Catalytic Anodes for Electro-chlorination via Cobalt Oxide

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Solution Overview

Problem

Existing catalytic anodes for electro-chlorination systems are costly due to the use of precious metals like iridium and ruthenium, and they suffer from durability issues and inefficiencies in chlorine evolution reactions, leading to high over-potentials and short operational lifetimes.

Innovation Solution

A catalytic anode structure featuring a composite metallurgical layer with a structural base composition of ruthenium, tin, and titanium, and a catalyst composition of cobalt oxide particles, which provides high selectivity, durability, and resistance to acid, while avoiding the need for expensive precious metals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If precious metals like iridium and ruthenium are used in catalytic anodes, then catalytic activity for chlorine evolution is improved, but manufacturing cost increases significantly

Engineering Contradiction:

Improvechlorine evolution efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameters by replacing precious metals (iridium, ruthenium) with base metals (cobalt, nickel, copper, zinc) in the catalyst layer. This substitution maintains catalytic functionality while dramatically reducing material cost, directly resolving the contradiction between productivity and manufacturing cost

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs inexpensive base metal catalysts that can be replaced more frequently rather than using expensive precious metals for long-term service. This approach trades component lifetime for cost reduction, making the system economically viable through lower initial investment and operational flexibility

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Productivity

If conventional catalytic coatings are used, then chlorine generation is promoted, but operational lifetime is reduced due to durability issues

Engineering Contradiction:

Improvechlorine generation rateVSAvoidanode operational lifetime

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent creates a composite metallurgical layer combining multiple base metals (cobalt, nickel, copper, zinc) with titanium substrate. This composite structure provides both catalytic activity for chlorine evolution and enhanced mechanical durability, resolving the contradiction between productivity and operational lifetime

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different metal compositions to different layers: the catalyst layer contains cobalt/nickel/copper/zinc for catalytic activity, while the metallurgical layer provides structural support and adhesion. This localized functional differentiation maintains high chlorine generation rates while extending anode lifetime

Inventive Principle:

Principle #3Local quality

3Reliability

If high precious metal content is used, then catalytic performance is enhanced, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvecatalytic performanceVSAvoidanode structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent simplifies the device by changing the material parameters from precious metals to base metals. The catalyst layer can be formed by straightforward electroplating or chemical deposition processes, reducing manufacturing complexity while maintaining reliable catalytic performance through optimized base metal compositions

Inventive Principle:

Principle #35Parameter changes

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

The anode achieves efficient chlorine evolution with improved durability and mechanical adhesion, maintaining low over-potentials over extended periods, thus enhancing the operational lifetime and reducing costs.

Implementation Method 1

a catalyst composition essentially comprising crystalline cobalt oxide particles to promote the chlorine evolution reaction

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

an electrically conductive composite metallurgical layer... comprising a structural base composition... and a catalyst composition

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

electro-chlorination systems which generate chlorine from aqueous solutions containing chloride ions, via the chlorine evolution reaction

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Data Source

PatentUS20240426004A1Catalytic Anodes and Processes for Use in Electro-chlorination-1

Publication Date: 2024.12.26 INFINEUM INT LTD

AI summary

The present invention relates to catalytic anodes for use in electro-chlorination systems which generate chlorine from aqueous solutions via the chlorine evolution reaction. These anodes comprise an electrically conductive composite metallurgical layer comprising a specific structural base composition to support the catalyst, this base composition essentially comprising ruthenium, tin and titanium, and a specific catalyst composition essentially comprising crystalline cobalt oxide particles. The desired characteristics of this composite metallurgical layer may be realised via a process of preparation employing specific control of reactants and process conditions.