Segmented Hollow Anode Electrolyzer for Horizontal Catholyte Production
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Solution Overview
Problem
Existing electrolyzers are inefficient in producing catholyte, with low productivity and proportion of catholyte in the total volume, and are not suitable for horizontal operation due to design limitations, particularly in the production of high NaOH concentrations.
Innovation Solution
The electrolyzer design features a longer working part of the anode chamber relative to its diameter, allowing for the connection of anode sections via a sleeve, and optimized lid openings for filling and cooling, enabling higher NaOH production and increased catholyte proportion without the need for complex external cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the length of the operating part of the anode chamber is increased to increase productivity, then the catholyte production volume increases, but the device complexity increases due to the need for longer anodes and larger diaphragms that are difficult to manufacture and install
Solution Approach 1:
The anode is divided into multiple sections that can be connected in series. Each section has standardized dimensions that are easy to manufacture, and they are joined together to achieve the required total length. This segmentation allows the device to achieve high productivity through increased anode length without facing the manufacturing and installation difficulties of a single long anode.
2Productivity
If the electric current is increased to increase NaOH production, then the productivity increases, but the anode surface area requirement increases, leading to larger and more complex device dimensions
Solution Approach 1:
The anode is segmented into multiple sections connected in series, allowing the total active surface area to be increased by adding more sections rather than making a single large anode. This modular approach enables scaling of the anode surface area to match the required current load while maintaining manageable individual component sizes.
Solution Approach 2:
Instead of increasing the surface area of a single anode by making it larger in all dimensions, the solution extends the anode in one dimension (length) by connecting multiple sections in series. This dimensional approach allows achieving the required total surface area while keeping each individual section compact and manageable.
3Adaptability or versatility
If the electrolyzer is operated in horizontal position to improve space utilization, then the installation flexibility increases, but gas bubbles accumulate in the inner electrode hollow impairing cooling efficiency
Solution Approach 1:
The inlet and outlet openings of the inner electrode are positioned asymmetrically at opposite ends of the diameter rather than at the center. This asymmetric positioning creates a slope that prevents gas bubbles from accumulating in the hollow, allowing the electrolyzer to be operated in horizontal position while maintaining effective cooling.
4Device complexity
If the cathode chamber processes acid anolyte to produce catholyte, then the device structure is simplified, but the catholyte pH and ORP values are insufficient for technological requirements
Solution Approach 1:
The cathode chamber is designed to process neutral electrolyte before it becomes acidified in the anode chamber. By performing the catholyte production step first with neutral electrolyte, the system achieves the required high pH and ORP values. The subsequent acidification in the anode chamber does not affect the already produced catholyte quality.
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 design achieves catholyte productivity of up to 1200 grams per hour with a catholyte proportion exceeding 92% and allows for horizontal operation, reducing water usage and maintaining efficient cooling, while producing high NaOH concentrations.
Implementation Method 1
electrolyzer for the production of catholyte... electrolyte circulation in an anode chamber... electrochemically converted to a catholyte
Implementation Method 2
slow filling of the anode chamber by filtration of the electrolyte through the diaphragm wall
Data Source
AI summary
Electrolyzer for catholyte production comprises an inner hollow cylindrical anode, an outer cylindrical cathode, and a diaphragm interposed between them. The length of the working part of the anode is at most 2 to 6 times the outer diameter of the anode. The inner hollow anode is made of one or two sections, the sections being connected to each other by a flow dielectric cylindrical sleeve having a diameter not larger than the outer diameter of the anode. The inner hollow anode has openings for introduction of water into inner cavity of the anode and openings for discharge of water at opposite ends of diameters of the anode lid. The electrolyzer for catholyte production operates in a horizontal position because outlet openings of the anode lid are located at the ends of the diameter of the anode lid, close to the outlet openings of the electrolyzer lid facing vertically upwards.