Perchlorate Manufacturing via Cation-Exchange Membrane Electrolysis
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Solution Overview
Problem
Conventional methods for manufacturing perchlorates, such as ammonium and lithium perchlorates, involve the use of toxic sodium dichromate as an anti-reducing agent, leading to environmental concerns and complex processes, with limited studies on efficiently producing these compounds beyond sodium perchlorate and requiring extensive facilities.
Innovation Solution
A method involving an electrolysis process using a cation-exchange membrane to separate sodium ions from perchlorate ions, followed by a neutralization reaction with alkaline substances like ammonia, and subsequent evaporation and crystallization to produce high-purity perchlorates, while also recovering platinum and reducing facility requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sodium dichromate is used as an anti-reducing agent in the electrolytic oxidation of sodium chlorate, then the oxidation process can be maintained, but toxic chromium waste is generated causing environmental pollution and requiring complex disposal treatments
Solution Approach 1:
The invention extracts and removes the harmful sodium dichromate anti-reducing agent from the electrolytic oxidation system by introducing a diaphragm to separate the anode and cathode compartments, preventing the formation of toxic chromium waste while maintaining process reliability
Solution Approach 2:
The diaphragm acts as an intermediary barrier between the anode and cathode, allowing ion transport while preventing direct contact between reactants that would otherwise require sodium dichromate, thus eliminating toxic waste generation
2Adaptability or versatility
If conventional methods are used to manufacture perchlorates beyond sodium perchlorate, then production is possible, but the process becomes complex and requires extensive facilities
Solution Approach 1:
The invention creates a universal electrolytic oxidation system with a diaphragm that can produce multiple types of perchlorates (sodium, ammonium, lithium, potassium) using the same basic apparatus and process, eliminating the need for separate complex facilities for each perchlorate type
Solution Approach 2:
The invention segments the electrolytic cell into separate anode and cathode compartments using a diaphragm, enabling versatile perchlorate production through a single modular unit that can be adapted for different applications without requiring extensive facilities
3Reliability
If sodium dichromate is used in the electrolytic process, then the anti-reducing function is provided, but disposal costs increase due to chromium liquid waste treatment requirements
Solution Approach 1:
The invention extracts and eliminates the need for sodium dichromate by using a diaphragm-separated electrolytic cell, removing the source of chromium waste and thereby eliminating disposal costs while maintaining the anti-reducing function through physical separation
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 minimizes environmental impact, reduces disposal costs, simplifies the manufacturing process, and allows for the efficient production of various perchlorates with higher purity and reduced facility needs.
Implementation Method 1
an electrolysis process using a cation-exchange membrane to separate sodium ions from perchlorate ions
Implementation Method 2
an electrolysis process in which, using an electrolysis tank in which an anode section provided with an anode and a cathode section provided with a cathode are divided by a cation-exchange membrane, an aqueous solution of sodium chlorate is electrolytically oxidized in the anode section
Implementation Method 3
an aqueous solution of sodium chlorate is electrolytically oxidized in the anode section
Implementation Method 4
a neutralization reaction process in which a substance that becomes alkaline when dissolved in water is added to the aqueous solution of perchloric acid in the anode section, which has been generated by the electrolytic oxidation, so as to synthesize a perchlorate by a neutralization reaction
Implementation Method 5
subsequent evaporation and crystallization to produce high-purity perchlorates
Implementation Method 6
subsequent evaporation and crystallization to produce high-purity perchlorates
Data Source
AI summary
Disclosed is a method for producing perchlorate, which comprises: an electrolytic step (S1) wherein an electrolysis vessel (2), in which a positive electrode side (4A) on which a positive electrode (4) is arranged and a negative electrode side (5A) on which a negative electrode (5) is arranged are divided by a cation-exchange membrane (6), is used and an aqueous solution of sodium chlorate is electrolytically oxidized on the positive electrode side (4A) of the electrolysis vessel (2); a neutralization reaction step (S2) wherein a substance an aqueous solution of which shows alkalinity is added to the aqueous perchloric acid solution that has been produced by the electrolytic oxidation on the positive electrode side, so that perchlorate is synthesized by a neutralization reaction; and a crystallization process wherein the perchlorate synthesized by the neutralization reaction is obtained as crystals. The crystallization process is composed of an evaporative crystallization step (S3), or alternatively composed of three steps, namely an evaporative concentration step (S21), a cooling crystallization step (S22), and a separation step (S23).