Electrolyser Electrode Assembly Tapered Outlet Headers
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Solution Overview
Problem
Conventional bipolar electrolysers face challenges in minimizing ohmic losses and maintaining small anode/cathode gaps without damaging separators, while also efficiently managing gas and liquid separation in the electrolysis process.
Innovation Solution
The design of an electrode assembly with tapered outlet headers and optimized structural features, such as inwardly and outwardly projecting projections, allows for reduced volume and cross-sectional area ratios, enabling efficient gas and liquid separation and minimizing separator damage, while maintaining low electrical resistance and efficient current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the distance between anode and cathode is reduced to minimize ohmic losses, then electrical resistance decreases, but the risk of separator damage increases
Solution Approach 1:
The separator is designed as a thin film structure with optimized thickness (0.5-2.0 mm) that provides sufficient mechanical strength to prevent damage even at reduced electrode gaps, while maintaining its separating function. The thin film design allows closer electrode spacing without compromising separator integrity.
Solution Approach 2:
The electrode gap is optimized to a specific range (5-20 mm) based on systematic parameter analysis. This parameter optimization balances the reduction of ohmic losses with the maintenance of adequate separator protection, achieving minimum electrical resistance while preventing separator damage through carefully controlled spacing.
2Productivity
If the outlet header volume is reduced to increase chlorine production per unit volume, then productivity increases, but gas/liquid separation efficiency may deteriorate
Solution Approach 1:
The outlet header employs a tapered design that extends in the longitudinal direction, transforming the volume optimization problem from a three-dimensional constraint to a directional extension solution. This allows increased chlorine production capacity through longitudinal extension rather than cross-sectional expansion, maintaining effective gas/liquid separation area while increasing overall output volume.
Solution Approach 2:
The tapered outlet header uses curved transitional surfaces instead of abrupt geometric changes. The gradual tapering profile ensures smooth flow transitions that maintain effective gas/liquid separation while optimizing the volume utilization for chlorine production, avoiding dead zones and flow stagnation.
3Volume of moving object
If the cross-sectional area of outlet header is reduced to minimize device volume, then space utilization improves, but flow capacity decreases
Solution Approach 1:
The outlet header is segmented into multiple sections with varying cross-sectional areas along its length. The tapered design creates zones of different flow capacity matched to the local production requirements, allowing compact overall volume while maintaining adequate flow capacity in critical sections through strategic area distribution.
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 configuration enhances chlorine production per unit volume, maintains high current efficiency, and extends the life of electrodes and membranes by improving gas/liquid separation and circulation, reducing the risk of separator damage and maintaining stable operation over extended periods.
Implementation Method 1
the outlet header on the anode structure has a total internal volume of V A cm 3, wherein V A /(A A × L A ) is less than 1
Implementation Method 2
an electrode assembly comprising an anode structure and a cathode structure... for use in the electrolysis of alkali metal chlorides
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The present invention relates to an electrode assembly and an electrolyser using said assemblies/structures, wherein the electrode assembly comprises an anode structure and a cathode structure, each of said anode structure and cathode structure comprising an outlet header for evolved gas and spent liquid, wherein each of said anode structure and cathode structure comprising an outlet header for evolved gas and spent liquid, wherein the outlet header on the anode structure has a total internal volume of VA cm3 and the outlet header on the cathode structure has a total volume of VC cm3 wherein VA is less than VC, and/or i) the outlet header on the anode structure has an internal volume, VA cm3, an internal cross sectional area at the exit end of the header of ΑA cm2 and an internal length LA cm, and ii) the outlet header on the cathode structure has an internal volume, VC cm3, an internal cross sectional area at the exit end of the header of AC cm2 and an internal length LC cm, and one or both of the ratios VA/(AA X LA) and VC/(AC x LC) are less than 1.