Electrolyzers

Patent metadata

Field	Value
Publication number	US-2025171912-A1
Application number	US-202519036604-A
Country	US
Kind code	A1
Filing date	Jan 24, 2025
Priority date	Jul 28, 2022
Publication date	May 29, 2025
Grant date	—

Abstract

Disclosed herein is an electro-synthesizer unit comprising a first compartment comprising a cathode and a first electrolyte, a second compartment comprising an anode and a second electrolyte and a third compartment comprising a third electrolyte. The unit is configured to produce acid and base solution at desired concentrations. Also disclosed are methods of using the electro-synthesizer unit and producing the acid and base solution at desired concentrations.

First claim

1 .- 42 . (canceled)

43 . A method comprising:
providing an electro-synthesizer unit, wherein the electro-synthesizer unit is a flow unit comprising: a first compartment comprising a cathode and a first inlet configured to receive a first flow of a first electrolyte solution, wherein the first electrolyte solution is in electrical and fluid communication with the cathode; a second compartment comprising an anode, a second inlet configured to receive a second flow of a second electrolyte solution, and a third inlet configured to receive a stream comprising a hydrogen gas, wherein the second electrolyte solution is in electrical and fluid communication with the anode; and a third compartment positioned between and in fluid communication with the first compartment and the second compartment, wherein the third compartment is separated from the first compartment with one or more cation exchange membranes and is separated from the second compartment with one or more anion exchange membranes, wherein the third compartment comprises a fourth inlet configured to receive a third flow of a third electrolyte solution; flowing the first electrolyte solution into the first compartment, the second electrolyte solution into the second compartment, and the third electrolyte solution into the third compartment; generating a hydrogen gas stream and a-hydroxide ions on the cathode in the first compartment; directing a stream comprising a hydrogen gas into the second compartment; wherein the hydrogen gas present in the stream is the generated hydrogen gas and/or a hydrogen gas provided from an external source; generating hydrogen ions on the anode in the second compartment; and collecting a generated base solution comprising hydroxide ions and a generated acid solution comprising hydrogen ions.

44 . The method of claim 43 , wherein the electro-synthesizer unit operates as a recirculated-in-a-loop system.

45 . The method of claim 43 , wherein the generated base and acid solutions have a molarity from greater than 0 to about 3 M.

46 . The method of claim 43 , wherein the generated base solution has a molarity greater than 0 to about 20 M, and the acid solution has a molarity greater than 0 to about 10 M.

47 . The method of claim 46 , wherein at least a portion of the collected generated base and acid solution is diluted and used as the first and the second electrolyte solution, respectively.

48 . The method of claim 43 , wherein a pH of the first electrolyte solution is about 6≤pH≤15.5, a pH of the second electrolyte solution is about −1.5≤pH≤8, and a pH of the third electrolyte solution is about 4≤pH≤10.

49 . The method of claim 43 , wherein the anode is configured to oxidate the hydrogen gas to generate the hydrogen ions.

50 . The method of claim 43 , wherein the anode comprises a gas diffusion layer.

51 . The method of claim 50 , wherein the gas diffusion layer comprises a carbon-based gas diffusion layer, a fluorocarbon-based gas diffusion layer, a hydrophobic material comprising a plurality of pores, or any combination thereof.

52 . The method of claim 50 , wherein the anode further comprises a hydrogen oxidation catalyst layer.

53 . The method of claim 52 , wherein the hydrogen oxidation catalyst layer comprises one or more Pt group metal (PGM) or alloys thereof-based catalysts, PGM-free catalysts, and any combination thereof.

54 . The method of claim 43 , wherein the cathode comprises a Pt group metal or their alloys based electrode, a Ni- and its alloys-based electrode, a NiFe-based electrode, NiTi-based electrode, steel-based electrode, transition metal sulfates-based electrode, transition metal phosphide-based electrode, Fe-based catalysts, carbon-based materials, or any combination thereof.

55 . The method of claim 43 , wherein the cation and/or anion exchange membranes are polymer reinforced, wherein the polymer is inert to the first, second, and/or third electrolyte solutions.

56 . The method of claim 43 , wherein the third electrolyte solution comprises one or more inorganic salts.

57 . The method of claim 56 , wherein the one or more inorganic salts comprise chlorides, sulfates, nitrates, phosphates, citrates, formates, lactates, tartrates, malates, fumarates, oxalates, succinates, gluconates, ascorbates, acetates of alkaline metals and/or alkaline-earth metals, or mixtures thereof.

58 . The method of claim 43 , wherein the base solution comprises one or more of sodium hydroxide, lithium hydroxide, potassium hydroxide, magnesium hydroxide, calcium hydroxide, ammonium hydroxide, amine-based bases, sodium acetate, or any combination thereof.

59 . The method of claim 43 , wherein the acid comprises one or more of hydrochloric acid, hydrobromic acid, hydroiodic acid, sulfurous acid, sulfuric acid, nitric acid, phosphorous acid, phosphoric acid, hypochlorous acid, chlorous acid, chloric acid, perchloric acid, formic acid, acetic acid, carbonic acid, or any combination thereof.

60 . The method of claim 43 , wherein the flow of the first electrolyte, the second electrolyte, and/or the third electrolyte is the same as or different from one another.

61 . The method of claim 60 , wherein a flow rate is from about 1 to about 5,000,000 mL/h.

Assignees

• Univ Johns Hopkins

Inventors

• Wang Chao
• Shen Hao
• Zhou Chengao

Classifications

• C25B13/04

  characterised by the material · CPC title

• C25B1/22 Primary

  Inorganic acids · CPC title

• C22B3/06

  in inorganic acid solutions {, e.g. with acids generated in situ; in inorganic salt solutions other than ammonium salt solutions} · CPC title

• B01D2257/504

  Carbon dioxide · CPC title

• B01D2251/604

  Hydroxides · CPC title