EP2852697B1 - Electrode for evolution of gaseous products and method of manufacturing thereof - Google Patents
Electrode for evolution of gaseous products and method of manufacturing thereof Download PDFInfo
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- EP2852697B1 EP2852697B1 EP13724230.1A EP13724230A EP2852697B1 EP 2852697 B1 EP2852697 B1 EP 2852697B1 EP 13724230 A EP13724230 A EP 13724230A EP 2852697 B1 EP2852697 B1 EP 2852697B1
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- electrode according
- titanium
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- powder
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- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 239000010936 titanium Substances 0.000 claims description 36
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 30
- 229910052719 titanium Inorganic materials 0.000 claims description 30
- 239000000843 powder Substances 0.000 claims description 29
- 238000000034 method Methods 0.000 claims description 26
- 239000000758 substrate Substances 0.000 claims description 25
- 239000003054 catalyst Substances 0.000 claims description 18
- 229910052751 metal Inorganic materials 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 17
- 239000010410 layer Substances 0.000 claims description 16
- 229910000510 noble metal Inorganic materials 0.000 claims description 14
- 238000000151 deposition Methods 0.000 claims description 9
- 239000011248 coating agent Substances 0.000 claims description 8
- 238000000576 coating method Methods 0.000 claims description 8
- 238000011068 loading method Methods 0.000 claims description 8
- 239000002243 precursor Substances 0.000 claims description 8
- 239000007921 spray Substances 0.000 claims description 8
- 238000005868 electrolysis reaction Methods 0.000 claims description 7
- 150000004706 metal oxides Chemical class 0.000 claims description 7
- 238000005979 thermal decomposition reaction Methods 0.000 claims description 7
- 239000011247 coating layer Substances 0.000 claims description 5
- 230000008021 deposition Effects 0.000 claims description 5
- HTXDPTMKBJXEOW-UHFFFAOYSA-N dioxoiridium Chemical compound O=[Ir]=O HTXDPTMKBJXEOW-UHFFFAOYSA-N 0.000 claims description 5
- 229910000457 iridium oxide Inorganic materials 0.000 claims description 5
- 238000002360 preparation method Methods 0.000 claims description 2
- 238000005470 impregnation Methods 0.000 claims 1
- 239000007789 gas Substances 0.000 description 23
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 13
- 239000000203 mixture Substances 0.000 description 9
- 238000005507 spraying Methods 0.000 description 8
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 7
- WQYVRQLZKVEZGA-UHFFFAOYSA-N hypochlorite Chemical compound Cl[O-] WQYVRQLZKVEZGA-UHFFFAOYSA-N 0.000 description 6
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 6
- 239000003929 acidic solution Substances 0.000 description 5
- 238000009835 boiling Methods 0.000 description 5
- 229910010293 ceramic material Inorganic materials 0.000 description 5
- 229910052593 corundum Inorganic materials 0.000 description 5
- 239000010431 corundum Substances 0.000 description 5
- 229910052741 iridium Inorganic materials 0.000 description 5
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 239000002245 particle Substances 0.000 description 5
- 239000000243 solution Substances 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 4
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 4
- 229910021638 Iridium(III) chloride Inorganic materials 0.000 description 3
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 238000007750 plasma spraying Methods 0.000 description 3
- 229910052707 ruthenium Inorganic materials 0.000 description 3
- YBCAZPLXEGKKFM-UHFFFAOYSA-K ruthenium(iii) chloride Chemical compound [Cl-].[Cl-].[Cl-].[Ru+3] YBCAZPLXEGKKFM-UHFFFAOYSA-K 0.000 description 3
- DANYXEHCMQHDNX-UHFFFAOYSA-K trichloroiridium Chemical compound Cl[Ir](Cl)Cl DANYXEHCMQHDNX-UHFFFAOYSA-K 0.000 description 3
- 229910052786 argon Inorganic materials 0.000 description 2
- 239000012159 carrier gas Substances 0.000 description 2
- 239000003792 electrolyte Substances 0.000 description 2
- 238000007590 electrostatic spraying Methods 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 239000011780 sodium chloride Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- 229910017135 Fe—O Inorganic materials 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 239000007832 Na2SO4 Substances 0.000 description 1
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000013590 bulk material Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000005474 detonation Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 239000002019 doping agent Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000010411 electrocatalyst Substances 0.000 description 1
- 239000007772 electrode material Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000010285 flame spraying Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- SOQBVABWOPYFQZ-UHFFFAOYSA-N oxygen(2-);titanium(4+) Chemical group [O-2].[O-2].[Ti+4] SOQBVABWOPYFQZ-UHFFFAOYSA-N 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 230000001012 protector Effects 0.000 description 1
- 229910001925 ruthenium oxide Inorganic materials 0.000 description 1
- WOCIAKWEIIZHES-UHFFFAOYSA-N ruthenium(iv) oxide Chemical compound O=[Ru]=O WOCIAKWEIIZHES-UHFFFAOYSA-N 0.000 description 1
- 229910052938 sodium sulfate Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- 238000007751 thermal spraying Methods 0.000 description 1
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
- 239000004408 titanium dioxide Substances 0.000 description 1
- 238000004448 titration Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
- C25B11/00—Electrodes; Manufacture thereof not otherwise provided for
- C25B11/04—Electrodes; Manufacture thereof not otherwise provided for characterised by the material
- C25B11/051—Electrodes formed of electrocatalysts on a substrate or carrier
- C25B11/073—Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material
- C25B11/075—Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material consisting of a single catalytic element or catalytic compound
- C25B11/077—Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material consisting of a single catalytic element or catalytic compound the compound being a non-noble metal oxide
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
- C25B11/00—Electrodes; Manufacture thereof not otherwise provided for
- C25B11/04—Electrodes; Manufacture thereof not otherwise provided for characterised by the material
- C25B11/051—Electrodes formed of electrocatalysts on a substrate or carrier
- C25B11/052—Electrodes comprising one or more electrocatalytic coatings on a substrate
- C25B11/053—Electrodes comprising one or more electrocatalytic coatings on a substrate characterised by multilayer electrocatalytic coatings
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
- C25B1/00—Electrolytic production of inorganic compounds or non-metals
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
- C25B11/00—Electrodes; Manufacture thereof not otherwise provided for
- C25B11/04—Electrodes; Manufacture thereof not otherwise provided for characterised by the material
- C25B11/051—Electrodes formed of electrocatalysts on a substrate or carrier
- C25B11/073—Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material
- C25B11/091—Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material consisting of at least one catalytic element and at least one catalytic compound; consisting of two or more catalytic elements or catalytic compounds
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
- C25B11/00—Electrodes; Manufacture thereof not otherwise provided for
- C25B11/04—Electrodes; Manufacture thereof not otherwise provided for characterised by the material
- C25B11/051—Electrodes formed of electrocatalysts on a substrate or carrier
- C25B11/073—Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material
- C25B11/091—Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material consisting of at least one catalytic element and at least one catalytic compound; consisting of two or more catalytic elements or catalytic compounds
- C25B11/093—Electrodes formed of electrocatalysts on a substrate or carrier characterised by the electrocatalyst material consisting of at least one catalytic element and at least one catalytic compound; consisting of two or more catalytic elements or catalytic compounds at least one noble metal or noble metal oxide and at least one non-noble metal oxide
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
- C25B9/00—Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
- C25B9/17—Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof
- C25B9/19—Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof with diaphragms
Definitions
- the invention relates to an electrode suitable for functioning as anode in electrolysis cells, for instance as oxygen-evolving anode in electrolysis cells used in electrometallurgical processes, as chlorine-evolving anode either in chlor-alkali cells or as anode for hypochlorite generation in undivided cells.
- Substoichiometric compositions of titanium oxides of formula Ti x O 2x-1 , with x ranging from 4 to 10, also known as titanium Magnéli phases, are obtained by high temperature reduction of titanium dioxide under a hydrogen atmosphere.
- These suboxides are corrosion-resistant ceramic materials comparable to graphite in terms of electrical conductivity. In light of such corrosion resistance and conductivity characteristics these materials, which are produced both in massive and in powder form, may be used as protective coatings of metal substrates for electrochemical applications.
- doping agents to these ceramic materials, such as for instance tin oxide, in order to slightly increase their conductivity, stability and resistance to corrosion.
- the deposition of these ceramic materials as metal substrate protectors is carried out starting from the material in powder form in accordance with known techniques, such as, hot flame spraying, plasma spraying or detonation thermal spraying. All of these techniques share the common feature of requiring a high operative temperature (>400 °C) in order to obtain an acceptable adhesion between sprayed powder particles and metal substrate. Furthermore, the good adhesion of deposited powder particles to the substrate also depends on the reciprocal nature of the substrate and the powder.
- These ceramic materials may also be used as catalyst supports.
- the catalyst is applied in a step subsequent to the deposition of the titanium Magnéli phase onto such substrate, generally by thermal decomposition of precursors.
- This mode of application has the drawback of leading to the formation of ceramic layers wherein a major fraction of the catalyst applied turns out to be scarcely accessible to the electrolyte, the final product thus being hardly efficient in terms of activity and lifetime.
- the loading of the Magnéli phase-supported catalyst must be not lower than 20-30 g/m 2 .
- US 201 111 47205 Al describes a method for preparing electrocatalytic layers of Ti-Ru-Fe-O on an electrode substrate such as titanium by cold gas spraying. From US 4 422 91 7 A an electrode material prepared by coating an electrocatalyst on a porous titanium suboxide bulk material is known, GB 2 309 230 A describes a method for preparing an electrode by coating a valve metal substrate with a titanium suboxide coating.
- the inventors surprisingly found out a method for manufacturing electrodes comprising a valve metal-based substrate coated with at least one layer of noble metals or oxides thereof supported on titanium suboxides overcoming the inconveniences of the prior art.
- the invention is concerned with electrodes for evolution of gaseous products in electrolytic cells comprising a valve metal substrate whereto at least one layer of a coating having an interconnected porosity is attached, the layer consisting of at least one catalyst containing noble metals or oxides thereof taken alone or in admixture, supported on titanium suboxide species expressed by the formula Ti x O 2x-1 , with x ranging from 4 to 10, the specific catalyst loading being comprised between 0.1 and 25 g/m 2 .
- interconnected is used herein to mean a porosity mostly consisting of a network of pores in mutual fluid communication and not isolated.
- apparent density of such layer must be lower than 95% of the overall theoretical density which a compact layer with no porosity at all having an equivalent composition would exhibit.
- the invention relates to an electrode for evolution of gaseous products in electrolytic cells consisting of a valve metal substrate and at least a coating layer having an interconnected porosity bound thereto, said at least one layer comprising at least one catalyst consisting of noble metals or oxides thereof taken alone or in admixture, supported on a mixture of titanium suboxides of formula Ti x O 2x-1 , with x ranging from 4 to 10, said at least one layer being deposited onto said substrate by cold gas spray technique.
- cold gas spray is used herein to mean a deposition technique of solid particles onto substrates supposedly known to a person skilled in the art, based on accelerating powder particles transported by a compressed carrier gas. During their trajectory, the carrier gas and the particles are split into two different paths so that the time of residence of powders inside the hot gas phase is limited, thereby preventing powders to be heated above 200 °C.
- the inventors have surprisingly observed that the deposition via cold gas spray technique of a Magnéli phase-type ceramic powder, for example consisting of a titanium Magnéli phase powder previously catalysed with noble metal oxides by thermal decomposition of precursors, onto a substrate made of a valve metal such as titanium, tantalum, zirconium or niobium, leads to a structure of surprisingly enhanced duration even at very low catalyst loadings.
- a valve metal such as titanium, tantalum, zirconium or niobium
- valve metal of choice for the substrate is titanium
- the coating layer has an interconnected porosity with an apparent density ranging higher than 75% and lower than 95% of the overall theoretical density.
- the electrode has a coating layer containing a specific catalyst loading of 0.1 to 10 g/m 2 .
- the noble metal oxide-based catalyst consists of iridium oxide.
- the invention relates to a method for manufacturing an electrode according to the invention comprising the steps of: preparing a titanium suboxide powder expressed by the formula Ti x O 2x-1 , with x ranging between 4 and 10; impregnating said powder with a precursor solution of a noble metal oxide-based catalyst with subsequent thermal decomposition; depositing the obtained powder on a valve metal substrate by cold gas spray technique.
- the invention relates to an electrolysis cell comprising a cathodic compartment containing a cathode and an anodic compartment containing an anode, wherein said anode of said anodic compartment is an electrode as hereinbefore described.
- the invention relates to an industrial electrochemical process comprising the anodic evolution of a gas from an electrolytic bath on an electrode as hereinbefore described.
- titanium Magnéli phase powder in admixture with iridium oxide was sprayed onto a titanium grade 1 sheet of 10 cm x 10 cm x 0.2 cm size, previously sandblasted with corundum grit #36 and etched in boiling hydrochloric acid in order to obtain a rough surface free of titanium oxide species.
- Such powder was obtained by mixing a suitable mass of titanium Magnéli phase powder - previously sieved to a size range of 100 to 400 ⁇ m - to an acidic solution containing a soluble precursor of iridium, namely iridium trichloride in aqueous HCl. Such mixture was then calcined in oxidising atmosphere in a rotary oven.
- the spraying parameters selected for cold gas spray technique application were the following:
- the thus obtained electrode was identified as sample #1.
- titanium Magnéli phase powder in admixture with ruthenium oxide was sprayed onto a titanium grade 1 sheet of 10 cm x 10 cm x 0.2 cm size, previously sandblasted with corundum grit #36 and etched in boiling hydrochloric acid in order to obtain a rough surface free of titanium oxide species.
- Such powder was obtained by mixing a suitable mass of titanium Magnéli phase powder - previously sieved to a size range of 100 to 400 ⁇ m - to an acidic solution containing a soluble precursor of ruthenium, namely ruthenium trichloride in aqueous HCl. Such mixture was then calcined in oxidising atmosphere in a rotary oven.
- the spraying parameters selected for cold gas spray technique application were the following:
- the thus obtained electrode was identified as sample #2.
- titanium Magnéli phase powder in admixture with iridium oxide was plasma-sprayed onto a titanium grade 1 sheet of 10 cm x 10 cm x 0.2 cm size, previously sandblasted with corundum grit #36 and etched in boiling hydrochloric acid in order to obtain a rough surface free of titanium oxide species.
- Such powder was obtained by mixing a suitable mass of titanium Magnéli phase powder - previously sieved to a size range of 100 to 400 ⁇ m - to an acidic solution containing a soluble precursor of iridium, namely iridium trichloride in aqueous HCl. Such mixture was then calcined in oxidising atmosphere in a rotary oven.
- An acidic solution was subsequently prepared containing ruthenium trichloride and iridium trichloride in suitable concentration and stoichiometric ratio.
- the above plasma-sprayed titanium sheet was dipped in such solution for 15 seconds, allowed to dry slowly and finally placed in a batch furnace at 450 °C in oxidising atmosphere.
- the dipping and thermal decomposition cycle was repeated 4 times.
- the solution was allowed to dry slowly and then decomposed in a batch furnace at 450 °C in oxidising atmosphere.
- the sample under test is the working anode, while the counterelectrode consists of a titanium sheet. **Accelerated test: electrolysis carried out in a solution of 5 g/l NaCl and 50 g/l Na 2 SO 4 , 30 °C, 1 kA/m 2 . Anode and cathode are made of the same material. Electrode polarity is reversed every 2 minutes.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Electrochemistry (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- Electrodes For Compound Or Non-Metal Manufacture (AREA)
- Electrolytic Production Of Non-Metals, Compounds, Apparatuses Therefor (AREA)
- Catalysts (AREA)
Description
- The invention relates to an electrode suitable for functioning as anode in electrolysis cells, for instance as oxygen-evolving anode in electrolysis cells used in electrometallurgical processes, as chlorine-evolving anode either in chlor-alkali cells or as anode for hypochlorite generation in undivided cells.
- Substoichiometric compositions of titanium oxides of formula TixO2x-1, with x ranging from 4 to 10, also known as titanium Magnéli phases, are obtained by high temperature reduction of titanium dioxide under a hydrogen atmosphere. These suboxides are corrosion-resistant ceramic materials comparable to graphite in terms of electrical conductivity. In light of such corrosion resistance and conductivity characteristics these materials, which are produced both in massive and in powder form, may be used as protective coatings of metal substrates for electrochemical applications. There is also known the possibility of adding small amounts of doping agents to these ceramic materials, such as for instance tin oxide, in order to slightly increase their conductivity, stability and resistance to corrosion. In general, the deposition of these ceramic materials as metal substrate protectors is carried out starting from the material in powder form in accordance with known techniques, such as, hot flame spraying, plasma spraying or detonation thermal spraying. All of these techniques share the common feature of requiring a high operative temperature (>400 °C) in order to obtain an acceptable adhesion between sprayed powder particles and metal substrate. Furthermore, the good adhesion of deposited powder particles to the substrate also depends on the reciprocal nature of the substrate and the powder.
- The above mentioned spraying techniques allow depositing very compact layers of ceramic material on the surface of a metal substrate. Such compactness is in fact required for an efficient anticorrosion function. More precisely, it is generally accepted in the art that the apparent density of the deposited ceramic layer must not be lower than 95% of the overall theoretical density in order to obtain an efficient material.
- These ceramic materials may also be used as catalyst supports. In the manufacturing of an electrode starting from a metal substrate, the catalyst is applied in a step subsequent to the deposition of the titanium Magnéli phase onto such substrate, generally by thermal decomposition of precursors. This mode of application, however, has the drawback of leading to the formation of ceramic layers wherein a major fraction of the catalyst applied turns out to be scarcely accessible to the electrolyte, the final product thus being hardly efficient in terms of activity and lifetime. Usually, in order to obtain electrodes of suitable performances for an industrial application, the loading of the Magnéli phase-supported catalyst must be not lower than 20-30 g/m2.
- Moreover, the use of the above mentioned powder deposition techniques on metal substrates is not advisable whenever such powders also comprise noble metal oxides as catalysts, because such oxides are not stable to temperatures above 400 °C and tend to decompose, thereby hindering an appropriate deposition. The preparation of titanium suboxide and noble metal oxide mixtures to be subsequently deposited onto a substrate by means of the above mentioned techniques is hence not easy to practise.
-
US 201 111 47205 Al describes a method for preparing electrocatalytic layers of Ti-Ru-Fe-O on an electrode substrate such as titanium by cold gas spraying. FromUS 4 422 91 7 A an electrode material prepared by coating an electrocatalyst on a porous titanium suboxide bulk material is known,GB 2 309 230 A - The inventors surprisingly found out a method for manufacturing electrodes comprising a valve metal-based substrate coated with at least one layer of noble metals or oxides thereof supported on titanium suboxides overcoming the inconveniences of the prior art.
- Various aspects of the invention are set out in the accompanying claims.
- The invention is concerned with electrodes for evolution of gaseous products in electrolytic cells comprising a valve metal substrate whereto at least one layer of a coating having an interconnected porosity is attached, the layer consisting of at least one catalyst containing noble metals or oxides thereof taken alone or in admixture, supported on titanium suboxide species expressed by the formula TixO2x-1, with x ranging from 4 to 10, the specific catalyst loading being comprised between 0.1 and 25 g/m2.
- The term interconnected is used herein to mean a porosity mostly consisting of a network of pores in mutual fluid communication and not isolated. In order to obtain a layer having an interconnected porosity, it is normally considered that the apparent density of such layer must be lower than 95% of the overall theoretical density which a compact layer with no porosity at all having an equivalent composition would exhibit.
- Under one aspect, the invention relates to an electrode for evolution of gaseous products in electrolytic cells consisting of a valve metal substrate and at least a coating layer having an interconnected porosity bound thereto, said at least one layer comprising at least one catalyst consisting of noble metals or oxides thereof taken alone or in admixture, supported on a mixture of titanium suboxides of formula TixO2x-1, with x ranging from 4 to 10, said at least one layer being deposited onto said substrate by cold gas spray technique. The term cold gas spray is used herein to mean a deposition technique of solid particles onto substrates supposedly known to a person skilled in the art, based on accelerating powder particles transported by a compressed carrier gas. During their trajectory, the carrier gas and the particles are split into two different paths so that the time of residence of powders inside the hot gas phase is limited, thereby preventing powders to be heated above 200 °C.
- The inventors have surprisingly observed that the deposition via cold gas spray technique of a Magnéli phase-type ceramic powder, for example consisting of a titanium Magnéli phase powder previously catalysed with noble metal oxides by thermal decomposition of precursors, onto a substrate made of a valve metal such as titanium, tantalum, zirconium or niobium, leads to a structure of surprisingly enhanced duration even at very low catalyst loadings. In particular, the lifetime of an electrode obtained as hereinbefore described in common industrial electrochemical applications is much higher compared to the one of an electrode having the same nominal content of catalyst but prepared by traditional thermal decomposition.
- In one embodiment, the valve metal of choice for the substrate is titanium.
- In one particular embodiment, the coating layer has an interconnected porosity with an apparent density ranging higher than 75% and lower than 95% of the overall theoretical density.
- In another embodiment, the electrode has a coating layer containing a specific catalyst loading of 0.1 to 10 g/m2.
- In yet another embodiment, the noble metal oxide-based catalyst consists of iridium oxide.
- Under another aspect, the invention relates to a method for manufacturing an electrode according to the invention comprising the steps of: preparing a titanium suboxide powder expressed by the formula TixO2x-1, with x ranging between 4 and 10; impregnating said powder with a precursor solution of a noble metal oxide-based catalyst with subsequent thermal decomposition; depositing the obtained powder on a valve metal substrate by cold gas spray technique.
- Under yet another aspect, the invention relates to an electrolysis cell comprising a cathodic compartment containing a cathode and an anodic compartment containing an anode, wherein said anode of said anodic compartment is an electrode as hereinbefore described.
- Under yet another aspect the invention relates to an industrial electrochemical process comprising the anodic evolution of a gas from an electrolytic bath on an electrode as hereinbefore described.
- The following examples are included to demonstrate particular embodiments of the invention, whose practicability has been largely verified in the claimed range of values. It should be appreciated by those of skill in the art that the compositions and techniques disclosed in the examples which follow represent compositions and techniques discovered by the inventors to function well in the practice of the invention; however, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed and still obtain a like or similar result without departing from the scope of the invention.
- An appropriate volume of titanium Magnéli phase powder in admixture with iridium oxide was sprayed onto a titanium grade 1 sheet of 10 cm x 10 cm x 0.2 cm size, previously sandblasted with corundum grit #36 and etched in boiling hydrochloric acid in order to obtain a rough surface free of titanium oxide species. Such powder was obtained by mixing a suitable mass of titanium Magnéli phase powder - previously sieved to a size range of 100 to 400 µm - to an acidic solution containing a soluble precursor of iridium, namely iridium trichloride in aqueous HCl. Such mixture was then calcined in oxidising atmosphere in a rotary oven.
- The spraying parameters selected for cold gas spray technique application were the following:
- Nozzle-to-sheet gap: 20 mm
- Primary gas: nitrogen
- (Primary) gas pressure: 30 bar
- Gas flow-rate: 6 m3/h
- Feeder gas flow-rate: 4 %
- Throat size: 1 mm
- Scan rate: 50 mm/s
- As a final target of the cold gas spraying process, a homogeneous coating containing 10 g/m2 of iridium was obtained.
- The thus obtained electrode was identified as sample #1.
- An appropriate volume of titanium Magnéli phase powder in admixture with ruthenium oxide was sprayed onto a titanium grade 1 sheet of 10 cm x 10 cm x 0.2 cm size, previously sandblasted with corundum grit #36 and etched in boiling hydrochloric acid in order to obtain a rough surface free of titanium oxide species. Such powder was obtained by mixing a suitable mass of titanium Magnéli phase powder - previously sieved to a size range of 100 to 400 µm - to an acidic solution containing a soluble precursor of ruthenium, namely ruthenium trichloride in aqueous HCl. Such mixture was then calcined in oxidising atmosphere in a rotary oven.
- The spraying parameters selected for cold gas spray technique application were the following:
- Nozzle-to-sheet gap: 20 mm
- Primary gas: nitrogen
- (Primary) gas pressure: 30 bar
- Gas flow-rate: 6 m3/h
- Feeder gas flow-rate: 4 %
- Throat size: 1 mm
- Scan rate: 50 mm/s
- As a final target of the cold gas spraying process, a homogeneous coating containing 10 g/m2 of ruthenium was obtained.
- The thus obtained electrode was identified as sample #2.
- An appropriate volume of titanium Magnéli phase powder in admixture with iridium oxide was plasma-sprayed onto a titanium grade 1 sheet of 10 cm x 10 cm x 0.2 cm size, previously sandblasted with corundum grit #36 and etched in boiling hydrochloric acid in order to obtain a rough surface free of titanium oxide species. Such powder was obtained by mixing a suitable mass of titanium Magnéli phase powder - previously sieved to a size range of 100 to 400 µm - to an acidic solution containing a soluble precursor of iridium, namely iridium trichloride in aqueous HCl. Such mixture was then calcined in oxidising atmosphere in a rotary oven.
- The following spraying parameters were applied:
- Nozzle-to-sheet gap: 90 mm
- Primary gas: argon
- (Primary) gas pressure: 60 bar
- Throat size: 5 mm
- Scan rate: 200 mm/s
- As a final target of the plasma-spraying process, a homogeneous coating containing 10 g/m2 of iridium was obtained.
- Due to the high temperature reached by the powder during the plasma spraying process, it was observed that Magnéli phase-supported iridium oxide was partially converted to iridium metal.
- The thus obtained electrode was identified as sample #C1.
- An appropriate volume of titanium Magnéli phase powder, previously sieved to a size range of 100 to 400 µm, was plasma-sprayed onto a titanium grade 1 sheet of 10 cm x 10 cm x 0.2 cm size, previously sandblasted with corundum grit #36 and etched in boiling hydrochloric acid in order to obtain a rough surface free of titanium oxide species.
- The following spraying parameters were applied:
- Nozzle-to-sheet gap: 90 mm
- Primary gas: argon
- (Primary) gas pressure: 60 bar
- Throat size: 5 mm
- Scan rate: 200 mm/s
- An acidic solution was subsequently prepared containing ruthenium trichloride and iridium trichloride in suitable concentration and stoichiometric ratio. The above plasma-sprayed titanium sheet was dipped in such solution for 15 seconds, allowed to dry slowly and finally placed in a batch furnace at 450 °C in oxidising atmosphere. In order to obtain the required noble metal loading (5 g Ru/m2 and 2 g Ir/m2) the dipping and thermal decomposition cycle was repeated 4 times.
- The thus obtained electrode was identified as sample #C2.
- A known volume of acidic solution containing a soluble precursor of ruthenium, namely highly concentrated ruthenium trichloride, was applied by electrostatic spraying onto a titanium grade 1 sheet of 10 cm x 10 cm x 0.2 cm size, previously sandblasted with corundum grit #36 and etched in boiling hydrochloric acid in order to obtain a rough surface free of titanium oxide species. The solution was allowed to dry slowly and then decomposed in a batch furnace at 450 °C in oxidising atmosphere.
- In order to obtain the required noble metal loading (24 g Ru/m2) the electrostatic spraying and thermal decomposition cycle was repeated 18 times.
- The thus obtained electrode was identified as sample #C3.
- The samples obtained in the above examples and counterexamples were subjected to electrolysis tests, as reported in Table 1 below:
TABLE 1 Sample ID Resistivity (Ωm) Hypochlorite production faradaic efficiency* (%) Service life in accelerated test** (hours) Catalyst loading (gNM/m2) 1 5 exp -6 73 1600 10 (Ir) 2 5 exp -6 75 1550 10 (Ru) C1 5 exp -3 39 240 10 (Ir) C2 5 exp -6 71 290 5+2 (Ru + Ir) C3 5 exp -6 78 150 24 (Ru) *Hypochlorite production faradaic efficiency: measure of faradaic efficiency by titration of active chlorine present in an electrolyte sample obtained starting from an aqueous NaCl solution at 30 g/l subjected to electrolysis for 10 minutes, at 25 °C and at a current density of 2 kA/m2. The sample under test is the working anode, while the counterelectrode consists of a titanium sheet.
**Accelerated test: electrolysis carried out in a solution of 5 g/l NaCl and 50 g/l Na2SO4, 30 °C, 1 kA/m2. Anode and cathode are made of the same material. Electrode polarity is reversed every 2 minutes. - The previous description shall not be intended as limiting the invention, which may be used according to different embodiments without departing from the scopes thereof, and whose extent is solely defined by the appended claims.
- Throughout the description and claims of the present application, the term "comprise" and variations thereof such as "comprising" and "comprises" are not intended to exclude the presence of other elements, components or additional process steps.
- The discussion of documents, acts, materials, devices, articles and the like is included in this specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters formed part of the prior art base or were common general knowledge in the field relevant to the present invention before the priority date of each claim of this application.
Claims (8)
- Electrode for evolution of gaseous products in electrolytic cells comprising a valve metal substrate whereto at least one layer of a coating having an interconnected porosity is attached, said at least one layer being comprised of titanium suboxides expressed by the formula TixO2x-1, with x ranging from 4 to 10, in admixture with at least one catalyst based on noble metals or oxides thereof, said at least one layer being deposited on said substrate by cold gas spray technique.
- The electrode according to claim 1 wherein said valve metal of said substrate is titanium.
- The electrode according to any one of claims 1 or 2 wherein said at least one coating layer attached to the substrate has an apparent density of 75 to 95% of the overall theoretical density of said layer.
- The electrode according to any one of claims 1 to 3 wherein the specific catalyst loading in least one coating layer ranges between 0.1 and 10 g/m2.
- The electrode according to any one of claims 1 to 4 wherein said at least one catalyst based on noble metal oxides consists of iridium oxide.
- Method for manufacturing an electrode according to claim 1 comprising the following steps:- preparation of a powder of titanium suboxides expressed by the formula TixO2x-1, with x ranging between 4 and 10,- impregnation of said powder with a precursor solution of a noble metal or noble metal oxide-based catalyst- thermal decomposition,- deposition of said powder on a valve metal substrate by cold gas spray technique.
- Electrolysis cell comprising a cathodic compartment containing a cathode and an anodic compartment containing an anode, wherein said anode of said anodic compartment is an electrode according to any one of claims 1 to 5.
- Industrial electrochemical process comprising the anodic evolution of a gas on an electrode according to any one of claims 1 to 5 from an electrolytic bath.
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IT000873A ITMI20120873A1 (en) | 2012-05-21 | 2012-05-21 | ELECTRODE FOR EVOLUTION OF GASEOUS PRODUCTS AND METHOD FOR ITS ACHIEVEMENT |
PCT/EP2013/060177 WO2013174718A1 (en) | 2012-05-21 | 2013-05-16 | Electrode for evolution of gaseous products and method of manufacturing thereof |
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ITUB20159439A1 (en) | 2015-12-21 | 2017-06-21 | Industrie De Nora Spa | ANTI-CORROSIVE COATING AND METHOD FOR ITS ACHIEVEMENT |
CN105776429B (en) * | 2016-03-15 | 2019-08-09 | 中国矿业大学(北京) | With active tubular ring Asia oxidation titanium film electrode of electrochemical oxidation and preparation method thereof |
CN106082399B (en) * | 2016-06-01 | 2018-12-25 | 深圳市大净环保科技有限公司 | A kind of electrochemical advanced oxidation device |
WO2019176956A1 (en) * | 2018-03-12 | 2019-09-19 | 三菱マテリアル株式会社 | Titanium base material, method for producing titanium base material, electrode for water electrolysis, and water electrolysis device |
US11668017B2 (en) | 2018-07-30 | 2023-06-06 | Water Star, Inc. | Current reversal tolerant multilayer material, method of making the same, use as an electrode, and use in electrochemical processes |
US11557767B2 (en) * | 2018-10-03 | 2023-01-17 | University Of Ontario Institute Of Technology | Fuel cell catalyst support based on doped titanium sub oxides |
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NO141419C (en) * | 1974-02-02 | 1980-03-05 | Sigri Elektrographit Gmbh | ELECTRODE FOR ELECTROCHEMICAL PROCESSES |
DE2405010C3 (en) * | 1974-02-02 | 1982-08-05 | Sigri Elektrographit Gmbh, 8901 Meitingen | Sintered electrode for electrochemical processes and methods of manufacturing the electrode |
US4422917A (en) * | 1980-09-10 | 1983-12-27 | Imi Marston Limited | Electrode material, electrode and electrochemical cell |
DE3423605A1 (en) * | 1984-06-27 | 1986-01-09 | W.C. Heraeus Gmbh, 6450 Hanau | COMPOSITE ELECTRODE, METHOD FOR THEIR PRODUCTION AND THEIR USE |
JPH06192870A (en) * | 1992-12-24 | 1994-07-12 | Permelec Electrode Ltd | Electrolytic electrode |
GB9601236D0 (en) * | 1996-01-22 | 1996-03-20 | Atraverda Ltd | Conductive coating |
US6120659A (en) * | 1998-11-09 | 2000-09-19 | Hee Jung Kim | Dimensionally stable electrode for treating hard-resoluble waste water |
FI118159B (en) * | 2005-10-21 | 2007-07-31 | Outotec Oyj | Method for forming an electrocatalytic surface of an electrode and electrode |
CA2671211A1 (en) * | 2009-07-08 | 2011-01-08 | Hydro-Quebec | Highly energy efficient bipolar electrodes and use thereof for the synthesis of sodium chlorate |
CA2726859C (en) * | 2009-12-21 | 2018-03-13 | Institut National De La Recherche Scientifique (Inrs) | Method and system for producing electrocatalytic coatings and electrodes |
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WO2013174718A1 (en) | 2013-11-28 |
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EP2852697A1 (en) | 2015-04-01 |
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ITMI20120873A1 (en) | 2013-11-22 |
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