEM may be an anion exchange membrane (AEM), a cation exchange membrane (CEM), or both, depending on the desired reaction at the anode and cathode. Various additional separator components may be provided between these components to, for example, separate the AEM from the anode, separate the CEM from the cathode, and / or separate the AEM from the CEM, and to provide mechanical integrity to the membrane. In addition to these components, individual gaskets or gasket tapes may be provided between the components and along their outer circumference to seal the compartment from fluid leakage.

[0060] All components described above can be aligned parallel to one another, and optional peripheral bolting can be provided to stack them together within the electrochemical cell. In a filter press configuration, no peripheral bolting may be required. In a stack of electrochemical cells, the anode of one electrochemical cell is in contact with the cathode of an adjacent electrochemical cell. Current flows through the stack of electrochemical cells during operation.

[0061] In an illustrative embodiment, an anode pan assembly or cathode pan assembly of the present invention is shown in Figure 1 (the right-hand figure shows a front view of the assembly, and the left-hand figure shows a cross-sectional view of the assembly). It should be understood that in an electrochemical cell, either or both of the anode pan assembly or cathode pan assembly provided herein may be used. For example, the assembly shown in Figure 1 may be an anode pan assembly or a cathode pan assembly or both, depending on the need and the reactions in the anode and cathode. The following components of the cell, such as the anode or cathode, will be placed on top of the anode pan assembly or cathode pan assembly shown on the right side of Figure 1, which is a front view of the assembly.

[0062] As shown in Figure 1, the anode pan assembly or cathode pan assembly 100 comprises an anode pan or a cathode pan 101, respectively. Inside the depth of the anode pan or cathode pan, and above the pan (as shown in the left figure), a manifold 102 is housed. The manifold 102 is fluidly connected to an outlet pipe 103 through a nozzle. The manifold may be connected to one or more outlet pipes, depending on the requirements. For example, the design may incorporate two, three, four, or more outlet pipes on each anode and / or cathode pan assembly on the same side or both sides to minimize cell thickness and maximize the number of cells that can fit within an electrolytic device frame or a particular size.

[0063] In one aspect, an anode and / or cathode pan assembly, a method for forming, using, and manufacturing the same is provided herein, the pan assembly comprising an anode and / or cathode pan and a manifold positioned inside the anode and / or cathode pan, the manifold having a cross-sectional area and a depth of manifold of about 0.25 to 0.75 of the depth of pan. In some embodiments, the aforementioned anode and / or cathode pan assembly further comprises an outlet pipe.

[0064] In some embodiments, the depth of the manifold and / or the cross-sectional area of ​​the manifold and / or outlet pipes need to be optimized to be deep enough to provide a large cross-sectional area of ​​the manifold to avoid sludge and plug flow in the two-phase system, but also to provide sufficient space between the manifold walls and the electrodes mounted on the pan to allow for unobstructed flow of gases and liquids and to keep the membranes moist. The depth of the manifold and / or the cross-sectional area of ​​the manifold and / or outlet pipes also determine the cell thickness, and therefore the cross-sectional area of ​​the manifold is important for achieving various functions in the cell.

[0065] In some embodiments of the anode and / or cathode pan assembly and its method, the cross-sectional area of ​​the manifold is approximately 0.25 to 0.75 of the pan depth, or approximately 0.25 to 0.6 of the pan depth, or approximately 0.25 to 0.5 of the pan depth, or approximately 0.25 to 0.4 of the pan depth, or approximately 0.25 to 0.3 of the pan depth, or approximately 0.3 to 0.75 of the pan depth, or the depth of the pan The manifold has a depth of approximately 0.3 to 0.6, or approximately 0.3 to 0.5, or approximately 0.3 to 0.4, or approximately 0.4 to 0.75, or approximately 0.4 to 0.6, or approximately 0.4 to 0.5, or approximately 0.5 to 0.75, or approximately 0.5 to 0.6, or approximately 0.6 to 0.75.

[0066] Another cross-sectional and enlarged view of the manifold and outlet pipe inside the anode or cathode pan is shown in Figure 2. The depth of manifold 102 is marked D, and the width of manifold is marked W. The equivalent diameter of outlet pipe 103 is marked ED. The depth of manifold 102, the width of manifold 102, and the depth of anode or cathode pan 101 are also illustrated in Figure 3. As is evident, the manifold has an upward taper at the top. The upward taper creates an internal volume or region above the upper edge of the membrane positioned adjacent to the electrode, providing a small area for the formation of a gas-rich mixture without causing the membrane to dry out.

[0067] The direction of gas and liquid flow through the anode pan assembly or cathode pan assembly is shown as a dotted line in Figure 4. The gas and liquid two phases flow upward to the top of the manifold 102 and downward into the manifold through the notch 104 at the top. The gas and liquid then flow out through the outlet pipe 103.

[0068] To accommodate large volumes of gas and liquid flowing through the manifold and outlet pipe (due to high current density and high flow rate), and to prevent slug and plug flow (and for other benefits enumerated herein), in some embodiments, the cross-sectional area of ​​the manifold and outlet pipe needs to be large enough to maintain the surface liquid velocity of the anode and / or cathode liquid at less than 0.1 m / s, or less than 0.08 m / s, or less than 0.05 m / s.

[0069] In some embodiments, an electrochemical cell comprising the anode and / or cathode pan assembly disclosed herein produces approximately 300 mA / cm². 2 ~6,000mA / cm 2 , or approximately 300mA / cm² 2 ~5,000mA / cm 2 , or approximately 300mA / cm² 2 ~4,000mA / cm 2 , or approximately 300mA / cm²2 ~3,000mA / cm 2 , or approximately 300mA / cm² 2 ~2,000mA / cm 2 , or approximately 300mA / cm² 2 ~1,000mA / cm 2 , or approximately 300mA / cm² 2 ~800mA / cm 2 , or approximately 300mA / cm² 2 ~600mA / cm 2 , or approximately 300mA / cm² 2 ~500mA / cm 2 , or approximately 500mA / cm² 2 ~6,000mA / cm 2 , or approximately 500mA / cm² 2 ~5,000mA / cm 2 , or approximately 500mA / cm² 2 ~4,000mA / cm 2 , or approximately 500mA / cm² 2 ~3,000mA / cm 2 , or approximately 500mA / cm² 2 ~2,000mA / cm 2 , or approximately 500mA / cm² 2 ~1,000mA / cm 2 , or approximately 500mA / cm² 2 ~800mA / cm 2 , or approximately 500mA / cm² 2 ~600mA / cm 2 , or approximately 600mA / cm² 2 ~6,000mA / cm 2 , or approximately 600mA / cm² 2 ~5,000mA / cm 2 , or approximately 600mA / cm² 2 ~4,000mA / cm 2 , or approximately 600mA / cm² 2 ~3,000mA / cm 2 , or approximately 600mA / cm² 2 ~2,000mA / cm 2 , or approximately 600mA / cm² 2 ~1,000mA / cm 2 , or approximately 600mA / cm² 2~800 mA / cm 2 、 or about 800 mA / cm 2 ~6,000 mA / cm 2 、 or about 800 mA / cm 2 ~5,000 mA / cm 2 、 or about 800 mA / cm² to 4,000 mA / cm 2 、 or about 800 mA / cm 2 ~3,000 mA / cm 2 、 or about 800 mA / cm 2 ~2,000 mA / cm 2 、 or about 800 mA / cm 2 ~1,000 mA / cm 2 、 or about 1,000 mA / cm 2 ~6,000 mA / cm 2 、 or about 1,000 mA / cm 2 ~5,000 mA / cm 2 、 or about 1,000 mA / cm 2 ~4,000 mA / cm 2 、 or about 1,000 mA / cm 2 ~3,000 mA / cm 2 、 or about 1,000 mA / cm 2 ~2,000 mA / cm 2 、 or about 2,000 mA / cm 2 ~6,000 mA / cm 2 、 or about 2,000 mA / cm 2 ~5,000 mA / cm 2 、 or about 2,000 mA / cm 2 ~4,000 mA / cm 2 、 or about 2,000 mA / cm 2 ~3,000 mA / cm 2 、 or about 3,000 mA / cm 2 ~6,000 mA / cm 2 、 or about 3,000 mA / cm 2 ~5,000 mA / cm 2 、 or about 3,000 mA / cm 2 ~4,000 mA / cm 2 、 or about 4,000 mA / cm 2 ~6,000 mA / cm 2 、 or about 5,000 mA / cm2 ~6,000mA / cm 2 It operates at high-density currents. In some embodiments, an electrochemical cell comprising the anode and / or cathode pan assembly disclosed herein operates at approximately 300 mA / cm². 2 ~3,000mA / cm 2 , or approximately 300mA / cm² 2 ~2,000mA / cm 2 , or approximately 300mA / cm² 2 ~1,000mA / cm 2 , or approximately 300mA / cm² 2 ~800mA / cm 2 , or approximately 300mA / cm² 2 ~600mA / cm 2 , or approximately 300mA / cm² 2 ~500mA / cm 2 , or approximately 300mA / cm² 2 ~400mA / cm 2 It operates at high current density.

[0070] In some embodiments, the anode and / or cathode pan assemblies are configured to handle loads of approximately 200-10,000 kg / hour, or approximately 200-9,000 kg / hour, or approximately 200-8,000 kg / hour, or approximately 200-7,000 kg / hour, or approximately 200-6,000 kg / hour, or approximately 200-5,000 kg / hour, or approximately 200-4,000 kg / hour, or approximately 200-3,000 kg / hour, or approximately 200-2,000 kg / hour, or approximately 200-1,000 kg / hour, or approximately 500-10,000 kg / hour, or approximately 500-9, 000 kg / hour, or approximately 500-8,000 kg / hour, or approximately 500-7,000 kg / hour, or approximately 500-6,000 kg / hour, or approximately 500-5,000 kg / hour, or approximately 500-4,000 kg / hour, or approximately 500-3,000 kg / hour, or approximately 500-2,000 kg / hour, or approximately 500-1,000 kg / hour, or approximately 800-10,000 kg / hour, or approximately 800-9,000 kg / hour, or approximately 800-8,000 kg / hour, or approximately 800-7,000 kg / hour, or approximately 800-6,000 kg / hour, or approximately 800 ~5,000 kg / hour, or approximately 800~4,000 kg / hour, or approximately 800~3,000 kg / hour, or approximately 800~2,000 kg / hour, or approximately 800~1,000 kg / hour, or approximately 1,000~10,000 kg / hour, or approximately 1,000~9,000 kg / hour, or approximately 1,000~8,000 kg / hour, or approximately 1,000~7,000 kg / hour, or approximately 1,000~6,000 kg / hour, or approximately 1,000~5,000 kg / hour, or approximately 1,000~4,000 kg / hour, or approximately 1,000~3,000 kg / hour, or approximately 1, 000-2,000 kg / hour, or approximately 3,000-10,000 kg / hour, or approximately 3,000-9,000 kg / hour, or approximately 3,000-8,000 kg / hour, or approximately 3,000-7,000 kg / hour, or approximately 3,000-6,000 kg / hour, or approximately 3,000-5,000 kg / hour, or approximately 5,000-10,000 kg / hour, or approximately 5,000-8,000 kg / hour, or approximately 5,000-6,000 kg / hour, or approximately 6,000-10,000 kg / hour, or approximately 6,000-8,000 kg / hour, or approximately 8,000-10,It is equipped with a high-flow anode or cathode solution of 000 kg / hour. Examples of anode and / or cathode solutions include water, or water with alkali (e.g., alkali metal hydroxides, e.g., NaOH or KOH in water).

[0071] To accommodate high current density and high flow rates and other benefits as described herein, in some embodiments the cross-sectional area of ​​the manifold (e.g., with a manifold depth of approximately 0.25 to 0.75 times the depth of the pan) is approximately 520 to 6,200 mm². 2 , or approximately 520-6,000 mm 2 , or approximately 520-5,000 mm 2 , or approximately 520-4,000 mm 2 , or approximately 520-3,000 mm 2 , or approximately 520-2,000 mm 2 , or approximately 520-1,000 mm 2 , or approximately 600-6200mm 2 , or approximately 600-6,000 mm 2 , or approximately 600-5,000 mm 2 , or approximately 600-4,000 mm 2 , or approximately 600-3,000 mm 2 , or approximately 600-2,000 mm 2 , or approximately 600-1,000 mm 2 , or approximately 800-6,200 mm 2 , or approximately 800-6,000 mm 2 , or approximately 800-5,000 mm 2 , or approximately 800-4,000 mm 2 , or approximately 800-3,000 mm 2 , or approximately 800-2,000 mm 2 , or approximately 800-1,000 mm 2 , or approximately 1,000~6,200mm 2 , or approximately 1,000-6,000 mm 2 , or approximately 1,000-5,000 mm 2 , or approximately 1,000-4,000 mm 2 , or approximately 1,000-3,000 mm2 , or approximately 1,000-2,000 mm 2 , or approximately 2,000~6,200mm 2 , or approximately 2,000-5,000 mm 2 , or approximately 2,000-4,000 mm 2 , or approximately 2,000-3,000 mm 2 , or approximately 3,000-6,000 mm 2 , or approximately 3,000-5,000 mm 2 , or approximately 3,000-4,000 mm 2 , or approximately 4,000-6,000 mm 2 , or approximately 4,000-5,000 mm 2 , or approximately 5,000-6,000 mm 2 That is the case.

[0072] Therefore, in some embodiments of the cross-sectional area of ​​the manifold described above, the outlet pipes fluidly connected to the manifold are approximately 26-89 mm, or approximately 26-80 mm, or approximately 26-75 mm, or approximately 26-70 mm, or approximately 26-60 mm, or approximately 26-50 mm, or approximately 26-40 mm, or approximately 26-30 mm, or approximately 30-89 mm, or approximately 30-80 mm, or approximately 30-75 mm, or approximately 30-70 mm, or approximately 30-60 mm, or approximately 30-50 mm. Alternatively, the outlet pipe has an equivalent diameter of approximately 30-40 mm, or approximately 40-89 mm, or approximately 40-80 mm, or approximately 40-75 mm, or approximately 40-70 mm, or approximately 40-60 mm, or approximately 40-50 mm, or approximately 50-89 mm, or approximately 50-80 mm, or approximately 50-75 mm, or approximately 50-70 mm, or approximately 50-60 mm, or approximately 60-89 mm, or approximately 60-80 mm, or approximately 60-75 mm, or approximately 70-89 mm, or approximately 70-80 mm.

[0073] It should be understood that high liquid flow rates may be relative to electrochemical cells of a specific size. For example, high flow rates for relatively narrow cells, e.g., 300-600 mm wide, may correspond to flow rates of approximately 200 kg / hour or more, or high flow rates for large commercial-sized cells, e.g., 2-3 m wide, may correspond to flow rates of approximately 800 kg / hour or more. The cross-sectional area of ​​the manifold, the cross-sectional area of ​​the outlet pipe, and / or the baffle plate are adapted to the high liquid and gas flow rates associated with operation at high current densities, ensuring that the surface liquid velocity is less than 0.1 m / sec so that neither slug nor plug flow develops.

[0074] In some embodiments, the anode and / or cathode pan assembly is Each is equipped with a high-flow anode or cathode liquid of approximately 200-5,000 kg / hour, or approximately 200-4,000 kg / hour, or approximately 200-3,000 kg / hour, or approximately 200-2,500 kg / hour, or approximately 200-2,000 kg / hour, or approximately 200-1,000 kg / hour. The cross-sectional area of ​​the manifold (for example, having a manifold depth of approximately 0.25 to 0.75 times the depth of the pan) is approximately 300 to 6,200 mm². 2 , or approximately 300-6,000 mm 2 , or approximately 300-5,000 mm 2 , or approximately 300-4,000 mm 2 , or approximately 300-3,000 mm 2 , or approximately 300-2,000 mm 2 , or approximately 300-1,000 mm 2 , or approximately 300-500mm 2 And, The surface liquid velocity of the anode and / or cathode is less than 0.1 m / sec, or less than 0.08 m / sec, or less than 0.05 m / sec, or less than 0.01 m / sec.

[0075] In some embodiments, the aforementioned anode and / or cathode pan assembly further comprises an outlet pipe fluidly connected to a manifold having an equivalent diameter such as approximately 26–89 mm.

[0076] In some embodiments, an electrochemical cell comprising the aforementioned anode and / or cathode pan assembly disclosed herein produces approximately 300 mA / cm². 2 ~3,000mA / cm 2 , or approximately 300mA / cm² 2 ~2,000mA / cm 2 , or approximately 300mA / cm² 2 ~1,000mA / cm 2 , or approximately 300mA / cm² 2 ~800mA / cm 2 , or approximately 300mA / cm² 2 ~600mA / cm 2 , or approximately 300mA / cm² 2 ~500mA / cm 2 , or approximately 300mA / cm² 2 ~400mA / cm 2 It operates at high current density.

[0077] In one aspect, to minimize the effect of increasing or decreasing power dissipation on the internal temperature of the cell, an internal baffle plate configuration within the anode and / or cathode pan assembly is also provided. The applicant designed a baffle plate suspended within the anode and / or cathode pan assembly and positioned between the pan bed on one side and the electrode on the other side.

[0078] In one aspect, an anode and / or cathode pan assembly is provided, the anode and / or cathode pan assembly comprising: an anode and / or cathode pan; one or more ribs on the inside of the pan having one or more notches; and a baffle plate, the baffle plate having one or more or more slots, one or more or more slots configured to fit onto one or more notches of one or more ribs.

[0079] In one aspect, an anode and / or cathode pan assembly is provided, which comprises an anode and / or cathode pan, a manifold positioned inside the anode and / or cathode pan, the cross-sectional area of ​​the manifold having a depth of manifold which is about 0.25 to 0.75 of the depth of the pan, and one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs. In some embodiments, the anode and / or cathode pan assembly further comprises an outlet pipe. The cross-sectional areas of the manifold and outlet pipe are provided herein.

[0080] An example of an anode and / or cathode pan assembly is shown in Figure 5. The right-hand side of Figure 5 shows a front view of the anode and / or cathode pan assembly, and the left-hand side shows a cross-sectional view of the pan assembly. The anode and / or cathode pan assembly 200 comprises an anode and / or cathode pan 201, and a baffle plate 202 is fitted into the pan. The baffle plate has two or more slots 203. The baffle plate may have any number of slots depending on the number of ribs in the pan and the number of notches on the ribs. The number of slots may be, for example, about 2 to 200 in the baffle plate. This baffle plate 202 is fitted onto the vertical ribs 204 in the anode and / or cathode pan 201. One or more ribs are perpendicular to the anode and / or cathode pan, and the baffle plate is perpendicular to one or more ribs. Therefore, the baffle plate is parallel to the anode and / or cathode pan. The positioning of one or more ribs with one or more notches and the fitting of two or more slots in the baffle plate onto one or more notches of the one or more ribs are as illustrated in Figure 6.

[0081] As shown in Figure 6, one or more ribs 204 have one or more notches 205. One or more ribs 204 are positioned perpendicular to the anode and / or cathode pan 201. A baffle plate 202 with two or more slots 203 (which may also be slits or cutouts) is configured to fit over one or more notches 205 of one or more ribs 204. The slots are not visible in Figure 6 because they are fitted with the ribs 204. One or more notches 205 of one or more ribs 204 facilitate the suspension of the baffle plate 202 within the pan. An electrode 206 may be mounted on top of the anode pan assembly and / or cathode pan assembly 200. The baffle plate is suspended between the electrode 206 and the anode and / or cathode pan or pan floor 207. The distance of the baffle plate from the electrode can be increased or decreased by increasing the depth of the notches on the ribs.

[0082] Another design of the baffle plate (not shown in the figures) is a baffle plate with one or more long slots that fit over the entire length of the ribs. In such embodiments, the number of long slots on the baffle plate is equivalent to the number of ribs in the pan. In such embodiments, the ribs may or may not have notches, or they may have notches at the top and bottom of each rib to accommodate the baffle plate with long slots over the ribs. All of these embodiments are well within the scope of the invention. All geometric shapes and dimensions provided herein with respect to the ribs and baffle plates apply to the embodiments described above.

[0083] The baffle plate 202 is illustrated in Figure 7. As shown in Figure 7, the baffle plate 202 has two or more slots 203 throughout the plate. The positioning of the slots, the length of the slots, and / or the distance between the slots determine the fit of the baffle plate over one or more ribs, as the slots of the baffle plate fit over the notches of one or more ribs. The baffle plate may be a solid plate with slots (e.g., as shown in Figure 7), or in some embodiments, the baffle plate may be an expanded metal plate or mesh. The baffle plate may be made from any conductive metal such as nickel or stainless steel, but is not limited.

[0084] In some embodiments, the width of the slots in the baffle plate is equal to the width of the ribs so that the slots fit over the ribs. The width of the slots is shown as W_slot in Figure 7.

[0085] The length of the slot (shown as L_slot in Figure 7) is equal to the length of the rib between the two cuts. In some embodiments, the length of the slot (equal to the length of the rib) is approximately 0.25–1.0 m, or approximately 0.25–0.8 m, or approximately 0.25–0.6 m, or approximately 0.25–0.5 m, or approximately 0.25–0.4 m, or approximately 0.25–0.3 m, or approximately 0.5–1.0 m, or approximately 0.5–0.8 m, or approximately 0.5–0.6 m, or approximately 0.6–1.0 m, or approximately 0.6–0.8 m, or approximately 0.7–1.0 m, or approximately 0.7–0.8 m, or approximately 0.8–1.0 m.

[0086] In some embodiments, the distance between slots (shown as D_slot in Figure 7) is equal to the length of the cut in the rib, such that the slot fits over one or more cuts in one or more ribs. In some embodiments, the distance between two or more slots or the length of one or more cuts is approximately 5 to 100 mm, or approximately 5 to 80 mm, or approximately 5 to 60 mm, or approximately 5 to 50 mm, or approximately 5 to 40 mm, or approximately 5 to 30 mm, or approximately 5 to 20 mm, or approximately 5 to 10 mm, or approximately 10 to 100 mm, or approximately 10 to 50 mm, or approximately 10 to 40 mm, or approximately 10 to 30 mm, or approximately 10 to 20 mm, or approximately 20 to 100 mm, or approximately 20 to 50 mm, or approximately 20 to 40 mm, or approximately 20 to 30 mm, or approximately 30 to 100 mm, or approximately 30 to 50 mm, or approximately 30 to 40 mm, or approximately 40 to 100 mm, or approximately 40 to 50 mm, or approximately 50 to 100 mm, or approximately 75 to 100 mm.

[0087] As previously described, the effect of internal power dissipation on the internal temperature distribution of the cell can be minimized through operating conditions such as the temperature and flow rate of the incoming electrolyte. High electrolyte flow rates can help maximize convective heat transfer within the cell, thereby minimizing heat accumulation and associated temperature rise within the cell that would otherwise result from the high current density described herein. As discussed above, operating at high electrolyte flow rates and high current densities can lead to slugging at the cell outlet, which can result in pressure fluctuations that shorten the membrane life. The pan assemblies described herein, with manifold and outlet configurations and / or baffle plate configurations, are designed to avoid or minimize sluggish and plug flow.

[0088] At the high current densities described herein, the electrolyte may be heated to tens to hundreds of degrees Celsius as it flows through the cell. Top-to-bottom mixing may be required to enable operation at high current densities. Such mixing can be achieved by including a baffle plate, as described herein, that separates the electrode from the cathode or anode pan bed (a pan bed shown as 207 in Figure 6).

[0089] In some embodiments, the baffle plate is designed and positioned in such a way that the gas produced at the electrode mixes with the electrolyte on the electrode side of the baffle plate, resulting in a relatively low-density column and defining an upward section. The low-density mixture can rise relatively rapidly through the upward section. Upon reaching the upper part of the baffle plate, the gas can detach and flow into the manifold and outlet pipe, while a portion of the electrolyte falls back down to the lower side (above the pan bed) of the baffle plate, into a downward section, thereby defining a circulating loop. This circulating loop is illustrated in Figure 8, showing a comparison between a system with and without a baffle plate. The upward section is indicated by an upward arrow, and the downward section by a downward arrow. The baffle plate can be used to create a rapidly flowing circulating loop, ensuring that the electrolyte remains substantially isothermal as it flows through the cathode or anode. Due to the high degree of mixing and circulation from top to bottom, rapid thermal equilibrium of the incoming electrolyte can be achieved. Another advantage is that a relatively cold liquid can be introduced into the cell and equilibrium with the warm circulating fluid. The circulation rate (or the number of recirculation loops during the passage of the electrolyte through the cell) can be anywhere between 1 and 200. A high circulation rate can also drive a greater shear rate adjacent to the membrane, which can help sweep gas away from the membrane.

[0090] The applicant found that the positioning of the baffle plate relative to its distance from the electrodes and pan bed, and / or its width and length, affects the velocity of the rising and falling sections, and thereby affects the circulation rate. If the baffle plate is positioned beyond a certain critical distance from the electrodes, it may not promote the circulation pattern. Free convection in a relatively lightweight, gas-rich area adjacent to the electrodes can rise relatively rapidly compared to the liquid rising more slowly further from the electrodes. The resulting shear force can pull up some of the liquid. This liquid may fall back down towards the electrode side of the baffle plate as the gas escapes at the top of the cell, resulting in the formation of weak circulation on the electrode side of the baffle plate. In this case, the baffle plate may not divide the rising section from the falling section, and strong circulation may not be formed. If the baffle plate is too close to the electrodes, the space between the electrodes and the baffle plate can be filled with gas, clogging the liquid flow in that area. Furthermore, a high volume fraction of gas within that region can lead to masking of the membrane and / or electrodes, as well as poor electrical and thermal transport.

[0091] The optimal baffle offset or distance from the electrodes may differ with respect to the cathode pan assembly and anode pan assembly due to the different material properties of the gases (O2 at the anode and H2 at the cathode) generated within each half-cell. For example, H2 gas may be lighter than O2 gas, and their bubble sizes may also differ, and for any given current density through the cell, twice the number of moles of H2 may be produced compared to O2. Therefore, due to the different properties of H2 and O2 gases, H2 gas may rise faster, and the distance between the baffle plate and the electrodes may need to be adjusted.

[0092] The pan depth (d_pan), the relative location of the baffle through the pan depth (d_b), the baffle height relative to the cell height (h_baffle), and / or the vertical location of the baffle plate within the pan (h_t, the distance of the baffle plate from the top of the pan, and h_b, the distance of the baffle plate from the bottom of the pan) as illustrated in Figure 9 can influence the electrolyte circulation pattern.

[0093] In some embodiments, in the anode and / or cathode pan assembly, the distance of the baffle plate from the electrode (d_b as illustrated in Figure 9) is approximately 5–15 mm, or approximately 5–12 mm, or approximately 5–10 mm, or approximately 5–8 mm, or approximately 5–6 mm, or approximately 6–15 mm, or approximately 6–12 mm, or approximately 6–10 mm, or approximately 6–8 mm, or approximately 8–15 mm, or approximately 8–12 mm, or approximately 8–10 mm, or approximately 10–15 mm, or approximately 10–12 mm, or approximately 12–15 mm. In some embodiments, the distance of the baffle plate from the electrode is equivalent to the depth of the cut on the rib.

[0094] In some embodiments, in the anode and / or cathode pan assembly, the baffle plate is installed at a depth of approximately 0.25–0.5 of the anode and / or cathode pan, or approximately 0.25–0.4, or approximately 0.25–0.3, or approximately 0.3–0.5, or approximately 0.4–0.5 of the anode and / or cathode pan.

[0095] In some embodiments, in the anode and / or cathode pan assembly, the height of the baffle plate is such that it leaves space (e.g., the distance h_t from the top of the pan and the distance h_b from the bottom of the pan, as illustrated in Figure 9) above and below the anode and / or cathode pan for gas and liquid flow. In some embodiments where both the manifold and the baffle plate are present within the cell, depending on the placement of the baffle plate relative to the depth of the manifold and the depth of the pan, the baffle plate may extend towards the top of the cell behind the manifold (between the manifold and the electrodes) or the baffle plate may terminate below the manifold. In either embodiment, the baffle plate leaves space above and / or below the anode and / or cathode pan for gas and liquid flow.

[0096] In some embodiments, in the anode and / or cathode pan assembly, the space between the baffle plate and the bottom of the anode and / or cathode pan (h_b as illustrated in Figure 9) is approximately 6-75 mm, or approximately 6-65 mm, or approximately 6-50 mm, or approximately 6-40 mm, or approximately 6-30 mm, or approximately 6-20 mm, or approximately 6-10 mm, or approximately 10-75 mm, or approximately 10-65 mm, or approximately 10-50 mm, or approximately 10- 40mm, or approximately 10-30mm, or approximately 10-20mm, or approximately 10-15mm, or approximately 20-75mm, or approximately 20-65mm, or approximately 20-50mm, or approximately 20-40mm, or approximately 20-30mm, or approximately 30-75mm, or approximately 30-65mm, or approximately 30-50mm, or approximately 30-40mm, or approximately 40-75mm, or approximately 40-65mm, or approximately 50-75mm, or approximately 50-65mm, or approximately 60-75mm.In some embodiments, the space between the baffle plate and the top of the anode and / or cathode pan or the bottom of the manifold (h_t as illustrated in Figure 9) is approximately 6-150 mm, or approximately 6-140 mm, or approximately 6-130 mm, or approximately 6-120 mm, or approximately 6-110 mm, or approximately 6-100 mm, or approximately 6-80 mm, or approximately 6-70 mm, or approximately 6-50 mm, or approximately 6-25 mm, or approximately 10-150 mm, or approximately 10-140 mm, or approximately 10-130 mm, or approximately 10-120 mm, or approximately 10-110 mm, or approximately 10-100 mm, or approximately 10-80 mm, or approximately 10-70 mm, or approximately 10-50 mm, or approximately 10-25 mm, or approximately 25 ~150mm, or approximately 25~140mm, or approximately 25~130mm, or approximately 25~120mm, or approximately 25~110mm, or approximately 25~100mm, or approximately 25~80mm, or approximately 25~70mm, or approximately 25~50mm, or approximately 50~150mm, or approximately 50~140mm, or approximately 50~130mm, or approximately 50~120mm, and The dimensions are approximately 50-110 mm, or approximately 50-100 mm, or approximately 50-80 mm, or approximately 50-70 mm, or approximately 100-150 mm, or approximately 100-140 mm, or approximately 100-130 mm, or approximately 100-120 mm, or approximately 125-150 mm, or approximately 125-140 mm, or approximately 130-150 mm, or approximately 75-120 mm. It should be understood that either of the aforementioned dimensions regarding the space between the baffle plate and the bottom of the anode and / or cathode pan, or the dimensions regarding the space between the baffle plate and the top of the anode and / or cathode pan or the bottom of the manifold, can be combined to achieve the optimal electrolyte circulation pattern.

[0097] In some embodiments, in the anode and / or cathode pan assembly, the space between the baffle plate and the bottom of the anode and / or cathode pan (h_b as illustrated in Figure 9) is approximately 6 to 75 mm, and the space between the baffle plate and the top of the anode and / or cathode pan or the bottom of the manifold (h_t as illustrated in Figure 9) is approximately 6 to 150 mm.

[0098] In some embodiments, the anode and / or cathode pan assemblies provided herein, with the aforementioned manifold and outlet pipe and / or baffle plate, are adapted to the aforementioned high-flow anode or cathode fluid and / or gas to prevent slug or plug flow, and offer several advantages, such as preventing large spatial and / or temporal temperature fluctuations, preventing pressure fluctuations due to multiphase flow within the cell to less than 0.5 psi, and / or preventing film erosion and / or fatigue.

[0099] In some embodiments, the anode and / or cathode pan assembly provided herein is located inside a hydrogen gas production electrochemical cell.

[0100] Therefore, in one aspect, an electrochemical cell is provided, for example, a hydrogen gas production electrochemical cell, which comprises an anode pan assembly having an anode pan and a manifold positioned inside the anode pan, the cross-sectional area of ​​the manifold having a depth of manifold of about 0.25 to 0.75 times the depth of the pan. In some embodiments of the aforementioned aspect, the electrochemical cell further comprises an anode positioned on the anode pan assembly, a cathode positioned on the cathode pan assembly, and an ion exchange membrane disposed between the anode and the cathode. In some embodiments of the aforementioned aspect, the anode pan assembly further comprises an outlet tube.

[0101] In one aspect, for example, an electrochemical cell such as a hydrogen gas production electrochemical cell is provided, the electrochemical cell comprising an anode pan assembly, an anode pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit onto one or more notches of the one or more ribs. In some embodiments of the aforementioned aspect, the electrochemical cell further comprises an anode positioned on the anode pan assembly, a cathode positioned on the cathode pan assembly, and an ion exchange membrane disposed between the anode and the cathode.

[0102] In one aspect, for example, an electrochemical cell such as a hydrogen gas production electrochemical cell is provided, the electrochemical cell comprising an anode pan assembly, the anode pan assembly comprising an anode pan, a manifold positioned inside the anode pan, the manifold having a cross-sectional area having a depth of manifold of about 0.25 to 0.75 of the depth of the pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs. In some embodiments of the aforementioned aspect, the electrochemical cell further comprises an anode positioned on the anode pan assembly, a cathode positioned on the cathode pan assembly, and an ion exchange membrane disposed between the anode and the cathode.

[0103] The cathode pan assembly in the three aspects mentioned above can be any conventional cathode pan assembly.

[0104] In some embodiments of the aforementioned aspects, the electrochemical cell further comprises an outlet pipe. All of the various dimensions of the cross-sectional area of ​​the manifold, the cross-sectional area of ​​the outlet pipe, the notches in the ribs and slots in the baffle plate, and / or the location and installation of the components are described herein and can be applied to any of the aforementioned aspects.

[0105] In one aspect, for example, an electrochemical cell such as a hydrogen gas production electrochemical cell is provided, the electrochemical cell comprising a cathode pan assembly, the cathode pan assembly comprising a cathode pan and a manifold positioned inside the cathode pan, the cross-sectional area of ​​the manifold having a depth of approximately 0.25 to 0.75 times the depth of the pan. In some embodiments of the aforementioned aspect, the electrochemical cell further comprises an anode positioned on an anode pan assembly, a cathode positioned on a cathode pan assembly, and an ion exchange membrane disposed between the anode and the cathode.

[0106] In one aspect, for example, an electrochemical cell such as a hydrogen gas production electrochemical cell is provided, the electrochemical cell comprising a cathode pan assembly, the cathode pan assembly comprising a cathode pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit onto one or more notches of the one or more ribs. In some embodiments of the aforementioned aspect, the electrochemical cell further comprises an anode positioned on an anode pan assembly, a cathode positioned on a cathode pan assembly, and an ion exchange membrane disposed between the anode and the cathode.

[0107] In one aspect, for example, an electrochemical cell such as a hydrogen gas production electrochemical cell is provided, the electrochemical cell comprising a cathode pan assembly, the cathode pan assembly comprising a cathode pan, a manifold positioned inside the cathode pan, the manifold having a cross-sectional area having a depth of manifold of about 0.25 to 0.75 of the depth of the pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs. In some embodiments of the aforementioned aspect, the electrochemical cell further comprises an anode positioned on an anode pan assembly, a cathode positioned on a cathode pan assembly, and an ion exchange membrane disposed between the anode and the cathode.

[0108] The anode pan assembly in the three aspects mentioned above can be any conventional anode pan assembly.

[0109] In some embodiments of the aforementioned aspects, the electrochemical cell further comprises an outlet pipe. All of the various dimensions of the cross-sectional area of ​​the manifold, the cross-sectional area of ​​the outlet pipe, the notches in the ribs and slots in the baffle plate, and / or the location and installation of the components are described herein and can be applied to any of the aforementioned aspects.

[0110] In one aspect, for example, an electrochemical cell such as a hydrogen gas production electrochemical cell is provided, and the electrochemical cell is An anode pan assembly comprising an anode pan and a manifold positioned inside the anode pan, wherein the cross-sectional area of ​​the manifold has a depth of approximately 0.25 to 0.75 times the depth of the pan, Anode positioned on the anode pan assembly, A cathode pan assembly comprising a cathode pan and a manifold positioned inside the cathode pan, wherein the cross-sectional area of ​​the manifold has a depth of approximately 0.25 to 0.75 times the depth of the pan. A cathode positioned on the cathode pan assembly, It includes an ion exchange membrane positioned between the anode and the cathode.

[0111] In one aspect, for example, an electrochemical cell such as a hydrogen gas production electrochemical cell is provided, and the electrochemical cell is An anode pan assembly comprising an anode pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs, Anode positioned on the anode pan assembly, A cathode pan assembly comprising a cathode pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs, A cathode positioned on the cathode pan assembly, It includes an ion exchange membrane positioned between the anode and the cathode.

[0112] In one aspect, for example, an electrochemical cell such as a hydrogen gas production electrochemical cell is provided, and the electrochemical cell is An anode pan assembly comprising an anode pan, a manifold positioned inside the anode pan, the manifold having a cross-sectional area and a depth of approximately 0.25 to 0.75 times the depth of the pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs, Anode positioned on the anode pan assembly, A cathode pan assembly comprising a cathode pan, a manifold positioned inside the cathode pan, the manifold having a cross-sectional area and a depth of approximately 0.25 to 0.75 times the depth of the pan, one or more ribs on the inside of the pan having one or more notches, and a baffle plate having two or more slots configured to fit over one or more notches of the one or more ribs, A cathode positioned on the cathode pan assembly, It includes an ion exchange membrane positioned between the anode and the cathode.

[0113] In some embodiments, an electrolytic apparatus is provided that comprises an individual electrochemical cell with a number of the aforementioned sides.

[0114] The components of the anode and / or cathode pan assembly may be made from conductive materials such as nickel, stainless steel, or stainless steel alloys, but are not limited. The anode and cathode pan may be made from conductive metals. Conductive metals include any conductive metal suitable for use as an anode pan or cathode pan. For example, in some embodiments, the anode pan in an anode pan assembly or the cathode pan in a cathode pan assembly may be made from conductive metals such as nickel, stainless steel, or stainless steel alloys, but are not limited.

[0115] An electrolytic apparatus may comprise a single cell or a stack of cells connected in series or parallel. An electrolytic apparatus may be a stack of five, six, fifty, 100, or more electrochemical cells connected in series or parallel. Each cell comprises an anode, a cathode, and an ion exchange membrane, along with an anode and / or cathode pan assembly as described herein.

[0116] In some embodiments, the electrolytic apparatus provided herein is a unipolar electrolytic apparatus. In a unipolar electrolytic apparatus, the electrodes may be connected in parallel, with all anodes and all cathodes connected in parallel. In some embodiments, the electrolytic apparatus provided herein is a bipolar electrolytic apparatus. In a bipolar electrolytic apparatus, the electrodes may be connected in series, with all anodes and all cathodes connected in series. In some embodiments, the electrolytic apparatus is a combination of a unipolar and a bipolar electrolytic apparatus and may be called a hybrid electrolytic apparatus.

[0117] In some embodiments of the bipolar electrolytic apparatus described above, the cells are stacked in series to form the entire electrolytic apparatus and are electrically connected in two directions. In a bipolar electrolytic apparatus, a single plate, called a bipolar plate, may serve as the base plate for both the cathode and anode. The electrolyte solution may be connected hydraulically through a common manifold and collector inside the cell stack. The stack may be compressed from the outside to seal all the frames and plates against each other; these are typically referred to as a filter-press design. In some embodiments, the bipolar electrolytic apparatus may also be designed as a series of cells that are individually sealed and electrically connected through back-to-back contacts, typically known as a single-element design. The single-element design may also be connected in parallel, in which case it would be a unipolar electrolytic apparatus.

[0118] In some embodiments, the cell size may be expressed by the dimensions of the active area. In some embodiments, the active area of ​​the electrolytic apparatus used herein may range from 0.5 to 1.5 meters in height and 0.25 to 3 meters in width. The thickness of individual compartments may range from 10 mm to 100 mm.

[0119] Examples of electrocatalysts described herein, but not limited to, include highly dispersed metals or alloys of platinum metals such as platinum, palladium, ruthenium, rhodium, iridium, or combinations thereof such as platinum-rhodium, platinum-ruthenium, or nickel mesh coated with RuO2. Electrodes may be coated with the electrocatalyst using processes well known in the art.

[0120] In some embodiments, the ion exchange membrane is an anion exchange membrane (for alkaline conditions) or a cation exchange membrane (for acidic conditions). In some embodiments, the cation exchange membranes in the electrochemical cell, as disclosed herein, are conventional and available, for example, from Asahi Kasei (Tokyo) in Japan, or from Membrane International (Glen Rock, NJ) or Chemours in the United States. Examples of CEMs include, but are not limited to, N2030WX (Chemours), F8020 / F8080, and F6801 (Aciplex). Desired CEMs in the methods and systems herein may have minimal resistance loss, selectivity greater than 90%, and high stability. For example, fully quaternized amine-containing polymers may be used as AEMs.

[0121] Examples of cation exchange membranes include, but are not limited to, cationic membranes composed of perfluorinated polymers containing anionic groups such as sulfone groups and / or carboxyl groups. However, in some embodiments, depending on the need to restrict or enable the movement of specific cation or anion species between electrolytes, more restrictive cation exchange membranes can be used that allow the movement of one species of cation while restricting the movement of another species of cation. Similarly, in some embodiments, depending on the need to restrict or enable the movement of specific anion species between electrolytes, more restrictive anion exchange membranes can be used that allow the movement of one species of anion while restricting the movement of another species of anion. Such restrictive cation exchange membranes and anion exchange membranes are commercially available and can be selected by those skilled in the art.

[0122] In some embodiments, the membranes can be selected such that they can function appropriately in acidic and / or alkaline electrolyte solutions. Other desirable properties of the membranes include high ion selectivity, low ion resistance, high burst strength, and high stability in electrolyte solutions within a temperature range from room temperature to 150 °C or higher.

[0123] In some embodiments, membranes that are stable within a range of 0 °C to 150 °C, 0 °C to 100 °C, 0 °C to 90 °C, or 0 °C to 80 °C, or 0 °C to 70 °C, or 0 °C to 60 °C, or 0 °C to 50 °C, or 0 °C to 40 °C, or 0 °C to 30 °C, or higher can be used. For other embodiments, it may be useful to utilize ion-specific ion exchange membranes that allow the movement of one type of ion (cations for CEMs, anions for AEMs) to achieve the desired product or products in the electrolyte but not the movement of another, or that allow the movement of one type of anion but not the movement of another.

[0124] The ohmic resistance of the membrane can affect the voltage drop across the anode and cathode. For example, as the ohmic resistance of the membrane increases, the voltage across the anode and cathode can increase, and vice versa. Membranes that can be used include, but are not limited to, membranes with relatively low ohmic resistance and relatively high ion mobility, and membranes with relatively high hydration properties that increase with temperature and thus decrease the ohmic resistance. By selecting a membrane with a lower ohmic resistance known in the art, the voltage drop across the anode and cathode at a specified temperature can be reduced.

[0125] Voltage can be applied to the electrochemical cell by any means for applying a current across the anode and cathode of the electrochemical cell. Such means are well known in the art and include, but are not limited to, devices such as power sources, fuel cells, devices powered by sunlight, devices powered by wind, and combinations thereof. The type of power source for providing the current can be any power source known to those skilled in the art. For example, in some embodiments, the voltage can be applied by connecting the anode and cathode of the cell to an external direct current (DC) power source. The power source can be alternating current (AC) rectified to DC. The DC power source can have adjustable voltage and current to apply the required amount of voltage to the electrochemical cell.

[0126] (Method) In some aspects, methods of making, manufacturing, and / or using the anode and / or cathode pan assemblies provided herein are provided.

[0127] In one aspect, a method is provided which includes positioning a manifold inside the anode and / or cathode pan of an electrochemical cell, fluidly connecting an outlet pipe to the manifold, thereby forming an anode and / or cathode pan assembly, wherein the cross-sectional area of ​​the manifold has a depth of manifold which is about 0.25 to 0.75 times the depth of the anode and / or cathode pan. The cross-sectional area of ​​the manifold combined with the equivalent diameter of the outlet pipe is provided herein.

[0128] In one aspect, a method is provided, which includes positioning one or more ribs inside the anode and / or cathode pan of an electrochemical cell, wherein one or more ribs are provided with one or more notches; and placing a baffle plate on one or more ribs, wherein the baffle plate is provided with two or more slots; and fitting two or more slots on one or more notches of one or more ribs.

[0129] In one aspect, a method for forming an anode and / or cathode pan assembly is provided, the method comprising: positioning a manifold inside the anode and / or cathode pan of an electrochemical cell; fluidly connecting an outlet pipe to the manifold, wherein the cross-sectional area of ​​the manifold has a depth of manifold which is about 0.25 to 0.75 of the depth of the anode and / or cathode pan; positioning one or more ribs inside the anode and / or cathode pan of an electrochemical cell, wherein one or more ribs have one or more notches; placing a baffle plate on one or more ribs, wherein the baffle plate has two or more slots; and fitting two or more slots on one or more notches of one or more ribs.

[0130] In some embodiments of the aforementioned aspects, the method further includes mounting the baffle plate perpendicular to one or more ribs. In some embodiments of the aforementioned aspects and embodiments, the method further includes mounting the electrode to one or more ribs and the top of the anode and / or cathode pan. In some embodiments of the aforementioned aspects and embodiments, the method further includes suspending the baffle plate between the electrode and the anode and / or cathode pan. In some embodiments of the aforementioned aspects and embodiments, the method further includes leaving space between the baffle plate and the top and / or bottom of the anode and / or cathode pan and / or manifold for gas and liquid flow.

[0131] In some embodiments of the aspects and embodiments provided herein, manifolds, outlet pipes, ribs, and / or electrodes are metallurgically attached to the anode and / or cathode pan. In some embodiments of the aspects and embodiments provided herein, baffle plates are metallurgically attached to one or more ribs. As used herein, “metallurgical” or its grammatical equivalent includes any metallurgical technique for attaching elements to the pan and / or electrochemical cell. Such techniques include, but are not limited to, diffusion bonding, soldering, welding, cladding, e.g., laser cladding, brazing, etc.

[0132] In some aspects and embodiments of the features provided herein, the method further includes operating the anode and / or cathode pan assemblies provided herein, respectively, under a high flow rate of anode or cathode fluid of about 200 to 10,000 kg / hour. The high flow rate anode and / or cathode fluids are provided herein.

[0133] In some aspects and embodiments of the features provided herein, the method involves positioning the anode and / or cathode pan assembly provided herein for assembling an electrochemical cell and generating approximately 300 mA / cm².2 ~6,000mA / cm 2 This further includes operating an electrochemical cell at a high current density. A range of high current densities for operating an electrochemical cell is provided herein.

[0134] In the aspects described above and in some embodiments of the embodiments, the electrochemical cell is a hydrogen gas production cell. The gases flowing through the manifold, outlet pipe, and / or baffle plate in the anode assembly or cathode assembly are oxygen gas and hydrogen gas, respectively.

[0135] In some embodiments of the aforementioned aspects and embodiments, the method further includes ensuring that the surface liquid velocity of the anode and / or cathode fluid through the manifold and outlet pipe and / or baffle plate is less than 0.1 m / sec, or less than 0.08 m / sec, or less than 0.05 m / sec. In some embodiments of the aforementioned aspects and embodiments, the method further includes adapting to high flow rates of anode or cathode fluid and / or gas to prevent slag or plug flow. High flow rates of anode and / or cathode fluid through the anode and cathode are illustrated herein. In some embodiments of the aforementioned aspects and embodiments, the method further includes preventing pressure increases or decreases due to multiphase flow in the cell from being less than 0.5 psi, or less than 0.4 psi, or less than 0.3 psi, or less than 0.2 psi, or less than 0.1 psi. In some embodiments of the aforementioned aspects and embodiments, the method further includes preventing film erosion and / or fatigue.

[0136] In some aspects and embodiments of the aforementioned features, the method further includes creating a gas-rich elevated region between the baffle plate and the electrode and an electrolyte-rich descending region between the baffle plate and the bottom of the pan by partitioning the internal volume of the anode and / or cathode pan using the baffle plate.

[0137] In some aspects and embodiments of the aforementioned features, the method further includes using a baffle plate to enable electrolyte circulation and mixing from top to bottom, causing thermal equilibrium of the incoming electrolyte and preventing overheating of the cell.

[0138] In one aspect, a process for manufacturing an anode and / or cathode pan assembly is provided, the process comprising mounting a manifold inside the anode and / or cathode pan of an electrochemical cell, fluidly connecting an outlet pipe to the manifold, thereby forming an anode and / or cathode pan assembly, the cross-sectional area of ​​the manifold having a depth of manifold which is about 0.25 to 0.75 times the depth of the anode and / or cathode pan. The cross-sectional area of ​​the manifold combined with the equivalent diameter of the outlet pipe and the material of the structure are provided herein.

[0139] In one aspect, a process for manufacturing an anode and / or cathode pan assembly is provided, the process comprising: attaching one or more ribs inside the anode and / or cathode pan of an electrochemical cell, the one or more ribs having one or more notches; placing a baffle plate on the one or more ribs, the baffle plate having two or more slots; and fitting two or more slots on one or more notches of the one or more ribs.

[0140] In one aspect, a process for manufacturing an anode and / or cathode pan assembly is provided, the process comprising: attaching a manifold inside the anode and / or cathode pan of an electrochemical cell; fluidically connecting an outlet pipe to the manifold; thereby forming an anode and / or cathode pan assembly, wherein the cross-sectional area of ​​the manifold has a depth of manifold which is about 0.25 to 0.75 of the depth of the anode and / or cathode pan; attaching one or more ribs inside the anode and / or cathode pan of an electrochemical cell, wherein one or more ribs are provided which have one or more notches; placing a baffle plate on one or more ribs, wherein the baffle plate is provided which has two or more slots; and fitting two or more slots on one or more notches of one or more ribs.

[0141] In some embodiments of the aforementioned aspects, the process includes metallurgically mounting a manifold inside the anode and / or cathode pan of the electrochemical cell. In some embodiments of the aforementioned aspects, the process includes metallurgically mounting one or more ribs inside the anode and / or cathode pan of the electrochemical cell, and metallurgically mounting a baffle plate on one or more ribs.

[0142] In one aspect, a process for assembling an electrochemical cell is provided, and the process is Individual electrochemical cells are assembled by joining the anode pan assembly described herein together with a conventional cathode assembly comprising a cathode pan and a cathode. The process involves attaching the anode to the anode pan assembly to form the anode assembly, and The anode assembly and cathode assembly are installed in parallel and separated by an ion exchange membrane. This includes supplying cell current and electrolytic raw materials to an electrochemical cell using a feeder.

[0143] On one side, a process for assembling an electrochemical cell is provided. The process comprises assembling individual electrochemical cells by joining the cathode pan assembly described herein together with a conventional anode assembly comprising an anode pan and an anode, attaching a cathode to the cathode pan assembly to form a cathode assembly, placing the anode assembly and the cathode assembly in parallel and separating them by an ion exchange membrane, and supplying a cell current and electrolysis raw materials to the electrochemical cell using a feeder.

[0144] On one side, a process for assembling an electrochemical cell is provided. The process comprises assembling individual electrochemical cells by joining the anode pan assembly described herein together with the cathode pan assembly described herein, attaching an anode to the anode pan assembly to form an anode assembly, attaching a cathode to the cathode pan assembly to form a cathode assembly, placing the anode assembly and the cathode assembly in parallel and separating them by an ion exchange membrane, and supplying a cell current and electrolysis raw materials to the electrochemical cell using a feeder.

[0145] In some embodiments of the foregoing aspects, the electrochemical cell is a hydrogen gas production cell. The gases flowing through the manifolds, outlet pipes, and / or baffle plates in the anode assembly or the cathode assembly are oxygen gas and hydrogen gas, respectively.

[0146] In one aspect, a process for assembling an electrolytic device is provided, the process comprising assembling the aforementioned individual electrochemical cells, and arranging a plurality of assembled electrochemical cells side by side in a stack and fixing them together to maintain electrical contact between the electrochemical cells.

[0147] The following examples are provided to those skilled in the art to disclose and describe methods of constructing and / or using the present invention and are not intended to limit the scope of what the inventors consider to be their invention, nor are they intended to represent all or only experiments performed below. Various modifications of the present invention to those described herein will be apparent to those skilled in the art from the foregoing description and accompanying drawings. Such modifications fall within the scope of the appended claims. Efforts have been made to ensure accuracy with respect to the numbers used (e.g., quantity, temperature, etc.), but some degree of experimental error and deviation should be taken into consideration. Unless otherwise indicated, parts are parts by weight, molecular weight is weight-average molecular weight, temperature is on a Celsius scale, and pressure is atmospheric pressure or near atmospheric pressure.

[0148] In the examples and elsewhere, the abbreviations have the following meanings: [Table 1-1]

[0149] (Examples) (Example 1) (Manifolds and outlet pipes with large cross-sectional areas) Table 1 below demonstrates several examples of high cross-sectional area manifolds and outlet pipes to accommodate high flow rates, avoid plug and slug flow (ensuring surface liquid velocity of anode and / or cathode liquid is less than 0.1 m / sec), and prevent pressure fluctuations that could cause membrane damage. The manifold depth is 0.5 times the depth of the anode or cathode pan (to provide clearance for liquid and gas flow across the manifold). Table 1 shows exemplary manifold widths, manifold cross-sectional areas, and equivalent outlet pipe diameters for various high flow rates that provide a liquid surface velocity of less than 0.1 m / sec of KOH through the manifold and outlet pipe. [Table 1]

[0150] (Example 2) (Baffle plate configuration) Figure 10 demonstrates vector plots showing simulated liquid flow distribution with and without a baffle plate. Without a baffle plate (left image in Figure 10), the potassium hydroxide (KOH) solution slowly rises upward through the cell. The gas released at the electrode (corresponding to the left side of the model) affects the flow of the KOH, pulling some of the liquid upward and pushing some of it laterally. The gas lift is evident along the upper left wall (adjacent to the electrode) in the left image in Figure 10.

[0151] The inclusion and location of the baffle plate (right-hand image in Figure 10) create strong circulation within the half-shell. As is evident from the right-hand image in Figure 10, the flow on the electrode (upward) side of the baffle plate is strongly directed upward due to gas lift, and the flow on the pan floor (downward) side of the baffle plate is strongly directed downward. The relatively high velocity and shear rate on the upward side help to clear gas from the electrode, providing efficient top-to-bottom mixing and promoting increased convective cooling.

[0152] While the aforementioned inventions are described in some detail with illustrations and examples for the purpose of clarifying understanding, it should be readily apparent to those skilled in the art, in light of the teachings of the invention, that certain changes and modifications can be made thereto without departing from the spirit or scope of the appended claims. Therefore, the foregoing merely illustrates the principles of the invention. Those skilled in the art should understand that it will be possible to devise various arrangements that are not expressly described or shown herein but embody the principles of the invention and fall within its spirit and scope. Furthermore, all examples and conditional language enumerated herein are primarily intended to assist the reader in understanding the principles of the invention and the concepts to which the inventors have contributed to the development of the art, and are to be interpreted as not limiting such specifically enumerated examples and conditions. Moreover, all language in this specification enumerating the principles, aspects, and embodiments of the invention, and specific examples thereof, is intended to encompass both their structural and functional equivalents. In addition, such equivalents are intended to include both currently known equivalents and equivalents to be developed in the future, i.e., any developed elements that perform the same function regardless of their structure. The scope of the present invention is therefore not intended to be limited to the exemplary embodiments shown and described herein. The following claims define the scope of the present invention, and methods and structures within the scope of these claims and their equivalents are intended to be covered thereby.

Claims

1. An electrochemical cell for electrolysis, wherein the electrochemical cell is A first pan having a first pan depth, an upper pan edge, and a bottom pan edge, wherein the first pan is configured to allow a first electrolyte to flow through the first interior of the first pan, A first manifold located on the upper part of the first pan, inside the first interior of the first pan, the first manifold comprising a taper and notches extending along the depth of the first manifold, the first manifold depth being 0.25 to 0.75 of the depth of the first pan, A first electrode coupled to the first interior of the first pan, positioned in front of the first manifold such that a gap is formed between the first electrode and the first manifold, and gas and liquid enter the first manifold through the gap, and the gas flows along the taper to the notch, One or more ribs on the inside of the first bread, A first baffle plate coupled to one or more ribs, wherein the first baffle plate has an upper baffle end and a bottom baffle end, and the first space between the bottom pan end and the bottom baffle end is 6 mm to 75 mm, and An electrochemical cell equipped with the following features.

2. The cross-sectional area of ​​the first manifold ensures that the surface liquid velocity of the first electrolyte flowing through the first manifold is less than 0.1 meters per second, and the cross-sectional area in the depth direction is 520 mm². ２ ~6200mm ２ The electrochemical cell according to claim 1.

3. The electrochemical cell according to claim 2, wherein the cross-sectional area of ​​the first manifold provides a flow rate for the first electrolyte and / or gas that prevents slag or plug flow through the first manifold.

4. A second bread, wherein the second bread is configured to allow a second electrolyte to flow through the second interior of the second bread, A second manifold positioned inside the second interior of the second pan, A second electrode coupled to the second interior of the second pan and Furthermore, The electrochemical cell according to any one of claims 1 to 3, wherein the first pan is positioned adjacent to the second pan such that the second electrode is in close proximity to the first electrode.

5. The electrochemical cell according to claim 1, wherein each of the one or more first ribs is provided with one or more first notches, and the first baffle plate is provided with one or more first slots, the width of the one or more first slots in the first baffle plate is equal to the width of the one or more first ribs, such that the one or more first slots fit onto the one or more first notches of the one or more first ribs.

6. The electrochemical cell according to any one of claims 1 to 5, wherein the first baffle plate is suspended between the first electrode and the first pan.

7. The electrochemical cell according to any one of claims 1 to 6, wherein the distance of the first baffle plate from the first electrode is 5 millimeters to 15 millimeters.

8. The electrochemical cell according to any one of claims 1 to 7, wherein the first baffle plate is installed at a depth of 0.25 to 0.5 of the first pan.

9. The electrochemical cell according to any one of claims 1-8, wherein the first baffle plate is positioned within the first pan such that a first space is formed between the bottom pan end and the bottom baffle end, and a second space is formed between the top pan end and the top baffle end, and the first and second spaces are sized and positioned to allow gas and liquid to flow through them, and each of the first and second spaces forms part of a circulating loop for gas and liquid to flow around the first baffle plate.

10. The first baffle plate, by partitioning the volume within the first pan, creates a first rising region on the first side of the first baffle plate adjacent to the first electrode and a first descending region on the second side of the first baffle plate opposite to the first electrode. The first rising region facilitates the rise of the first gas formed at the first electrode, thereby avoiding the formation of a first gas pocket. The first descending region facilitates the downward flow of the first electrolyte placed within the first pan. The electrochemical cell according to any one of claims 1 to 9, wherein the upward movement of the first gas and the downward flow of the first electrolyte cause circulation of the first electrolyte within the first pan, and the circulation of the first electrolyte promotes thermal equilibrium in the first electrolyte.

11. The electrochemical cell according to claim 10, further comprising a second pan having a second electrode, and a separator disposed between the first electrode and the second electrode, wherein the circulation of the first electrolyte reduces heating of the separator.

12. The current density of the electrochemical cell is 300 mA / cm². ２ ~6,000mA / cm ２ The electrochemical cell according to any one of claims 1 to 11.

13. An electrolytic apparatus comprising a plurality of electrochemical cells as described in any one of claims 1 to 12.

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