Plate Gas-Liquid Separator to Limit Electrolyte Gas Crossover
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Solution Overview
Problem
Existing gas-liquid separators in electrolysis systems suffer from low efficiency, leading to contamination of product gases and increased risk of explosive mixtures due to crossover of hydrogen and oxygen bubbles between the cathode and anode sides.
Innovation Solution
A device comprising a separator vessel with a hold-up plate and multiple separator plates oriented along a horizontal axis, configured to separate a biphasic flow into a gas flow and a liquid electrolyte flow using gravitational separation, with specific openings and angles to enhance separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional gravity separator is used, then the structure is simple, but the separation efficiency is low leading to gas crossover
Solution Approach 1:
The separator is divided into multiple functional zones using vertical plates (coalescing plates in the first zone, separation plates in the second zone) and horizontal hold-up plates. This segmentation creates distinct regions for different separation mechanisms, improving overall separation efficiency while maintaining a manageable structural complexity through modular design.
Solution Approach 2:
The invention transitions from a simple horizontal or vertical gravity separator to a multi-dimensional separation system with plates arranged in both vertical and horizontal dimensions. The vertical plates create multiple flow paths and separation surfaces, while hold-up plates establish horizontal liquid levels, creating a three-dimensional separation architecture that enhances efficiency.
2Reliability
If the recycle rate is increased to improve separation, then more liquid is recycled, but product gas bubbles are carried over to the opposite side
Solution Approach 1:
The separator acts as an intermediary device between the cathode and anode sides, using multiple plates and hold-up mechanisms to prevent direct carryover of gas bubbles. The coalescing plates promote bubble merging and the separation plates provide additional separation surfaces, effectively mediating the liquid flow to prevent gas crossover while maintaining electrolyte recycle.
Solution Approach 2:
Different regions of the separator are designed with different plate configurations and orientations to address local separation needs. The first zone with coalescing plates addresses bubble coalescence, while the second zone with separation plates addresses final gas-liquid separation, creating localized quality improvements throughout the separator structure.
3Object-affected harmful factors
If hydrogen and oxygen crossover occurs, then contamination increases, but the risk of explosive mixtures increases
Solution Approach 1:
The separator is designed with multiple plates and hold-up mechanisms that create a cushioning effect against gas bubble carryover. The coalescing plates and separation plates provide multiple barriers that prevent gas crossover before it can occur, cushioning the system against the harmful effect of explosive mixture formation.
Solution Approach 2:
The separator converts the potential harm of gas bubble carryover into a benefit by using the liquid flow itself as the separation medium. The controlled liquid flow through the plate structures promotes bubble coalescence and separation, turning the flowing liquid from a potential transport medium for gases into an effective separation agent.
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 achieves more efficient separation of product gases and liquid electrolytes, reducing contamination and minimizing the risk of explosive mixtures, thereby enhancing safety and efficiency in electrolysis processes.
Implementation Method 1
configured to separate a biphasic flow into a gas flow and a liquid electrolyte flow using gravitational separation
Data Source
Figure 1~2
Figure 3~6
Figure 7
AI summary
Device (1.1) for separating a gas flow (2.1) and a liquid electrolyte flow (3.1) from a biphasic flow (4.1) comprising: ▪ a separator vessel (5.1) oriented along a horizontal axis (8), ▪ a hold-up plate (9), and ▪ multiple separator plates (10), wherein the separator vessel (5.1) comprises a biphasic flow inlet (21.1) and a product gas outlet (22.1) and a liquid electrolyte outlet (23.1), wherein the hold-up plate (9) and the multiple separator plates (10) are arranged in the separator vessel (5.1), wherein the hold-up plate (9) is arranged downstream of the multiple separator plates (10), wherein the hold-up plate (9) is arranged in a hold-up plane (11), and the multiple separator plates (10) are arranged in respective separator planes (12), wherein the multiple separator planes (10) are distanced axially from each other along the horizontal axis (8).