Electrochemical reactor, electrochemical reactor systems, processes for electrochemical reactions, and methods using same

Patent metadata

Field	Value
Publication number	US-12482836-B2
Application number	US-202418979352-A
Country	US
Kind code	B2
Filing date	Dec 12, 2024
Priority date	Dec 12, 2023
Publication date	Nov 25, 2025
Grant date	Nov 25, 2025

Abstract

Electrochemical systems providing reversible operation of high specific energy or gravimetric energy, and high energy density or volumetric energy battery chemistries, methods of operating such systems, processes providing high energy densities and high power densities, and architectures for the successful implementation of such systems, methods and processes. A number of interconnected electrochemical reactors can be assembled to create a battery. By presenting fluidic reactants via pumping, injection and/or other circulation technologies that enable high specific energy, high utilization of reactants, and efficient thermal control, the operation of the electrochemical reactor/battery can be optimized. In a flow battery system and method for handling molten alkali metal and hydroxide species, the volume of the reactants is maximized over inactive components and thus increase energy density. Molten and gaseous reactants/products are fed to/removed from a central power conversion module from/fed to reservoirs for discharge/charge.

First claim

What is claimed is:

1 . An electrochemical system comprising:
a first reservoir configured to contain a first reactant; a second reservoir configured to contain a second reactant separately from the first reactant; an electrochemical reactor in material transport communication with the first reservoir and the second reservoir; a reaction product reservoir in material transport communication with the electrochemical reactor; and a material transport assembly configured to:
provide the material transport communication between the electrochemical reactor and the first reservoir, the second reservoir, and the reaction product reservoir;
present the first reactant as a fluid to the electrochemical reactor; and
present the second reactant as a fluid to the electrochemical reactor;
wherein:
the electrochemical system is configured to maintain a reaction product as a fluid, the reaction product resultant from an electrochemical reaction in the electrochemical reactor between the first reactant and the second reactant, and the reaction product comprising an ionically conductive, yet electronically insulating, fluid; and
the reaction product reservoir is configured to contain the reaction product separately from the first reactant and the second reactant.

2 . The electrochemical system of claim 1 further comprising a thermal management mechanism configured to at least one of:
provide heat to one or more portions of the material transport assembly; or
remove heat from one or more portions of the material transport assembly;

such that a temperature of reactant and/or reaction product flowing through the material transport assembly at one or more locations of the thermal management mechanism is respectively raised or cooled.

3 . The electrochemical system of claim 2 , wherein the thermal management mechanism is further configured to exchange heat between the reservoirs.

4 . The electrochemical system of claim 1 , wherein the material transport assembly is further configured to:
draw at least a portion of the first reactant from the electrochemical reactor to the first reservoir; draw at least a portion of the second reactant from the electrochemical reactor to the second reservoir; and draw at least a portion of the reaction product from the electrochemical reactor to the reaction product reservoir.

5 . The electrochemical system of claim 4 , wherein the material transport assembly comprises:
conduits formed of one or more materials that are stable at temperatures at which the material transport assembly is subject to via the transport of the reactants, and the reaction product; and one or more transport control devices selected from a group consisting of valves, pumps, mass flow controllers, and a combination thereof.

6 . The electrochemical system of claim 1 , wherein the electrochemical reactor comprises:
a negative electrode portion in material transport communication with the first reservoir; and a positive electrode portion in material transport communication with the second reservoir.

7 . The electrochemical system of claim 6 , wherein the electrochemical reactor is configured such that the negative electrode portion and the positive electrode portion are separated one from the other via a density difference between the reaction product and the first and second reactants.

8 . The electrochemical system of claim 6 , wherein the negative electrode portion and the positive electrode portion of the electrochemical reactor are separated one from another via a physical separator positioned within the electrochemical reactor and forming a geometrical interface between the first reactant and the second reactant.

9 . The electrochemical system of claim 8 , wherein the separator is a high surface area current collector/current delivery structure positioned in the positive electrode portion of the electrochemical reactor.

10 . The electrochemical system of claim 9 , wherein the separator comprises a metallic mesh structure.

11 . An electrochemical system of claim 8 , comprising:
a first reservoir configured to contain a first reactant; a second reservoir configured to contain a second reactant separately from the first reactant; an electrochemical reactor comprising:
a negative electrode portion in material transport communication with the first reservoir; and
a positive electrode portion in material transport communication with the second reservoir;
wherein the negative electrode portion and the positive electrode portion are separated one from another via a separator positioned within the electrochemical reactor and forming a geometrical interface between the first reactant and the second reactant;
the separator is a high surface area current collector/current delivery structure positioned in the positive electrode portion of the electrochemical reactor; and
a material transport assembly configured to:
provide the material transport communication between the electrochemical reactor and the first reservoir and the second reservoir;
present the first reactant as a fluid to the electrochemical reactor; and
present the second reactant as a fluid to the electrochemical reactor;
wherein the electrochemical system is configured to maintain a reaction product as a fluid, the reaction product resultant from an electrochemical reaction in the electrochemical reactor between the first reactant and the second reactant, and the reaction product comprising an ionically conductive, yet electronically insulating, fluid.

12 . The electrochemical system of claim 11 further comprising:
a reaction product reservoir in material transport communication with the electrochemical reactor;
wherein:
the material transport assembly is further configured to provide the material transport communication between the electrochemical reactor and the reaction product reservoir; and
the reaction product reservoir is configured to contain the reaction product separately from the first reactant and the second reactant.

13 . The electrochemical system of claim 11 further comprising a thermal management mechanism configured to at least one of:
provide heat to one or more portions of the material transport assembly; or
remove heat from one or more portions of the material transport assembly;
such that a temperature of reactant and/or reaction product flowing through the material transport assembly at one or more locations of the thermal management mechanism is respectively raised or cooled.

14 . The electrochemical system of claim 11 , wherein the material transport assembly is further configured to:
draw at least a portion of the first reactant from the electrochemical reactor to the first reservoir; draw at least a portion of the second reactant from the electrochemical reactor to the second reservoir; and draw at least a portion of the reaction product from the electrochemical reactor to a reaction product reservoir.

15 . The electrochemical system of claim 13 , wherein the thermal management mechanism is further configured to exchange heat between the reservoirs.

16 . The electrochemical system of claim 14 , wherein the material transport assembly comprises:
conduits formed of one or more materials that are stable at temperatures at which the material transport assembly is subject to via the transport of the reactants, and the reaction product; and one or more transport control devices selected from a group consisting of valves, pumps, mass flow controllers, and a combination thereof.

Assignees

• Georgia Tech Res Inst

Inventors

• Henry Asegun
• Mcdowell Matthew
• Pishahang Mehdi

Classifications

• H01M8/04716

  of fuel cell exhausts · CPC title

• H01M8/0693

  Treatment of the electrolyte residue, e.g. reconcentrating · CPC title

• C25B1/16

  Hydroxides (by simultaneous production of alkali metal hydroxides and chlorine, oxyacids or salts of chlorine C25B1/34) · CPC title

• H01M8/04197

  Preventing means for fuel crossover · CPC title

• H01M8/188

  by recharging of redox couples containing fluids; Redox flow type batteries · CPC title