CA2510954A1 - Vertical chamber electrolyser booster (vceb) - Google Patents

Abstract

The Vertical Chamber Electrolyser Booster (VCEB) substantially reduces the electrical energy requirement to produce hydrogen gas by water electrolysis.
It can be attached to existing electrolysers without modifying the existing electrolyser.
The energy saving is achieved by a simple method of controlled release of hydrogen and oxygen gas in two separate chambers that are filled with a liquid and are connected to the gas output of the existing electrolyser. The buoyant force of the released gas will produce torque on turbine blades. This torque drives an electric generator and the generated electric current is used in a secondary electrolyser as input energy.
The first released hydrogen and oxygen gases then can be separately collected at the top of the vertical chamber at a marginally reduced pressure.

Description

CURRENT STATE OF ART
This invention relates to an electrochemical process where it will reduce the energy input requirement of water electrolysis to produce hydrogen, bringing a hydrogen based economy one step forward to become a realistic alternative to the current carbon based economy.
Expensive electric power makes water electrolysis a non-feasible process, and this is the main factor why water electrolysis is not seen today as a solution for energy problems. The potential exists, therefore large resources (fiscal and man power alike) are spent on finding ways) to reduce the input energy requirement of water electrolysis. These efforts already brought results, but still the produced hydrogen is not cost competitive with other energy sources and technologies.
The current invention makes water electrolysis a cost competitive alternative to other energy sources or energy Garners. The Vertical Chamber Electrolyser Booster (VCEB) will reduce the cost of the produced hydrogen gas by making it possible to separate larger volume of hydrogen gas with the same input electric energy level.
Some of the advantages of the Vertical Chamber Electrolyser Booster (VCEB) are:
- can be attached to existing water electrolysers without the need to alter the existing electrolyser, - doesn't produce any by-product, - can be used at any location where an electrolyser can be operated, - will work any time, it is not influenced by conditions of nature, - simple technology, therefore doesn't require substantial investments, - the VCEB unit itself can be produced in large quantities and doesn't require any high-tech (expensive) production line or materials.

t WORIONG OPERATION THEORY
The VCEB unit is based on a simple idea. Once we produce gases in an electrolyser, we could use those gases to drive a turbine and produce some low power electricity.
Energy equals SPEED times MASS.
Since the mass of hydrogen and oxygen gas is very small even in large volumes, the only factor would be speed to produce electricity. High speed could be achieved by high pressure electrolysers, but if we use the gas from such an electrolyser to drive a turbine, we would loose the pressure of the gas. We could be able to produce some electric power, but then the re-compression of the gases would require more energy than what we produced by the turbine. So this is not a way to go.
If we release the produced gas under water from the electrolyser, we create a completely dii~erent situation. The gas has buoyancy! The gas will form bubbles under the water. If we place a turbine blade ABOVE these bubbles under the water, the mass of the hydrogen gas will still be very small, but it becomes irrelevant. Under water the force of buoyancy is the weight of the disposed water: not the mass of the gas, but the volume of the gas.
In other words: only a few grams of hydrogen gas may produce a several kilograms force.
The speed of the buoyant gas will be low in terms of turbine technology, but the force of the buoyant gas will be substantial. The weight (mass) of one litre hydrogen gas is 0,09 grams. But this gas produces under water a buoyancy of almost 1,000 grams.
That is a difference of more than 100,000 times! ! !
A water electrolyser produces two gases. The VCEB unit will utilize the oxygen gas, as well as the hydrogen gas by a structural two chamber arrangement. As the two chambers are isolated from each other, the two gases are not mixed up during the process. Using the buoyancy of the oxygen gas alongside the hydrogen gas, will increase the efficacy of the VCEB
unit by 33 percent, because of the electrolyser gas production ratio of hydrogen and oxygen is 2:1.
Every electrolyser has a certain gas output pressure. There are high pressure water electrolysers with a gas output pressure of 370 PSI (25 Atm), or more. Significant pressure drop in the VCEB
unit would eliminate the purpose of the high pressure electrolyser. The VCEB
unit - by its design - is suitable for high pressure electrolysers as well. The pressure drop of the gasses can be marginal compared to the gain achieved in the turbine generating process.
[Theoretically it can be as low as 1 (one) PSI]
DESCRIPTION
The structure and composition of an embodiment of the current invention is illustrated in the accompanying drawings:
- Figure 1 is a representation of a fully assembled VCEB unit utilizing turbine blades.
- Figure 2 is a representation of a fully assembled VCEB unit utilizing cup collectors, in front and side views.
- Figure 3 is a representation of a VCEB unit with a secondary electrolyser.
Apart from the operational effects of the current invention, a major technical merit lies in the fact that the embodiment contains only a limited number and simple components.
To build an embodiment of the current invention as shown in Figure 1, we need to design the Chamber Housing ( 1 ). The vertical length of the Chamber Housing ( 1 ) will determine the water column height that will reside above the Gas Input Pipe (4). The pressure of the input gas must be higher than the pressure created by this water column.

The Chamber Cover (2) has all the other operational components built into it.
It has a special shape to accommodate the Collection Chamber (23), the Gas Output Pipe (5) with the Pressure Regulator ( 11 ). The other side accommodates the Water Filling Valve (3). The centre holds the Turbine Axel (6) with the Turbine Blades (7). The turbine Axel (6) passes through the Chamber Cover (2) at the Pressure Seal (12).
We affix the Chamber Cover (2) to the Chamber Housing (1) so it creates an airtight sphere inside.
The Turbine Axel (6) will be connected to the Electric Generator ( 10) by means of the Generator Shaft (9). If the design calls for a horizontal Electric Generator (10) placement - as opposed to a vertical placement - a 90° gear (8) will also be needed.
Since we will handle two gases exactly the same way but separately, we will need two VCEB
units side by side.
For simplicity reasons the two VCEB units should be placed beside the existing electrolyses. We call this electrolyses THE PRIMARY ELECTROLYSER.
All embodiments of the VCEB unit for either gas need a simple set up process in the following sequence:
1/ The Gas Input Pipe (4) of the VCEB unit need to be connected to one of the gas output pipes of the primary electrolyses. (Either hydrogen, or oxygen) 2/ The VCEB unit must be filled up with a liquid. This can be just water. We fill up the VCEB
unit through the Water Filling Valve (3). As the water level rises inside the unit, the air will leave the unit through the open Gas Output Pipe (5). When water starts appearing at the Gas Output Pipe (5) both - the Water Filling Valve (3) and also the Gas Output Pipe (5) should be closed.
Now the unit is free from air and completely filled with water.
3/ Start the operation of the primary electrolyses in a low gas volume production mode. The gas output from the primary electrolyses will go into the VCEB unit through the Gas Input Pipe (4), and it will bubble up to the Collection Chamber (23) right under the Gas Output Pipe (5). The Water Filling Valve (3) now needs to be opened. The gas pressure inside the VCEB unit will pump out water through the open Water Filling Valve (3). Continue feeding gas from the primary electrolyser into the VCEB unit until the water is completely pressed out from the Collection Chamber (23) under the closed Gas Output Pipe (S), and gas starts leaving the VCEB unit through the Water Filling Valve (3). Then close the Water Filling Valve (3) and stop the operation of the primary electrolyser.
4/ The Gas Output Pipe (5) of the VCEB unit needs to be connected to a gas storage device {i.e.
gas tank) where the ready made product (hydrogen gas or oxygen gas) would be otherwise stored either for further compression, or for delivery to the end user.

5/ The VCEB unit will produce electricity during the operation. The Electric Generator ( 10) of the VCEB unit needs to be connected to the means of the intended use of the generated electricity:
a/ it can be connected to a separate battery charging device, so the generated electric energy can be used at a later time, b/ it can be connected to a smaller, SECONDARY ELECTROLYSER (24), where further quantities of gases can be produced by this electric power in addition to the gas volume produced by the primary electrolyser, c/ it can be connected back to the electric supply line of the primary electrolyser where it will boost the gas production by generating additional gas volumes.
For simplicity purpose the following operation description will mention only one VCEB unit like as if the electrolyser would generate only one kind of gas.
After the initialization of the VCEB unit regular operation can be started and maintained.
The primary electrolyser now should run at full capacity. The produced gas will enter the VCEB
unit through the Gas Input Pipe (4) and due to the buoyancy of the gas the Turbine Blades (7) will come into motion and bring the Turbine Axel (6) into rotation. This torque will drive the Electric Generator (10) and thus electric power will be generated. This generated electric power will be proportionally very small compared to the electric power consumption of the primary electrolyses.
The Electric Generator ( I0) can be either AC or DC generator. Since water electrolysis requires DC input, if the Electric Generator ( 10) is an AC generator then the alternating current (AC) must be converted to direct current (DC). This direct current then can be loaded back to the primary electrolyses (with proper voltage regulation) to further increase the gas production, or can be used as the input power for a secondary electrolyses.
For simplicity reasons the following explanation of the operation will be based on a configuration where a secondary electrolyses is used. The secondary electrolyses should have the same gas output pressure as the primary electrolyses. The DC current generated by the VCEB unit is the input power on the secondary electrolyses. This secondary electrolyses will also produce separated hydrogen and oxygen gases, though in marginal volume compared to the primary electrolyses.
Each gas from the secondary electrolyses is reloaded. separately to the VGEB
unit of the same gas type through the Gas Input Pipe (4) where it will join the other larger gas volume coming from the primary electrolyses as shown in Figure 3.
This way the VCEB unit receives an increased volume of gas input which in turn will produce larger buoyant force to drive the Turbine Blades (7). Therefore now the Electric Generator (10) will produce slightly more energy; which in turn will produce slightly more gases in the secondary electrolyses. The combined volumes of gases leave the VCEB unit through the Gas output Pipe (5) toward the external gas tank as the end product of the process, or it can be used as feed gas to a second VCEB unit, and repeating the entire process to produce even more electricity.
Practically we initiated a recurring production process where the secondary electrolyses will produce gradually larger and larger volume of gases. The increase in volume of the produced gasses will be very small, but being a recurring process, the volume of the increased gas production will grow into substantial level by time.
This recurring process can not be increased without limitations.

The internal energy losses of both, the primary electrolyser and the VCEB unit will be the limiting factors of the achievable maximum additional gas production according to the laws of physiscs.
Water electrolysers have their designed pressure level for the output gas.
The VCEB unit will preserve much of this pressure. It is necessary to keep the gas pressure at the Gas Output Pipe (5) lower then the pressure of the input gas at the Gas Input Pipe (4) for the operation of the VCEB unit. Therefore a Pressure Regulator (11) is installed on the Gas Output Pipe (5). If the gas pressure is not lower at the Gas Output Pipe (5) than at the Gas Input Pipe (4) the gas from the primary electrolyser can not enter the VCEB unit. If the gas pressure inside the VCEB unit gets higher than the output gas pressure of the primary electrolyser then the water from the VCEB unit may enter backward to the primary electrolyser. Therefore the proper setting of the Pressure Regulator ( 11 ) is a critical factor in the operation.
Generally speaking, in most of the cases 1 or 2 PSI pressure drop in the VCEB unit is all what is needed for the operation.
Therefore the VCEB unit can be utilized to boost the gas production of high pressure electrolysers as well as with low pressure electrolysers.
After understanding the theoretical operation of the VCEB unit we have to examine how it will function under real conditions in practice. Our investigation now will focus on the laws of physics instead of theories.
A water electrolyser with a hydrogen gas output capacity of 2 Nm3 per hour will produce:
555 Ncm3 Hydrogen gas per second, and also 277 Ncm3 Oxygen gas per second.
That is a total of 833 cm3 gas volume per second that has over 800 grams (1.76 pound) buoyant force in water under normal water pressure.
The speed generated by the buoyant force of the rising gas will depend on the design structure of the VCEB unit. (i.e. pressure drop, turbine location and resistance, water column height, etc.) For our present calculation purpose it will be set at 1 footlsec.
. ,. .

A typical water electrolyses would consume an average of 4.2 kWh energy per one Nm3 hydrogen gas production.
As energy: 1 Watt second = 0.?4 Foot pound-force As power: 1 Watt = 0.74 Pound foot/second.
As we could see above we have 1.76 pound force available at 1 ft/sec velocity.
This would generate 2.38 Watt power.
Taking into consideration the internal losses of the system, and also for simplicity purpose of the following calculations, we consider only 1 (one) Watt power generation.
This "generous" allowance will increase the credibility of the following calculations as well.
If 4.2 kWh energy produces a total of 1,500,000 Ncm3 gas (hydrogen and oxygen as a total) then 1 Wh will produce 357 Ncm3 gas (hydrogen and oxygen together).
This translates into: 4.2 kWsec produces 416 Ncm3 gas (hydrogen and oxygen as a total) then 1 Wsec will produce 0.096 Ncm3 gas (hydrogen and oxygen as a total).
In a table form:
Additional Minute Volume (Ncm3) Volume (Ncm') 0 416.67 0.09583333 This is the starting gas volume condition when the operation of the VCEB unit begins.
As time passes the Additional Volume is added to the regular volume, which in turn will produce more Additional Volume.
If we update the Volume every 6 seconds, we get the following result:
Additional MinuteVolume (Ncm3)Volume (Ncm') 0 416.666666670.09583333 0.1 416.762500000.09585538 0.2 416.858355380.09587742 0.3 416.95423280 0.09589947 0.4 417.05013227 0.09592153 0.5 417.14605380 0.09594359 0.6 417.24199739 0.09596566 0.7 417.33796305 0.09598773 0.8 417:43395078 0.09600981 0.9 417.52996059 0.09603189 1 417.62599248 0.09605398 1.1 417.72204646 0.09607607 1.2 417.81812253 0.09609817 1.3 417.91422070 0.09612027 1.4 418.01034097 0.09614238 1.5 418.10648335 0.09616449 1.6 418.20264784 0.09618661 1.7 418.29883445 0.09620873 1.8 418.39504318 0.09623086 1.9 418.49127404 0.09625299 2 418.58752703 0.09627513 We can clearly see the volume steadily increases.
Continuing the calculation in the same manner we get the following result:
the total gas volume production is increased by 14.8 per cent in one how.
It is worth to mention that this is a pessimistic calculation as we reduced the actual power from 2.38 Watt to 1 Watt, and we updated the volume only by every 6 seconds. The actual recurnng effect will happen in a faster time cycle, therefore the gas volume will accumulate faster then the above table shows.
Another embodiment of the VCEB unit is shown in Figure 2.
This embodiment is almost identical to the embodiment shown in Figure 1 as explained in detail above. The only difference is that the buoyant force of the released gas is captured by Collector Cups ( 19) on a Belt ( 18) instead of a turbine blade assembly.
It is virtually indifferent for the functioning of the VCEB unit how the buoyant force of the released gas is captured, as long as it produces rotational motion to drive the Electric Generator (10).

The advantage of utilizing Collector Caps ( 19) can be that the input gas stays in the caps as it travels the length of the Belt (18), therefore several gas filled caps produce torque on the V-Belt Disk (15) and the Rotating Axle (16). At the Turbine Blade (7) configuration -as shown in Figure 1, once the gas hits the blade surface it escapes upward. Therefore several blades above each other would generate larger torque because the escaped gas from the first blade doesn't loose its energy. The gas will get its buoyant force again after leaving the area of the first blade; this force then can be harvested on the second blade and so forth.
The efficacy of the means of capturing the buoyant force doesn't influence much the efficacy of the VCEB unit. A less efficient capturing method will increase the time needed for the VCEB
unit, but the VCEB unit will achieve its full capacity to produce additional gas volume even with a less efficient capturing method.
The idea and the purpose of developing the current invention originally were to boost water electrolyses gas production. But it is evident that the VCEB unit will work on any kind of gas input. We can achieve the same working of the VCEB unit by connecting it to any gas source as input gas to the VCEB unit, not only to a water electrolyses.
For example, using a simple air compressor as the gas input device to the VCEB
unit would make the VCEB unit work as well, and produce electric energy. The secondary electrolyses would still produce hydrogen and oxygen gases separately. The oxygen gas then can be reloaded to the gas input pipe on one VCEB unit, while the hydrogen gas could be loaded into a separate VCEB unit.
This way again we can generate hydrogen gas in a pure form.
The above description of the VCEB unit is concentrating on one VCEB unit. In real life two units are necessary working parallel with each other, one to handle the oxygen gas, and the other to handle the hydrogen gas separately. The two VCEB units would have probably two independent electric generators. The output electricity of these two generators than can be combined as input energy on one secondary electrolyses.
r

Claims (5)

1/ A utility equipment for generating electricity by utilizing the buoyant forces of input gases from a gas producing source - primarily but not exclusively from water electrolysers - comprising a fluid filled chamber, input and output gas piping equipped with valves and pressure regulators, a mechanical assembly to produce rotational motion, and an electric generator.

2/ A utility equipment as defined in Claim 1, in which an input gas is released under a fluid inside the chamber, and the buoyant force of the released gas brings a mechanical assembly - preferably a turbine - into rotational motion, which in turn will drive an electric generator to produce electric energy.

3/ A utility equipment as defined in Claim 1 or Claim 2, where the generated electrical energy is loaded to a secondary electrolyses to produce additional quantities of gases.

4/ A utility equipment as defined in Claim 1 or Claim 2, where the generated electrical energy is loaded to the primary gas source equipment to boost gas production there.

5/ A utility equipment as defined in Claim 1 or Claim 2 or Claim 3 or Claim 4, where the produced additional quantity of gases are loaded back to the utility equipment of the current invention boosting increased electrical energy generation there.