Orthogonal Bubble Collector Guide for Electrolysis Acid Mist Reduction
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Solution Overview
Problem
Current methods for reducing acid mist in electrolysis processes, such as sulfate-based electrowinning, are impractical, expensive, and do not provide 100% reduction, as they either consume energy and water or require additional chemicals, and are ineffective when hoods are not in place during cathode harvesting.
Innovation Solution
A bubble collector guide comprising guide members arranged orthogonally on the electrode surface to collect and coalesce gas bubbles, forming larger bubbles that burst at the electrolyte surface, reducing aerosol formation, which can be easily installed and maintained without additional power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hoods and cell covers are used to remove acid mist, then acid mist removal effectiveness is improved, but device complexity and operational limitations increase
Solution Approach 1:
The invention extracts the acid mist reduction function from complex hood and scrubbing systems by using simple guide members attached directly to electrodes. The guide members with downward-facing surfaces collect and coalesce bubbles at the source, eliminating the need for external mist removal infrastructure.
Solution Approach 2:
The guide members act as intermediaries between the electrode surface and the electrolyte bulk. They provide a structured interface that facilitates bubble coalescence and directs larger bubbles to the surface, mediating the transition from fine aerosol-generating bubbles to larger, safer bubbles.
2Object-affected harmful factors
If chemicals such as surfactants are used to reduce acid mist, then acid mist reduction is achieved, but operational costs and environmental impact increase
Solution Approach 1:
The invention converts the harmful fine bubbles that generate acid mist into beneficial larger bubbles through coalescence. By providing guide members with downward-facing surfaces, small bubbles are collected and merged into larger bubbles that burst at the surface with minimal aerosol generation, turning an environmental problem into a solution.
3Object-affected harmful factors
If improved ventilation and hoods are used to remove acid mist, then acid mist removal is improved, but energy consumption increases
Solution Approach 1:
The guide members perform preliminary action by coalescing bubbles at the electrode surface before they can generate acid mist. This preventive approach eliminates the need for subsequent energy-intensive ventilation and mist removal operations, addressing the problem at its source rather than treating symptoms afterward.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces acid mist generation by over 75% when used alone and up to 96% when combined with acid mist suppressants, lowering energy consumption and maintenance costs, and can be applied to existing systems without complex installation.
Implementation Method 1
When bubbles are collected under said downwards facing surface that is substantially orthogonal to the vertical surface of the electrode, they coalesce together to form larger bubbles
Implementation Method 2
When the bubbles have reached a certain diameter, they will escape from said downwards facing surface of the guide member due to their buoyancy, reach the electrolyte surface level and burst
Data Source
AI summary
The invention concerns a bubble collector guide for use in an electrolysis process, which comprises a plurality of guide members arranged at a distance from each other, the guide members comprising a lower side. The guide members can be arranged horizontally on the vertical surface of an electrode so that the lower side of the guide member forms a downwards facing surface that is substantially orthogonal to the vertical surface of the electrode, so as to collect bubbles of gas generated at the electrode.