Electrolysis Separator with Cooling Channel for Hull Protection
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Solution Overview
Problem
Existing gas/liquid separators in electrolysis systems face damage from high temperatures and corrosion, particularly in alkaline systems, leading to inefficiencies or the need for expensive materials like nickel alloys.
Innovation Solution
A separator design featuring a partition element with a permeable section that forms a channel between the inner surface and the partition element, allowing a cooler medium to enter through a second inlet and mix with the high-temperature mixture, thereby cooling the inner section without direct contact with the separator hull, enabling operation at high temperatures with less expensive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive materials such as nickel alloys are used for the separators, then the separator can withstand high medium temperatures and corrosion, but the cost increases
Solution Approach 1:
The separator is divided into two functional zones: a protected inner section (separator chamber) that contacts the hot medium and requires high durability, and an outer section (hull) that can be made of less expensive material. This segmentation allows different material specifications for different functional requirements, reducing overall cost while maintaining reliability where needed.
Solution Approach 2:
A cooling medium is introduced as an intermediary substance that absorbs heat from the hot process medium in the inner section and transports it to the outer hull. This thermal intermediary protects the hull from direct exposure to high temperatures, enabling the use of less expensive materials in the outer structure while maintaining the ability to operate at high temperatures.
2Reliability
If polymer linings are applied to the inner surface of the separators, then corrosion resistance is improved, but 100% coverage is difficult to achieve and the lining may deteriorate over time
Solution Approach 1:
Instead of relying on polymer linings as an intermediary protective layer, the patent uses a cooling medium as a thermal intermediary. This approach addresses corrosion resistance indirectly by controlling the temperature of the separator hull, preventing thermal stress corrosion cracking without requiring complete surface coverage.
Solution Approach 2:
The patent changes the temperature parameter of the separator hull by introducing a cooling medium that maintains the hull temperature below the critical threshold for stress corrosion cracking (>90°C). This parameter change eliminates the need for protective linings while maintaining reliability.
3Reliability
If the temperature of the medium is reduced to prevent stress corrosion cracking, then separator durability is improved, but electrolysis efficiency decreases
Solution Approach 1:
The separator is segmented into thermal zones: the inner separator chamber maintains high temperature for efficient electrolysis, while the outer hull is cooled to prevent stress corrosion cracking. This spatial segmentation of temperature zones allows simultaneous optimization of both efficiency and durability.
Solution Approach 2:
A cooling medium acts as a thermal intermediary between the hot process medium and the separator hull. It absorbs excess heat from the inner chamber, maintaining the hull temperature below the stress corrosion cracking threshold, while allowing the process medium to remain at high temperature for efficient electrolysis.
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 allows for efficient separation of gases and liquids at high temperatures without damaging the separator, reducing material costs and maintaining efficiency, as the separator can be made with less expensive materials while maintaining high operational temperatures.
Implementation Method 1
a partition element (16) is arranged within the separator chamber (11) so as to form a channel (17) between an inner surface (18) of the separator chamber (11) and the partition element (16), wherein the second inlet (13) opens into the channel (17), and wherein the partition element (16) has a permeable section (19) arranged lower than the second inlet (13)
Data Source
Figure 1
Figure 2
AI summary
Separator (9,10) comprising a separator chamber (11) having ▪ a first inlet (12), ▪ a second inlet (13), ▪ a gas outlet (14), ▪ a liquid outlet (15), wherein the separator (9,10) is configured to separate a mixture of the gas and the liquid introduced into the first inlet (12) such that the gas is provided at the gas outlet (14) and the liquid is provided at the liquid outlet (15), wherein a partition element (16) is arranged within the separator chamber (11) so as to form a channel (17) between an inner surface (18) of the separator chamber (11) and the partition element (16), wherein the second inlet (13) opens into the channel (17), and wherein the partition element (16) has a permeable section (19) arranged lower than the second inlet (13). Due to the channel (17) the separator (9,10) can be used for an electrolysis at a particularly high temperature. Therefore, the hull (29) of the separator (9,10) does not have to be made of a particularly heat-resistant material.