Flow Distributors for Electrochemical Separation Current Bypass
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Solution Overview
Problem
Current electrochemical separation systems, such as cross-flow electrodialysis devices, face inefficiencies due to current bypass through inlet and outlet manifolds, leading to increased energy consumption and reduced membrane utilization, which affects the cost, weight, and space requirements of these systems.
Innovation Solution
The implementation of a modular electrochemical separation system with a cross-flow design that includes a frame surrounding the cell stack and a manifold system to facilitate fluid flow, along with blocking spacers and flow distributors to redirect current and fluid paths, reducing current leakage and enhancing membrane utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional manifold systems are used in electrochemical separation systems, then fluid flow is facilitated, but current bypass through manifolds increases energy consumption
Solution Approach 1:
The patent extracts and removes the manifold system from the electrochemical separation device, eliminating the source of current bypass. Instead of using traditional manifolds for fluid distribution, the invention uses edge-positioned flow distributors that supply feed to compartments without creating current leakage paths through the device interior.
Solution Approach 2:
The patent introduces edge-positioned flow distributors as intermediary components that perform fluid distribution without conducting current through the device. These distributors are positioned at the edges of the cell stack and supply feed to compartments through side connections, acting as mediators between the external fluid supply and the internal compartments without creating harmful current paths.
2Productivity
If membrane area is increased to improve separation capacity, then system weight and space requirements increase
Solution Approach 1:
The patent changes the operational parameters by optimizing feed flow distribution and compartment configuration to maximize the utilization efficiency of each unit area of membrane. By improving flow distributors and eliminating current bypass, the system achieves higher current efficiency and membrane utilization, allowing smaller membrane areas to achieve the same productivity.
3Productivity
If membrane area is increased to improve separation capacity, then manufacturing costs increase
Solution Approach 1:
The patent optimizes system parameters including flow distribution characteristics and compartment configuration to maximize membrane utilization efficiency. This allows achieving required separation capacity with smaller membrane areas, directly reducing manufacturing costs while maintaining productivity.
4Reliability
If current efficiency is improved by blocking current paths, then fluid flow distribution may be affected
Solution Approach 1:
The patent removes the manifold system that caused current bypass, eliminating the conflict between current efficiency and fluid distribution. By using edge-positioned flow distributors instead, the system achieves both high current efficiency and proper fluid flow distribution without the trade-off present in traditional designs.
Solution Approach 2:
The edge-positioned flow distributors act as intermediaries that independently handle fluid distribution without interfering with current paths. They supply feed to compartments through side connections at the device edges, decoupling the fluid distribution function from the current-conducting manifolds and allowing optimization of both functions separately.
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 approach improves current efficiency to at least 85% and reduces energy consumption, manufacturing costs, and space requirements, while increasing membrane utilization and the cost competitiveness of electrochemical separation systems for desalination processes.
Implementation Method 1
a flow distributor may be provided to promote uniform flow distribution within a cell stack
Implementation Method 2
electrochemical separation system may comprise a first electrode, a second electrode
Implementation Method 3
cross-flow electrodialysis devices
Data Source
AI summary
An electrochemical separation system may be modular and may include at least a first modular unit and a second modular unit. Each modular unit may include a cell stack and a frame. The frame may include a manifold system. A flow distribution system in the frame may enhance current efficiency. Spacers positioned between modular units may also enhance current efficiency of the system.