Spray Nozzle Reactant Dispersion for Electrochemical Power Density

Solution Overview

Problem

Continuous electrochemical reactors face inefficiencies in multi-phase reactant mixing, leading to suboptimal performance in terms of current density, selectivity, and energy consumption, particularly in mixed-reactant fuel cells where reactants are fed in separate phases without effective dispersion.

Innovation Solution

The use of fluid contacting devices such as spray nozzles and in-line mixers to disperse liquid reactants into gas or liquid phases, creating droplets or emulsions with specific diameters to enhance reactant dispersion and uniformity within the reactor, thereby improving fluid dynamics and electrode contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If reactants are fed to the reactor in separate streams without effective dispersion, then the reactor structure is simpler, but the current density and power density are suboptimal

Engineering Contradiction:

Improvepower densityVSAvoidreactor structure complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by dispersing liquid reactants into fine droplets (1-100 micrometers) using spray nozzles or in-line mixers before the reactants enter the electrochemical reactor. This pre-dispersion ensures uniform distribution of reactants throughout the reactor, maximizing electrode contact and reaction efficiency, thereby achieving optimal power density without requiring complex internal reactor structures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces fluid contacting devices (spray nozzles, in-line mixers) as intermediary components between the reactant feed and the reactor. These devices act as mediators that create uniform droplet dispersions of liquid reactants in gas or liquid phases, ensuring homogeneous reactant distribution and maximizing the power density achieved in the electrochemical reactor.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Power

If reactants are fed in separate phases without dispersion, then the device complexity is reduced, but the current density decreases

Engineering Contradiction:

Improvecurrent densityVSAvoidfeeding apparatus complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by dispersing liquid reactants into fine droplets (1-100 micrometers) using spray nozzles or in-line mixers before the reactants enter the electrochemical reactor. This pre-dispersion ensures uniform distribution of reactants throughout the reactor, maximizing electrode contact and reaction efficiency, thereby achieving optimal power density without requiring complex internal reactor structures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces fluid contacting devices (spray nozzles, in-line mixers) as intermediary components between the reactant feed and the reactor. These devices act as mediators that create uniform droplet dispersions of liquid reactants in gas or liquid phases, ensuring homogeneous reactant distribution and maximizing the power density achieved in the electrochemical reactor.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If reactants are mixed in a single conduit before entering the reactor, then the number of conduits is reduced, but the uniformity of reactant mixture is insufficient

Engineering Contradiction:

Improveuniformity of reactant mixtureVSAvoidmixing device complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by dispersing liquid reactants into fine droplets (1-100 micrometers) using spray nozzles or in-line mixers before the reactants enter the electrochemical reactor. This pre-dispersion ensures uniform distribution of reactants throughout the reactor, maximizing electrode contact and reaction efficiency, thereby achieving optimal power density without requiring complex internal reactor structures.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces fluid contacting devices (spray nozzles, in-line mixers) as intermediary components between the reactant feed and the reactor. These devices act as mediators that create uniform droplet dispersions of liquid reactants in gas or liquid phases, ensuring homogeneous reactant distribution and maximizing the power density achieved in the electrochemical reactor.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 increases current density and power density by ensuring uniform reactant distribution, reducing energy consumption and operational costs, and enhancing the overall performance of continuous electrochemical reactors.

Implementation Method 1

spray nozzles and in-line mixers to disperse liquid reactants into gas or liquid phases, creating droplets or emulsions with specific diameters

Methodology Applied

Scientific EffectSpray: Spray

Implementation Method 2

disperse liquid reactants into gas or liquid phases, creating droplets or emulsions with specific diameters

Methodology Applied

Scientific EffectEmulsion: Emulsion

Data Source

PatentUS10233552B2Apparatus and method for feeding a multi-phase mixture of reactants to an electrochemical reactor

Publication Date: 2019.03.19 0798465 B C

AI summary

This invention is a method and apparatus for operating electrochemical reactors with multi-phase feeds, in which a liquid feed stream is dispersed in a second fluid to form a spray, mist or emulsion before entering the reaction zone. The invention is applicable to both electro-synthesis and fuel cell reactors, with particular utility in mixed-reactant fuel cells.