Flow Reactor Additives Using Elastic Turbulence for Uniform Deposition
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Solution Overview
Problem
Existing electrochemical flow cells face inefficiencies due to overpotential and parasitic reactions, which consume significant electrical power and affect uniformity of deposition at the electrode, while there is a compromise between high surface area and low pressure drop, leading to increased energy consumption.
Innovation Solution
Employing the phenomenon of elastic turbulence by using a solute with elastic properties and configuring the flow path to compel changes in liquid flow direction, enhancing mass transport and reducing overpotential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the electrode surface area is increased to maximize reaction rate, then the productivity is improved, but the pressure drop across the electrode increases, requiring more energy for liquid circulation
Solution Approach 1:
The electrode is designed with a porous structure that provides high internal surface area for electrochemical reactions while maintaining permeability for liquid flow. The porous matrix allows electrolyte to penetrate through, reducing pressure drop while providing sufficient active surface area for high reaction rates.
Solution Approach 2:
The invention transitions from a flat 2D electrode surface to a 3D porous structure, utilizing the third dimension (depth/pore structure) to increase effective surface area without proportionally increasing the footprint or flow resistance. This dimensional transformation allows high surface area-to-volume ratio while maintaining fluid permeability.
2Power
If overpotential is increased to enhance transport of reactive species to the electrode surface, then the electric current flow is increased, but the electrical power consumption is significantly increased
Solution Approach 1:
The invention applies hydraulic principles by using pressurized liquid flow to enhance mass transport of reactive species to the electrode surface. Instead of relying solely on electrical potential-driven migration, the system uses hydraulic flow to physically transport species, reducing the need for high overpotential and associated energy losses.
Solution Approach 2:
The invention replaces part of the electrical field-driven mass transport mechanism with a mechanical flow system. By introducing forced liquid circulation and flow-through electrode design, the system substitutes some electrical energy consumption with mechanical pumping energy, which is more efficient for bulk transport of reactive species.
3Productivity
If overpotential is increased to increase electric current, then the productivity is improved, but parasitic reactions such as hydrogen evolution or oxygen evolution are promoted
Solution Approach 1:
By using hydraulic flow to enhance mass transport, the system achieves high current densities without excessive overpotential. The forced convection of electrolyte through the porous electrode maintains high concentration gradients at the reaction sites, enabling high productivity while operating at lower potentials that avoid triggering parasitic water splitting reactions.
Solution Approach 2:
The invention changes the operating parameters by implementing flow-through electrode design with controlled liquid velocity and pressure gradients. This parameter optimization allows the system to operate in a regime where mass transport is enhanced hydraulically rather than electrically, maintaining high productivity while avoiding the high overpotential conditions that promote parasitic reactions.
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
Elastic turbulence improves the transport of reactive species to and from the electrode, increasing electrical current density and reducing overpotential, resulting in more uniform deposition and decreased parasitic reactions.
Implementation Method 1
the liquid contains a solute enabling the liquid to display elastic turbulence, and the flow path to or at the electrode is configured to compel changes in the direction of liquid flow, to cause elastic turbulence within flow of the liquid in contact with the electrode
Implementation Method 2
the electrochemical reaction leads to deposition of a solid phase at an electrode... a liquid containing one or more species which undergo electrochemical reaction is pumped through the half-cell... the reaction converts the dissolved constituent to a solid which deposits on the electrode
Implementation Method 3
at least one pump for propelling the liquid along the flow path... the flow path to or at the electrode is configured to compel changes in the direction of liquid flow
Data Source
Figure 1~2
Figure 3~6
Figure 4
AI summary
An electrochemical reactor, which may be a half-cell of a rechargeable battery, contains a liquid electrolyte which is pumped through the half-cell and has an electrochemical system in which a solid is deposited at an electrode while electric current is flowing. The liquid contains a high molecular weight polymer or a viscoelastic surfactant enabling elastic turbulence to occur and the half-cell is configured to compel through flow to make changes in direction, so that elastic turbulence occurs, enhancing mass transport through the liquid and reducing overpotential at the electrode, which enhances uniformity of deposited solid and inhibits parasitic reactions.