Horizontal Plate Gas-Liquid Separator for Electrolyte Bubble Carryover
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Solution Overview
Problem
Existing gas-liquid separators in electrolysis systems suffer from low efficiency, leading to product gas bubbles crossing over to the wrong side of the electrolyser, which can create explosive mixtures due to contamination and increase safety risks.
Innovation Solution
A device comprising a separator vessel with a hold-up plate and multiple separator plates oriented along a horizontal axis, designed to separate gas and liquid electrolyte flows by exploiting density differences, using angled openings to enhance separation efficiency and prevent bubble carryover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional gravity separator is used, then the device complexity is low, but the separation efficiency is insufficient leading to gas bubbles crossing over
Solution Approach 1:
The separator is divided into multiple functional zones with separator plates creating distinct flow paths. The plates segment the biphasic flow into separate gas and liquid channels, preventing bubble crossover while maintaining a compact structure. This segmentation approach improves separation efficiency without proportionally increasing overall device complexity.
Solution Approach 2:
The invention transitions from conventional vertical gravity separation to horizontal multi-plane separation. By arranging separator plates in horizontal planes at different heights, the system utilizes the vertical dimension for gravity settling while the horizontal planes provide multiple separation stages, thereby improving efficiency within a compact footprint.
2Productivity
If the recycle rate is increased, then the liquid electrolyte circulation is improved, but product gas bubbles are carried over to the wrong side
Solution Approach 1:
The separator plates extract and remove gas bubbles from the liquid electrolyte stream through multiple gravity settling planes. By the time the liquid reaches the hold-up plate, gas bubbles have been extracted in previous stages, preventing them from being carried over to the opposite side of the electrolyser during recycle.
Solution Approach 2:
The multi-plane separator performs preliminary gas removal in advance before the liquid electrolyte re-enters the electrolyser. Each separator plane performs a preliminary separation stage, progressively removing bubbles before the liquid returns to the electrolysis stack, preventing harmful gas carryover.
3Reliability
If separator plates are added to improve separation, then the separation efficiency increases, but the device complexity increases
Solution Approach 1:
The separator plates serve multiple functions simultaneously: they act as gravity settling surfaces for gas-liquid separation, provide structural support for the biphasic flow, define flow channels for both gas and liquid phases, and serve as mounting surfaces for outlet connections. This multi-functionality reduces the need for additional components, thereby limiting the increase in device complexity.
Solution Approach 2:
The invention merges the separation function with the structural framework of the separator vessel. The separator plates are integrated into the vessel walls, combining the separation process with the containment structure. This merging approach allows multiple separation stages without requiring separate external components 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 device effectively separates product gas and liquid electrolyte flows, reducing contamination and minimizing the risk of explosive mixtures, thereby enhancing safety and efficiency in electrolysis processes.
Implementation Method 1
Gas-liquid separators are known. Commonly, gas-liquid separators are designed as empty gravity separators operating according to the gravity effect
Data Source
AI summary
A device for separating a gas flow and a liquid electrolyte flow from a biphasic flow including a separator vessel oriented along a horizontal axis, a hold-up plate, and multiple separator plates. Wherein the separator vessel includes a biphasic flow inlet and a product gas outlet and a liquid electrolyte outlet, wherein the hold-up plate and the multiple separator plates are arranged in the separator vessel, and wherein the hold-up plate is arranged downstream of the multiple separator plates. Wherein the hold-up plate is arranged in a hold-up plane, and the multiple separator plates are arranged in respective separator planes, wherein the multiple separator planes are distanced axially from each other along the horizontal axis.