Hydrodynamic Electrolytic Reactor for Calcium Hydroxide Precipitation
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Solution Overview
Problem
The production of calcium hydroxide through conventional methods releases significant carbon emissions due to high-temperature calcination processes, and there is a need for an efficient, low-temperature process to recover and separate calcium hydroxide from calcium-bearing materials.
Innovation Solution
A process using an electrolytic reactor with hydrodynamic separation to precipitate calcium hydroxide at low temperatures (T<40°C) from calcium-bearing materials like calcium carbonate or industrial wastes, employing a dissolution, impurity removal, nanofiltration, and electrolytic precipitation, with hydrodynamic separation to enhance mass transfer and reduce energy intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional calcination process is used to produce calcium hydroxide, then calcium hydroxide can be produced, but significant carbon emissions are released
Solution Approach 1:
The patent replaces the thermal calcination process with an electrolytic process. Instead of heating calcium carbonate at high temperatures (1070-1270°C) to produce calcium oxide and then reacting with water, the invention uses electrochemical reduction of calcium ions in aqueous solution at low temperatures (T<40°C) to directly produce calcium hydroxide, thereby eliminating the high-temperature thermal process and associated carbon emissions
Solution Approach 2:
The patent fundamentally changes the operating temperature parameter from high temperature (1070-1270°C) to low temperature (T<40°C). This parameter change transforms the process from thermal decomposition to electrochemical reaction, enabling calcium hydroxide production without conventional calcination and its associated environmental harm
2Object-generated harmful factors
If electrolytic precipitation is used to produce calcium hydroxide at low temperatures, then carbon emissions are reduced, but energy consumption increases
Solution Approach 1:
The patent converts the harmful effect of high energy consumption into a beneficial outcome by coupling the electrolytic process with waste heat utilization. The system uses waste heat from industrial processes to maintain the electrolytic reactor at optimal temperatures, thereby reducing the net energy input required while achieving low-carbon calcium hydroxide production
Solution Approach 2:
The electrolytic reactor serves multiple functions: it produces calcium hydroxide, generates hydrogen gas as a byproduct, and can utilize waste heat from industrial processes to maintain operating conditions. This multi-functionality reduces overall energy consumption by replacing single-purpose high-energy processes with a system that performs multiple functions simultaneously
3Productivity
If hydrodynamic separation is implemented in the electrolytic reactor, then mass transfer is enhanced, but device complexity increases
Solution Approach 1:
The patent employs hydrodynamic separation principles in the electrolytic reactor to enhance mass transfer between the electrolyte and electrode surfaces. By utilizing fluid dynamics and flow patterns within the reactor, the system improves reaction efficiency and calcium hydroxide production rates without requiring complex mechanical separation equipment
Solution Approach 2:
The patent merges the electrolysis and separation functions into a single integrated reactor system. The hydrodynamic separation mechanism is incorporated directly into the electrolytic cell design, combining multiple functions (electrochemical reaction, mass transfer, and solid-liquid separation) in one device rather than requiring separate units for each function
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 process achieves high-purity calcium hydroxide production with reduced energy consumption and minimal carbon emissions, utilizing industrial wastes and byproducts, and captures hydrogen gas for energy recovery.
Implementation Method 1
A process using an electrolytic reactor with hydrodynamic separation to precipitate calcium hydroxide at low temperatures (T<40°C) from calcium-bearing materials
Implementation Method 2
employing a dissolution, impurity removal, nanofiltration, and electrolytic precipitation, with hydrodynamic separation to enhance mass transfer
Implementation Method 3
combining a solid comprising target ions and a neutral fluid or an acidic fluid in a dissolution chamber, thereby forming a first suspension
Data Source
AI summary
A system and method to precipitate calcium hydroxide at low temperatures (T<40° C.) using an electrolytic reactor with hydrodynamic separation. The calcium can be supplied by any calcium bearing material such as calcium carbonate or basalt rock, or from industrial wastes such as brine or steel slag. The solid feedstock undergoes dissolution, whereas the brine may be utilized as is. Once in solution, the feed stream is directed towards an electrolyzer reactor which comprises a cathode, an anode, and a membrane separator. At the cathode, or in a separate precipitation chamber, an alkaline catholyte solution containing calcium hydroxide (portlandite) and magnesium hydroxide (brucite) precipitates, and hydrogen gas is produced.