Cylindrical Electrolyser Cover Redesign for Energy Efficiency
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Solution Overview
Problem
Existing electrolysers for producing active chlorine have high electric energy consumption and design flaws that lead to increased electrical resistance and inefficiency, such as non-conductive threaded covers and improper water flow paths, resulting in excessive energy use for producing disinfectants.
Innovation Solution
A cylindrical flow electrolyser design with a modified upper cover that aligns fresh water inlets and disinfectant outlets tangentially to the cylindrical surface, using conductive covers and terminals to minimize water flow into the anode chamber, allowing for efficient mixing and reduced electrical resistance, enabling voltage supply to both ends of the cathode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If water inlet and outlet are positioned at the same level in the upper cover, then mixing is enhanced, but electrical resistance increases and energy consumption rises
Solution Approach 1:
The patent repositions the water inlet and outlet openings from the same horizontal level to different vertical levels in the upper cover. The inlet is positioned at the top surface while the outlet is positioned on the side surface, creating a vertical dimension difference. This spatial reconfiguration allows water to flow directly from inlet to outlet without circulating through the anode chamber, thereby reducing electrical resistance and energy consumption while maintaining mixing effectiveness.
2Reliability
If non-conductive threaded covers are used to seal the cathode, then hermetic sealing is achieved, but voltage supply efficiency decreases due to resistance over cathode length
Solution Approach 1:
The patent changes the material parameter of the cathode covers from non-conductive (plastic or polymer materials) to conductive materials (metals such as stainless steel, nickel, or copper). This material substitution enables direct electrical contact with the cathode, allowing voltage to be supplied at both ends simultaneously. The conductive covers reduce electrical resistance along the cathode length, improving voltage supply efficiency while maintaining hermetic sealing through threaded connections.
3Ease of manufacture
If voltage is supplied to only one end of the long cathode, then assembly is simplified, but energy is lost overcoming resistance over the cathode length
Solution Approach 1:
The patent segments the voltage supply path by providing separate terminal connections at both ends of the cathode through the conductive covers. Instead of a single centralized voltage supply point, the electrical circuit is divided into two parallel paths from each end of the cathode to the power source. This segmentation reduces the effective resistance each current path must overcome, minimizing energy loss while maintaining assembly simplicity through symmetric terminal placement.
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
This design reduces electric energy consumption by up to 24% per gram of active chlorine produced, allowing for higher disinfectant concentration without additional cooling water and lowering operational costs, while improving appliance durability and reliability.
Implementation Method 1
electrolysers, which produce up to 16 grams of active chlorine in a solution per hour
Data Source
AI summary
The invention relates to the field of electrochemical production of disinfectants, where a solution of alkaline metals is used as the electrolyte in the anode chamber. The invention offers a new design for electrolyzers, reducing power consumption in the production of disinfectants by known methods. As a result of this invention, power consumed in the production of 1 gram of active chlorine by known methods will be reduced by 20%, and the possibilities for producing disinfectants with active chlorine content 7500 ppm in an electrolyzer without channelling the water into external cooling devices will also expand.