Sputtered Solid Ceramic Electrolyte for Low-Voltage Alkali Alcoholate Production
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Solution Overview
Problem
Existing electrolysis cells for producing alkali metal alkoxide solutions face challenges due to high resistance of solid-state electrolyte ceramics, leading to increased energy consumption and economic inefficiency. Additionally, these cells suffer from short-term stability when exposed to aqueous acids, which limits their industrial application.
Innovation Solution
The process involves using a three-chamber electrolysis cell with a pretreated alkali metal cation-conducting solid-state electrolyte ceramic. This ceramic is treated by sputtering with noble gas cations, increasing its mass-based specific surface area and conductivity, thereby reducing the voltage required for electrolysis. The cell design also includes a middle chamber to protect the solid-state electrolyte from acidic conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solid-state electrolyte ceramic is used in electrolysis cell, then alkali metal ion conduction is achieved, but resistance is high leading to increased energy consumption
Solution Approach 1:
The patent applies sputtering treatment to modify the surface parameters of the solid-state electrolyte ceramic, increasing its specific surface area and improving ionic conductivity. This parameter change reduces the resistance and energy consumption while maintaining the ion conduction function.
Solution Approach 2:
The sputtering treatment creates a porous or roughened surface structure on the ceramic electrolyte, increasing the effective surface area for ion transport. This porous structure enhancement improves conductivity without compromising the structural integrity and ion conduction reliability.
2Reliability
If solid-state electrolyte ceramic is exposed to aqueous acid, then charge balance is maintained, but stability deteriorates due to acidic corrosion
Solution Approach 1:
The patent introduces a middle chamber that segments the electrolysis cell into separate compartments. This segmentation isolates the solid-state electrolyte from direct contact with aqueous acid, protecting it from corrosion while maintaining its charge balance function through controlled ion migration.
Solution Approach 2:
The middle chamber acts as an intermediary barrier between the aqueous acid environment and the solid-state electrolyte. This intermediary structure allows necessary ion transport while preventing harmful acidic corrosion, thereby extending the electrolyte's service life.
3Reliability
If sputtering treatment is applied to ASC surface, then conductivity improves, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex chemical or thermal treatment methods with sputtering, a physical vapor deposition technique. This substitution simplifies the pretreatment process by using controlled ion bombardment to modify the surface, achieving improved conductivity through a more manageable manufacturing process.
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 improved conductivity of the pretreated solid-state electrolyte reduces energy consumption and maintains the longevity of the electrolysis cell components. The three-chamber design effectively protects the electrolyte from acidic corrosion, enhancing the process's efficiency and scalability.
Implementation Method 1
The charge is balanced in that alkali metal ions migrate from the middle chamber into the cathode chamber via the ceramic that is selective therefor
Implementation Method 2
by sputtering the surface OF' with noble gas cations N+, ASC is removed from F'
Implementation Method 3
hydrogen and alkoxide ions at the cathode
Data Source
AI summary
The invention relates to a method for producing an alkali metal alcoholate solution L1 in an electrolysis cell E which comprises at least one cathode chamber KK, at least one anode chamber KA, and at least one central chamber KM lying therebetween. The interior IKK of the cathode chamber KK is separated from the interior IKM of the central chamber KM by a separating wall W comprising at least one alkali-cation-conductive solid ceramic electrolyte (=“AFK”) F (e.g. NaSICON). F has the surface OF. A part OA/MK of the surface OF directly contacts the interior IKM, and a part OKK of the surface OF directly contacts the interior IKK. The surface OA/MK and/or the surface OKK comprises at least one part of a surface OFΔ. OFΔ is produced from a pre-treatment step in which F is produced from an AFK F′ comprising the surface OF′. In the pre-treatment step, AFK is removed from F′ by sputtering the surface OF′ using noble gas cations N+, and the AFK F with the surface OF comprising the surface OFΔ formed by the sputtering process is obtained. During the electrolysis process for producing the alkali metal alcoholates with F instead of F′, an improved conductivity is provided, whereby for a constant current density, a lower voltage can be used.