Electrolyte Circulation Device for Iron Electrolysis

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Solution Overview

Problem

Current electrochemical iron production methods are energy-intensive and have high operational costs due to the use of external pumps for electrolyte recirculation, leading to difficulties in scaling up production at high rates.

Innovation Solution

An apparatus for electrochemical iron production that includes a casing with a gas-permeable anode plate and a cathode plate, an electrolyte chamber, and a degassing unit with an electrolyte recirculation part. This apparatus features an electrolyte circulation device with a pumping device and non-return devices to aspirate and recirculate the electrolyte efficiently, reducing the need for fresh electrolyte and minimizing energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If external pumps are used for electrolyte recirculation, then electrolyte can be recirculated within the cell, but energy consumption increases and heat losses occur

Engineering Contradiction:

Improveelectrolyte lossVSAvoidenergy consumption

Core Design Contradiction:

Loss of substanceVSUse of energy by moving object

Solution Approach 1:

The electrolyte recirculation system uses the buoyancy force generated by gas bubbles rising through the electrolyte to drive circulation, eliminating the need for external pumps. The gas-liquid separation chamber allows electrolyte to be lifted and recirculated passively through gravity and buoyancy forces, making the system self-service and energy-efficient.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The mechanical pump system is replaced with a passive fluid dynamics-based recirculation system utilizing buoyancy and gravity. Gas bubbles rising through the electrolyte create upward flow, while the gas-liquid separation chamber directs electrolyte back to the cell, substituting mechanical energy input with natural physical forces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of substance

If external pumps are used for electrolyte recirculation, then electrolyte can be recirculated within the cell, but operative cost increases

Engineering Contradiction:

Improveelectrolyte lossVSAvoidoperative cost

Core Design Contradiction:

Loss of substanceVSEase of operation

Solution Approach 1:

The system automatically recirculates electrolyte using buoyancy-driven flow and gravity, requiring no external power input or complex control systems. This self-service mechanism reduces operative costs by eliminating pump energy consumption and associated maintenance.

Inventive Principle:

Principle #25Self-service

3Loss of substance

If external pumps are used for electrolyte recirculation, then electrolyte can be recirculated within the cell, but upscaling at high production rate becomes difficult

Engineering Contradiction:

Improveelectrolyte lossVSAvoidproduction rate

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The recirculation system dynamically adapts to production rate requirements through the gas-liquid separation chamber design. As gas generation increases with higher production rates, the buoyancy-driven flow automatically increases, providing scalable recirculation capacity without requiring proportionally larger pumps or more complex systems.

Inventive Principle:

Principle #15Dynamics

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 apparatus achieves improved energy efficiency and reduced operational costs by effectively recirculating the electrolyte within the system, thereby minimizing energy consumption and heat losses, and enabling higher production rates with a lower environmental footprint.

Implementation Method 1

an electrolyte circulation device including a pumping device located at one extremity of the casing

Methodology Applied

Scientific EffectPumping: Pump

Implementation Method 2

at least a first non-return device located in the electrolyte chamber and a second non-return device located in the gas recovery part

Methodology Applied

Scientific EffectOne-way flow control: Valve

Implementation Method 3

a gas permeable anode plate

Methodology Applied

Scientific EffectGas permeation: Permeation

Implementation Method 4

production of iron metal through reduction of iron ore by an electrolysis reaction

Methodology Applied

Scientific EffectElectrolysis: Electrolysis

Data Source

PatentUS20250027222A1Apparatus for production of iron metal by electrolysis

Publication Date: 2025.01.23 ARCELORMITTAL SA

AI summary

An apparatus (1) for the production of iron metal through reduction of iron ore by an electrolysis reaction, the apparatus including an electrolyte circulation device (30) including a pumping device (22) located at one extremity of the casing (4) and at least a first (31A) check valve located in the electrolyte chamber (6) and a second (31B) check valve located in the gas recovery part (8), the electrolyte circulation device (30) being designed, when actuating by an actuator (28), to aspirate the electrolyte (5) from the electrolyte chamber (6) or to pull the electrolyte (5) back into the gas recovery part (8).