Continuous Flow Electrochemical Reactor with Pulsatile Protrusion Mixing
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Solution Overview
Problem
Existing electrochemical reactors face limitations in current density and mass transport, necessitating high flow rates and recirculation methods, while increasing voltage does not proportionally increase current density due to restricted mass transport.
Innovation Solution
A continuous flow reaction device with discrete protrusions acting as electrodes, arranged to split and recombine fluid flow paths, utilizing pulsatile flow to enhance mixing and mass transport without increasing flow rates, and allowing for variable voltage applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If voltage difference between anode and cathode is increased to obtain higher reaction rate, then current increases, but mass transport reaches a limit and current plateaus
Solution Approach 1:
The electrode surface is segmented into multiple discrete protrusions (pillars) rather than a continuous surface. This segmentation creates multiple independent reaction sites that can operate in parallel, increasing the overall reaction rate without requiring proportional increases in mass transport to a single large surface.
Solution Approach 2:
The invention transitions from a two-dimensional planar electrode surface to a three-dimensional structure with vertical protrusions. This dimensional change increases the effective electrode surface area within the same footprint, allowing more reaction sites to be accessed by the flowing reagents without increasing the flow rate.
2Quantity of substance
If turbulence promotors are added to increase mass transport, then mass transport rate improves, but electrode surface area is shielded and flow rate must be increased
Solution Approach 1:
The invention merges the functions of turbulence promotors and electrodes into a single integrated structure. The discrete protrusions serve both to enhance mass transport through flow disruption and to provide active electrode surface area for electrochemical reactions, eliminating the need for separate turbulence promotors that would shield electrode surfaces.
Solution Approach 2:
The discrete protrusions perform multiple functions simultaneously: they act as electrodes for electrochemical reactions, serve as turbulence promotors to enhance mass transport, and provide flow distribution structures. This multi-functionality eliminates the trade-off between mass transport enhancement and electrode surface area availability.
3Power
If electrode surface area is increased to achieve higher current density, then total current increases, but current density remains limited by mass transport
Solution Approach 1:
The electrode is segmented into discrete protrusions that create localized reaction zones. Each protrusion acts as an independent electrode site with its own mass transport boundary layer, allowing high current density at each site while the overall structure maintains efficient bulk mass transport through the flow channels between protrusions.
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 device significantly enhances mass transport and current density, eliminating the need for recirculation and downstream separation, while supporting a wide range of electrochemical processes including photo-electrochemistry.
Implementation Method 1
a pumping system configured to generate a flow to the fluid inlet end, the flow being a pulsatile flow comprising a steady state flow rate and oscillatory flow rate superimposed on the steady state flow rate
Implementation Method 2
each discrete protrusion is configured such that a flow path of the fluid contacting an inlet end side of the discrete protrusion is split at least into two daughter flow paths on the outlet end side of the discrete protrusion
Implementation Method 3
The number of reagents reacting at the electrode surface corresponds to the amount of electrons, i.e. current, transferred over the electric circuit which contains minimal two electrodes: anode and cathode
Data Source
AI summary
A continuous flow reaction device (100) for an electrochemical process comprising: a reaction space (110), a pumping system (200) configured to generate a pulsatile flow, a plurality of discrete protrusions (120,a: 120,b) each configured such that a flow path (150a-150c) of the fluid contacting an inlet end (14) side of the discrete protrusion is split at least into two daughter flow paths (150b1; 150b2) on the outlet end (16) side of the discrete protrusion (120,a: 120,b); and the discrete protrusions (120,a: 120,b) being arranged so that at least one of the daughter flow paths (150b1) generated by one of the plurality of discrete protrusions (120) combines (152a) with at least one of the daughter flow paths (150a2) generated by another of the plurality of discrete protrusions (120) on the outlet end (16) side of both discrete protrusions (120) and wherein each (and every) discrete protrusion (120) is an electrode in the electrochemical process.