US20150056523A1 - Electrolyte system and method of preparation thereof - Google Patents

Electrolyte system and method of preparation thereof Download PDF

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Publication number
US20150056523A1
US20150056523A1 US14/390,494 US201314390494A US2015056523A1 US 20150056523 A1 US20150056523 A1 US 20150056523A1 US 201314390494 A US201314390494 A US 201314390494A US 2015056523 A1 US2015056523 A1 US 2015056523A1
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Prior art keywords
electrolyte
saturated
unit
solid
diluted
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US14/390,494
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English (en)
Inventor
Dekel Tzidon
Avraham Melman
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Phinergy Ltd
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Phinergy Ltd
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Priority to US14/390,494 priority Critical patent/US20150056523A1/en
Assigned to PHINERGY LTD. reassignment PHINERGY LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MELMAN, AVRAHAM, TZIDON, DEKEL
Publication of US20150056523A1 publication Critical patent/US20150056523A1/en
Priority to US16/792,928 priority patent/US11515574B2/en
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M12/00—Hybrid cells; Manufacture thereof
    • H01M12/08—Hybrid cells; Manufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/4242—Regeneration of electrolyte or reactants
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M12/00—Hybrid cells; Manufacture thereof
    • H01M12/04—Hybrid cells; Manufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type
    • H01M12/06—Hybrid cells; Manufacture thereof composed of a half-cell of the fuel-cell type and of a half-cell of the primary-cell type with one metallic and one gaseous electrode
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M12/00—Hybrid cells; Manufacture thereof
    • H01M12/08—Hybrid cells; Manufacture thereof composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type
    • H01M12/085—Zinc-halogen cells or batteries
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04082—Arrangements for control of reactant parameters, e.g. pressure or concentration
    • H01M8/04186—Arrangements for control of reactant parameters, e.g. pressure or concentration of liquid-charged or electrolyte-charged reactants
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04082—Arrangements for control of reactant parameters, e.g. pressure or concentration
    • H01M8/04201—Reactant storage and supply, e.g. means for feeding, pipes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04291—Arrangements for managing water in solid electrolyte fuel cell systems
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298—Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313—Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/0432—Temperature; Ambient temperature
    • H01M8/04365—Temperature; Ambient temperature of other components of a fuel cell or fuel cell stacks
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298—Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313—Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/0438—Pressure; Ambient pressure; Flow
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298—Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313—Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/0444—Concentration; Density
    • H01M8/04477—Concentration; Density of the electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/04—Auxiliary arrangements, e.g. for control of pressure or for circulation of fluids
    • H01M8/04298—Processes for controlling fuel cells or fuel cell systems
    • H01M8/04313—Processes for controlling fuel cells or fuel cell systems characterised by the detection or assessment of variables; characterised by the detection or assessment of failure or abnormal function
    • H01M8/04492—Humidity; Ambient humidity; Water content
    • H01M8/04529—Humidity; Ambient humidity; Water content of the electrolyte
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/20—Indirect fuel cells, e.g. fuel cells with redox couple being irreversible
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2250/00—Fuel cells for particular applications; Specific features of fuel cell system
    • H01M2250/20—Fuel cells in motive systems, e.g. vehicle, ship, plane
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M2300/00—Electrolytes
    • H01M2300/0002—Aqueous electrolytes
    • H01M2300/0014—Alkaline electrolytes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00—Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/40—Application of hydrogen technology to transportation, e.g. using fuel cells

Definitions

  • This invention relates to systems and methods for producing an electrolyte.
  • Batteries are electrochemical systems that in most cases require an electrolyte solution for their operation. Batteries utilizing an electrolyte solution require periodical electrolyte replacement, when the electrolyte cannot absorb additional reaction products.
  • a battery that is used for portable machines, engines or appliances such as batteries for electrical vehicles require electrolyte replacement at different sites, similar to gas refueling stations.
  • transportation of electrolyte in its operational liquid form, storage of liquid electrolyte in gas stations and filling up liquid electrolyte into the battery on the vehicle may be complicated and expensive. Therefore, there is a need for a system that efficiently and safely replenishes liquid electrolyte in a battery on e.g. an electrically-operated vehicle.
  • this invention provides systems and methods for preparing an electrolyte for use in metal air batteries.
  • the preparation of the electrolyte is done adjacent to the metal air battery that consumes the electrolyte.
  • the electrolyte production system of this invention is located in the vehicle.
  • electrolyte preparation and transfer is done automatically and safely, while optionally utilizing the excess heat formed during preparation for the benefit of the metal air battery.
  • systems and methods of the present invention provide increased safety and heat management efficiency due to dilution in two steps. This is achieved by first preparing a saturated solution and then diluting the saturated solution to the required concentration instead of preparing the diluted solution directly by dissolving solid in the correct amount of liquid. This stepwise preparation method reduces the corresponding heat release.
  • systems of the invention provide simpler and less expensive infrastructure for supplies as only solid is transported, and is diluted on-board.
  • systems and method of the present invention have the advantage that after system initialization the user only needs to add more water to produce more electrolyte. This is a big advantage for use in electric vehicles since the user of the electric vehicle only need to add water to the system to produce more electrolyte.
  • the possibility to take water for dilution on the vehicle's board from an exterior source has additional advantage of making the system of the invention much simpler and lighter.
  • this invention provides a system for producing an electrolyte for a metal air battery, said system comprising:
  • a first inlet of the saturated electrolyte unit, a second inlet of the diluted electrolyte unit or combination thereof are connected to a liquid source from which liquid can be transferred to said saturated electrolyte unit, to said diluted electrolyte unit or to a combination thereof.
  • this invention provides a method for producing an electrolyte for a metal air battery, said method comprising:
  • the adding water step is conducted prior to, during or after said transferring step.
  • this invention provides a method for producing an electrolyte for a metal air battery, said method comprising:
  • FIG. 1 is a flow chart illustrating an electrolyte production system of the invention and method of preparing the electrolyte.
  • this invention provides a system for producing an electrolyte for a metal air battery, said system comprising:
  • the first inlet of said saturated electrolyte unit, a second inlet of said diluted electrolyte unit or combination thereof are connected to a liquid source from which liquid can be transferred to said saturated electrolyte unit, to said diluted electrolyte unit or to a combination thereof.
  • the metal air battery is used for operating an electric vehicle.
  • the liquid source is located either on the vehicle's board or external to the vehicle.
  • the metal air battery is an Aluminum (Al) air battery.
  • the liquid source comprises a tank.
  • the liquid is water.
  • the liquid comprises water.
  • liquid further comprises stabilizing agents, wherein said stabilizing agent comprise stannates, nano-sized ceramic materials or combination thereof.
  • the system further comprising one or more heat exchanger(s) connected to the saturated electrolyte unit or to said diluted electrolyte unit.
  • the saturated electrolyte unit, said diluted electrolyte unit or combination thereof further comprise a liquid level tester, a density meter, a conductivity meter or combination thereof.
  • the saturated electrolyte unit comprises solid KOH and a KOH saturated solution or solid NaOH and a NaOH saturated solution.
  • the weight ratio of (solid KOH:KOH saturated solution) or of (solid NaOH:NaOH saturated solution) is between (1:20) to (100:1).
  • said diluted electrolyte unit comprises an electrolyte composition suitable for said metal air battery operation.
  • the electrolyte composition further comprises materials for enhancement of metal air battery performance.
  • the metal air battery further comprises electrolyte monitors/sensors for testing electrolyte pH, density, temperature, pressure, volume, weight, concentration of metal fuel, Na+ and/or K+ content, electrolyte conductivity or a combination thereof.
  • this invention provides a method for producing electrolyte for a metal air battery, said method comprising:
  • the adding water step is conducted prior to, during or after said transferring step.
  • the diluted electrolyte composition is transferred from said diluted electrolyte unit to said metal air battery.
  • the metal air battery is used for operating an electric vehicle.
  • the metal air battery is an Aluminum (Al) air battery.
  • the water further comprising stabilizing agents, wherein said stabilizing agent comprise stannates, nano-sized ceramic materials or a combination thereof.
  • the saturated electrolyte unit, said diluted electrolyte unit or combination thereof further comprises a liquid level tester, a density meter, a conductivity meter or a combination thereof.
  • the saturated electrolyte unit comprises solid KOH and KOH saturated solution; or solid NaOH and NaOH saturated solution. In one embodiment, upon depletion or consumption of said solid KOH or solid NaOH, more solid KOH or more solid NaOH is added to said saturated electrolyte unit.
  • the (solid:saturated solution) weight ratio of (solid KOH:KOH saturated solution) or of (solid NaOH:NaOH saturated solution) is between (1:20) to (100:1) in the saturated electrolyte unit.
  • the electrolyte composition further comprises materials for enhancement of metal air battery performance.
  • the metal-air battery further comprises electrolyte monitors/sensors for testing electrolyte pH, density, temperature, pressure, volume, weight, concentration of metal fuel, Na+ and/or K+ content, electrolyte conductivity or a combination thereof.
  • the method further comprising a step of solid addition to said saturated electrolyte unit when solid is depleted or consumed. In one embodiment, the method further comprising a step of liquid transfer from a liquid source to said saturated electrolyte unit, to said diluted electrolyte unit or to a combination thereof upon demand.
  • liquid transfer from a liquid source to said saturated electrolyte unit is conducted upon depletion or consumption of said saturated solution. In one embodiment, liquid transfer from a liquid source to said diluted electrolyte unit is conducted upon depletion or consumption of said diluted solution.
  • the liquid source is placed on a vehicle operated by said metal-air battery.
  • the vehicle is a bicycle, car, truck, bus, motorcycle, train, ship, boat, aircraft or a spacecraft.
  • the liquid source is placed external to said vehicle operated by said battery.
  • the liquid source is placed in a road-side station.
  • this invention provides a method for producing electrolyte for a metal air battery, said method comprising:
  • this invention provides a method for producing electrolyte for a metal air battery, said method comprising:
  • the step of adding water to the saturated unit is conducted prior to, during or after the step of adding water to the diluted unit. In one embodiment, at any given time, upon battery demand, diluted solution is transferred from the diluted unit to the battery. In one embodiment, at any given time, more solid ionic compound is added to the saturated unit.
  • this invention provides a method for producing electrolyte for a metal air battery, said method comprising:
  • step l of adding a solid is conducted prior to, during or after any of method steps f-k.
  • all method steps are the same except for step “a” wherein preparing a saturated electrolyte solution from a solid ionic compound and from a liquid is conducted outside the saturated electrolyte unit and the formed saturated solution and a corresponding solid are transferred to said saturated unit such that said unit comprises both said solution and said solid.
  • the saturated solution is aqueous KOH
  • the corresponding solid is KOH.
  • this invention provides a method for producing electrolyte for a metal air battery, the method comprising:
  • the systems and methods of this invention are directed to producing electrolyte for a metal air battery for operating an electrical vehicle.
  • the metal air battery is an Aluminum (Al) air battery.
  • the electrolyte comprises an alkaline salt.
  • the electrolyte comprises an alkaline hydroxide.
  • the electrolyte comprises NaOH or KOH.
  • the solid ionic compound forming the electrolyte is KOH or NaOH.
  • this invention provides systems and methods for the preparation of an electrolyte solution for use in a battery, wherein the electrolyte preparation system is located on the same appliance comprising the battery or in close proximity to it.
  • the electrolyte preparation system is located on the same appliance comprising the battery or in close proximity to it.
  • such configuration provides better conditions for storing raw materials and handling them prior to use in the battery (e.g. a metal air battery for an electric vehicle).
  • the electrolyte solution comprises KOH
  • dry solid KOH absorbs water and CO 2 from the air. It is therefore requires careful storage conditions.
  • KOH is stored in a saturated solution, and is not exposed to air, thus eliminating the need for sophisticated packaging and un-packaging of the solid.
  • systems and methods of this invention enable optional utilization of heat generated by dilution of the saturated solution.
  • the electrolyte needs to be hot prior to its use.
  • an electrolyte comprising sodium hydroxide (NaOH) may be functional at a temperature of 50° C. Since the dilution of the saturated electrolyte is exothermic, the resultant electrolyte is at higher temperature than the ambient temperature. For example, if the electrolyte in use comprises 20% (wt/wt) sodium hydroxide and the ambient temperature is about 25° C., the electrolyte formed by dilution will reach the required temperature of around 50° C. as a result of the exothermic dilution process.
  • a system of the invention comprises two units. One unit is used for the saturated electrolyte solution, and the other unit is used for dilution of the saturated solution. The latter may also serve for storing diluted solution.
  • the system further comprises accessories for mixing, heat exchanging, solution pumping, concentration monitoring, temperature and pressure monitoring, liquid level monitoring or a combination thereof.
  • the saturated electrolyte unit comprises solid and saturated electrolyte solution.
  • the saturated electrolyte unit comprises solid KOH and a KOH saturated solution or solid NaOH and a NaOH saturated solution. Due to the fact that the saturated unit comprises both solid and a saturated electrolyte solution formed by the same material forming the solid, equilibrium is formed between the solid and the solution, causing the solution to be saturated at all times.
  • the saturated solution is at a concentration much higher than the concentration needed for the consumer (e.g. a metal air battery).
  • the contents of the saturated electrolyte unit comprising the saturated solution and its corresponding solid serves as a reservoir of raw material for the preparation of electrolyte at the concentration required by the consumer.
  • the solid in the saturated tank is submerged in the solution, and therefore it is not exposed to air, and is less likely to deteriorate or to absorb contaminating materials.
  • the consumer e.g. the metal air battery
  • some of the saturated solution is pumped into the diluted electrolyte unit, and diluted to the required concentration.
  • the saturated solution may be replenished (when necessary) by adding more liquid (e.g. water) into the saturated electrolyte unit so that the saturated unit does not dry out. After replenishing, the solution will return to its saturation concentration due to solid dissolving. This process may be repeated until all the solid dissolves.
  • operation of the system continues in one of two options: (i) more solid is added; or (ii) the saturated solution left in the saturated unit is continued to be transferred to the diluted unit until it is completely consumed or until it reaches a certain volume level.
  • the additional solid is added to the saturated solution tank in order to compensate for the consumed solid. Such addition of solid can be done any time.
  • the system of this invention comprises a liquid source.
  • the liquid source includes water.
  • the liquid source includes deionized (DI) water.
  • the liquid further comprising stabilizing agents.
  • the stabilizing agent comprises stannates, nano-sized ceramic materials or combination thereof.
  • the liquid source is connected independently to the saturated electrolyte unit and to the diluted electrolyte unit.
  • the liquid source could exist out of the vehicle's board and could be used according the necessity.
  • the liquid source is placed in a road-side station.
  • the first inlet of said saturated electrolyte unit, the second inlet of the diluted electrolyte unit or combination thereof are connected to the liquid source such that liquid can be transferred independently from said liquid source to said saturated electrolyte unit, and/or to said diluted electrolyte unit.
  • the saturated electrolyte supplied by the saturated electrolyte unit is diluted with a liquid supplied by the liquid source, in the diluted electrolyte unit, thus producing an electrolyte composition suitable for the metal air battery operation.
  • liquid supplied by the liquid source
  • liquid supplied by the liquid source
  • Advantages of systems of the invention include but are not limited to production of electrolyte at a required site (e.g. on board the electric vehicle operated by the consumer), production of electrolyte on demand, using liquid for electrolyte dilution from external source, increased safety in dilution, simple and safe loading of raw materials, better storage and handling of raw materials, simple heat management, and utilization of heat generated in dilution.
  • all the actions or operation steps in the system are performed automatically.
  • the system provides control over the various pumps and it is capable of measuring temperature and concentration of the solutions in the saturated liquid tank, and in the diluted electrolyte tank. Such sensing, monitoring and control allows for thermal control by determining the paste of the dilution process.
  • the control and measurement elements and methods allows for production of electrolyte at the required concentration.
  • level and weight sensors in the tanks allow for accurate production of electrolyte at the required amount and concentration.
  • the electrolyte preparation system of this invention is safe with regards to handling the heat that may be released during the preparation process.
  • some of the energy that is released during electrolyte preparation is used to preheat the electrolyte.
  • FIG. 1 is a schematic block diagram of one embodiment of the invention.
  • the system depicted in FIG. 1 comprises a saturated electrolyte unit ( 1 - 10 ); a diluted electrolyte unit ( 1 - 20 ) and optional a liquid source ( 1 - 30 ).
  • the liquid source could exist either on the board (of the e.g. electric vehicle operated by the metal-air battery) or outside the vehicle/appliance operated by the battery.
  • the saturated electrolyte unit receives diluting liquid through inlet ( 1 - 90 ) as required.
  • the diluted electrolyte unit receives diluting liquid through inlet ( 1 - 100 ) as required.
  • the diluted electrolyte unit receives saturated solution from the saturated electrolyte unit by the connection ( 1 - 180 ) as required.
  • the liquid source receives diluting liquid through inlet ( 1 - 110 ) as required.
  • Inlet ( 1 - 120 ) is used for refilling solid into the saturated electrolyte unit.
  • the solid may be contained in a separate solid container (not shown) and may be drawn from there into the saturated electrolyte unit upon demand.
  • the system optionally comprises accessories for mixing the contents of the saturated electrolyte unit ( 1 - 40 ), the diluted electrolyte unit ( 1 - 50 ), the consumer (not shown) or a combination thereof.
  • the system optionally comprises heat exchangers for the saturated electrolyte unit ( 1 - 60 a ), the diluted electrolyte unit ( 1 - 60 b ), the consumer (element not shown) or combination thereof.
  • the system optionally comprises a concentration monitor for the saturated electrolyte unit ( 1 - 80 a ), the diluted electrolyte unit ( 1 - 80 b ), the consumer ( 1 - 80 c ) or combination thereof.
  • the system is connected to a consumer ( 1 - 130 ) through inlet ( 1 - 200 ).
  • the consumer comprises an outlet ( 1 - 190 ) to remove used electrolyte, while transferring fresh electrolyte composition from the diluted electrolyte unit.
  • the system further comprises a diluted electrolyte unit outlet ( 1 - 140 ) for removing excess dilution liquid from the diluted unit.
  • the saturated electrolyte unit ( 1 - 10 ), the diluted electrolyte unit ( 1 - 20 ), the consumer ( 1 - 130 ) or combination thereof further comprises a liquid level tester ( 1 - 150 a,b,c ).
  • the saturated electrolyte unit ( 1 - 10 ), the diluted electrolyte unit ( 1 - 20 ), the consumer ( 1 - 130 ) or combination thereof comprise a temperature gauge ( 1 - 160 a,b,c respectively) and/or a pressure gauge ( 1 - 170 a,b,c respectively).
  • a mixture of saturated electrolyte and solid electrolyte is prepared outside of the system, and is inserted into the saturated solution tank ( 1 - 10 ).
  • a saturated electrolyte solution is prepared outside of the system, and is inserted into the saturated solution tank ( 1 - 10 ).
  • the saturated solution is made within the saturated unit by adding solid and liquid such that a saturated solution is formed and excess solid precipitates at the bottom of the tank.
  • system can function in either batch mode or continues mode as will be described herein below:
  • an electrolyte producing system of the invention is operated as follows:
  • a demand for an electrolyte for the consumer ( 1 - 130 ) is made.
  • the demand for electrolyte is a result of a change in the electrolyte composition or electrolyte amount in the consumer.
  • a critical parameter of the electrolyte in the consumer is measured by an appropriate gauge (e.g a transducer).
  • the critical parameter that is used for determining demand for electrolyte is selected from but is not limited to the group consisting of electrolyte pH, electrolyte density, temperature, pressure, volume, weight and/or total amount; concentration of metal fuel (e.g. Al, Zn, etc.) in the electrolyte. Na + or K + content, electrolyte conductivity or combination thereof.
  • An electrolyte is transferred from the diluted electrolyte unit ( 1 - 20 ) to the consumer ( 1 - 130 ).
  • the transferred amount can be up to the full quantity of electrolyte in the diluted electrolyte unit.
  • the diluted electrolyte unit is refilled by transferring saturated electrolyte from the saturated electrolyte unit ( 1 - 10 ) to the diluted electrolyte unit ( 1 - 20 ). In one embodiment, transfer is conducted using a pump. A dilution liquid is added from the liquid source ( 1 - 30 ) or from an external source to the diluted electrolyte unit through inlet ( 1 - 100 ). The amount of each transfer/addition depends on the electrolyte critical parameters measured by a gauge located within the dilution tank. The gauge(s) are similar to the gauges utilized within the consumer as described herein above. In one embodiment, the dilution liquid is added first, followed by addition of saturated electrolyte.
  • the order of steps b and c described hereinabove is determined by the requirements of the consumer system.
  • Step c can be before step b, in case the diluted electrolyte unit is empty.
  • a heat exchanger ( 1 - 60 b ) is used to cool down the electrolyte within the diluted electrolyte unit ( 1 - 20 ).
  • mixing the solution in the diluted electrolyte unit using mixer ( 1 - 50 ) is conducted. This operation is optional, depending on the solution properties.
  • the solution concentration in the diluted electrolyte unit is monitored using monitor ( 1 - 80 ) and can be accurately adjusted to the concentration required by the consumer for any certain batch/delivery.
  • additional materials e.g. stannates and nano sized ceramic particles
  • the additional materials are introduced together with the dilution liquid in the liquid source ( 1 - 30 ).
  • the electrolyte composition further comprises materials for enhancement of metal air battery performance.
  • a heat exchanger ( 1 - 60 a ) is used to cool down the saturated electrolyte.
  • the contents of the saturated electrolyte tank are mixed using mixing element ( 1 - 40 ).
  • the operation cycle comprising steps a to d continues until all the solid dissolves in the saturated electrolyte unit.
  • concentrated solution from the saturated electrolyte unit is continued to be drawn into the diluted electrolyte unit for electrolyte preparation until the saturated solution is completely consumed or until it reaches a certain level.
  • the system has to be initialized again (as described in the system initialization section herein above).
  • step a to d more solid is added to the saturated electrolyte unit, and the operation cycle (steps a to d) continues.
  • the maximal production rate of the system is defined as the maximal rate in which the system can dissipate the heat that is generated during its operation. This parameter is determined by the ambient temperature and the electrolyte temperature required by the consumer.
  • a demand for electrolyte can be made in two ways, batch or continuous, at a rate that is equal or less than the maximal production rate.
  • steps b and c described hereinabove are performed in parallel.
  • the prepared electrolyte is transferred to the consumer ( 1 - 130 ).
  • the transfer is conducted in one batch or continuously, at the rate required by the consumer. In case of one batch transfer, the transferred amount can be up to the full quantity of electrolyte in the diluted electrolyte unit.
  • a continuous refilling of the diluted electrolyte unit is performed.
  • the saturated electrolyte is continuously transferred from the saturated electrolyte unit ( 1 - 10 ) to the diluted electrolyte unit ( 1 - 20 ).
  • the transfer is made by a pump, or by other means.
  • the diluting liquid is continuously being added from the liquid source ( 1 - 30 ) to the diluted electrolyte unit through connection ( 1 - 100 ).
  • the rate of transferring saturated electrolyte and of adding diluting liquid is determined by electrolyte concentration that is required by the consumer system.
  • the heat exchanger ( 1 - 60 b ) may be used to cool down the electrolyte. Mixing is optional, depending on the solution properties and is carried out by mixer ( 1 - 50 ).
  • the solution concentration is continuously monitored, so that it can be fixed to the concentration required by the consumer ( 1 - 80 b ).
  • the saturated electrolyte is continuously replenished by adding the diluting liquid through connection ( 1 - 90 ).
  • heat exchanger 1 - 60 a
  • Mixing operation in the saturated electrolyte tank is optional, depending on the solution properties (mixer element 1 - 40 ).
  • steps a to d may continue until all the solid in the saturated solution tank dissolves.
  • the concentration of the electrolyte solution in the diluted electrolyte unit is monitored by one of the following methods: (i) monitoring the conductivity of the electrolyte in the diluted electrolyte unit; (ii) monitoring the refraction index of the electrolyte in the diluted electrolyte unit; (iii) monitoring the pH of the electrolyte in the diluted electrolyte unit.
  • metal-air cells or batteries have high energy density.
  • the oxidizing reactant oxygen
  • the oxidizing reactant oxygen
  • This reaction of oxygen reduction occurs in the presence of water and gives hydroxide ions (OH—).
  • the oxygen is reduced on the surface of a cathode during discharge.
  • a consumer refers to the consumer of the prepared electrolyte.
  • the consumer is a battery.
  • the consumer is a battery comprising an electrolyte.
  • metal air battery refers to Al-air battery or Zn-air secondary battery.
  • a diluted or a saturated electrolyte unit comprises a tank, a reservoir, a container, a hose, a tube a conduit, or any element that encloses a volume wherein a liquid or solution may be contained.
  • the diluted electrolyte unit is termed the diluted unit.
  • the saturated electrolyte unit is termed the saturated unit.
  • a liquid refers to any material in a liquid form including pure materials and solutions comprising solvent(s) and solute(s).
  • a diluting liquid refers to water. In another embodiment to DI water.
  • a liquid source comprises a tank, a reservoir, a container, a hose, a tube a conduit, or any element that encloses a volume wherein a liquid or solution may be contained or transferred through.
  • this invention provides an electric vehicle comprising the electrolyte production system of this invention, wherein the vehicle drives on metal air energy and wherein solid is added to the saturated electrolyte unit for generating electrolyte, to allow additional driving range.
  • metal air energy refers to the energy provided by a metal air battery.
  • generating electrolyte refers to producing electrolyte.
  • driving range is the distance that can be traveled by the vehicle. In one embodiment, driving range is expressed in kilometers or miles.
  • an electrolyte is the phase through which charge is carried by the movement of ions.
  • Electrolytes may comprise liquid solutions or fused salts or ionically-conductive solids. Electrolytes may comprise solutions of ionic compounds dissolved in water.
  • the second phase at the boundary of the electrolyte may be another electrolyte or it might be an electrode. In a battery or cell, the electrolyte is in contact with an electrode in one embodiment.
  • the term “a” or “one” or “an” refers to at least one.
  • the phrase “two or more” may be of any denomination, which will suit a particular purpose.
  • “about” or “approximately” may comprise a deviance from the indicated term of +1%, or in some embodiments, ⁇ 1%, or in some embodiments, ⁇ 2.5%, or in some embodiments, ⁇ 5%, or in some embodiments, ⁇ 7.5%, or in some embodiments, ⁇ 10%, or in some embodiments, ⁇ 15%, or in some embodiments, ⁇ 20%, or in some embodiments, ⁇ 25%.
  • the system and method of this invention comprise a saturated electrolyte unit.
  • the saturated unit comprises a saturated electrolyte solution and a precipitate.
  • the saturated electrolyte solution comprises an aqueous alkaline saturated solution.
  • the saturated solution comprises an alkaline hydroxide.
  • the saturated solution comprises NaOH or KOH.
  • the concentration of the saturated alkaline solution is between 20% to 60% wt/wt.
  • the concentration of saturated KOH solution is between 50% to 60% wt/wt.
  • the concentration of the saturated KOH solution depends on temperature.
  • the saturated electrolyte unit comprises solid and saturated electrolyte solution.
  • the saturated electrolyte unit contains solid KOH and a KOH saturated solution or solid NaOH and a NaOH saturated solution.
  • the weight ratio between solid KOH and saturated solution of KOH or between solid NaOH and saturated solution of NaOH is between (1:20) to (100:1).
  • the volume of the saturated solution depends on the volume/size of the saturated electrolyte unit. In another embodiment, the saturated electrolyte unit comprises between 20 to 100 liters of saturated solution.
  • solid is added to the saturated electrolyte solution.
  • the solid is an alkaline solid corresponding to the electrolyte saturated solution.
  • the alkaline solid is NaOH(s) or KOH(s).
  • the system and methods of this invention comprise a diluted electrolyte unit.
  • the diluted electrolyte unit comprises an electrolyte in a concentration suitable for a metal air battery.
  • solid is added to the saturated electrolyte solution.
  • the solid is an alkaline solid corresponding to the electrolyte saturated solution.
  • the alkaline solid is NaOH(s), or KOH(s).
  • solid alkaline is added to the saturated solution in weight ratios between (1:20) to (100:1) of (solid:saturated solution). In another embodiment 1 to 2 kg solid alkaline is added to every 0.5 to 1 liter of saturated solution.
  • the system and method of this invention are directed to electrolyte production for metal air battery.
  • this invention is directed to aluminum air battery.
  • the aluminum of the aluminum air battery is mechanically loaded into the metal air cells.
  • the products of the electrochemical reaction in it mainly potassium aluminate
  • dissolve into the electrolyte which is circulated through the battery.
  • the battery performance is degraded, until the electrolyte is replaced.
  • one liter of electrolyte allows the utilization of 500 Wh before it has to be replaced. Additionally, it is considered that the electric vehicle consumes 125 Wh per one kilometer of driving. Accordingly, for long-term use of the metal air battery, fresh electrolyte has to be supplied to the system whenever the on-board electrolyte is completely utilized.
  • the practical size of an aluminum air battery with a capacity of 500 kWh is considered.
  • This system carries enough energy for 4,000 km of driving.
  • This system requires 1000 liters of electrolyte in order to utilize all the energy of the aluminum. It is only after using 500 kWh of energy from the aluminum, that new aluminum anode has to be loaded into the battery.
  • 10 batches of 100 liters of electrolyte need to be used, each allowing a driving range of 400 km. This requires the ability to load the battery with fresh electrolyte after every 400 km of driving.
  • the infrastructure required for this is similar to that of gasoline stations, where electrolyte has to be transported into distant loading points.
  • the practical size of an aluminum air battery with a capacity of 500 kWh is considered.
  • This system carries enough energy for 4,000 km of driving.
  • This system requires 1000 liters of electrolyte in order to utilize all the energy of the aluminum. It is only after using 500 kWh of energy from the aluminum, that new aluminum anode has to be loaded into the battery.
  • 10 batches of 100 liters of electrolyte need to be used, each allowing a driving range of 400 km. This requires the ability to generate fresh electrolyte after every 400 km of driving.
  • Each 400 km the system is refilled with water for generating electrolyte for the next 400 km.
  • Each 800 km the system is refilled with saturated electrolyte or solid for generating electrolyte for the next 800 km
  • the battery carries enough energy for 4,000 km of driving.
  • This battery requires 1000 liters of electrolyte in order to utilize all the energy of the aluminum.
  • 10 batches of 100 liters of electrolyte need to be used, each allowing a driving range of 400 km. This requires the ability to generate 100 liters of fresh electrolyte after every 400 km of driving.
  • systems and methods of this invention enable the generation of ten batches of 100 liters of electrolyte.
  • systems of the invention provide saturated electrolyte tank and a diluted electrolyte tank.
  • saturated electrolyte is transferred to the dilution tank and diluted by water to the concentration required by the battery.
  • the diluted electrolyte is then transferred to the battery.
  • water needs to be added to the dilution tank from a liquid source placed on the vehicle or external to the vehicle (e.g. at home or at a road-side station).
  • the 100 liters of electrolyte in the battery need to be replaced again, the used 100 liters is drained from the battery and the process of transferring saturated electrolyte to the dilution tank and adding water to it is repeated.
  • This process can be repeated numerous times until the saturated solution is depleted to some level or consumed.
  • the saturated solution is depleted or consumed, more water is added to the saturated solution tank to dissolve more solid and to produce more saturated solution.
  • the entire solid in the saturated solution tank is dissolved, more solid is added into the saturated solution tank.
  • preparation of diluted electrolyte solution, preparation of additional saturated solution, and refill and draining the battery electrolyte compartment and the diluted and saturated tanks can be conducted automatically in the case where the liquid source is placed on board the vehicle.
  • filling the diluted tank, the saturated tank or a combination thereof with water can be carried out manually.
  • Such process can be used for batteries of any volume and for any electrolyte concentration.
  • this invention provides an electric vehicle comprising an electrolyte production system of the invention, wherein the vehicle drives on metal air energy and wherein water is transferred to the saturated electrolyte unit, to the diluted electrolyte unit or to a combination thereof for electrolyte generation to allow additional driving range.
  • this invention provides an electric vehicle comprising an electrolyte production system of the invention, wherein the vehicle drives on metal air energy and wherein saturated electrolyte is added to said saturated electrolyte unit for electrolyte generation to allow additional driving range.
  • this invention provides an electric vehicle comprising an electrolyte production system of the invention, wherein the vehicle drives on metal air energy and wherein solid is added to the saturated electrolyte unit for generating electrolyte, to allow additional driving range.
  • the Aluminum electrode is being replaced once it is totally consumed. In another embodiment, the Al electrode is consumed within about. 4,000 km.
  • electrolyte production systems of the invention are utilized for metal air batteries in electric vehicles.
  • electric vehicles comprising electrolyte production systems of this invention comprise but are not limited to cars, trucks, motorcycles, bikes, golf carts/cars, three and four wheels mobility scooters (such as scooters for a disabled person), and toy vehicles.
  • KOH potassium hydroxide
  • solution A 30% (wt/wt) of potassium hydroxide in water was prepared.
  • solution B 4000 g of solution A were placed in a container and 1800 g of solid potassium hydroxide were added. The concentration of the resultant solution was about 51% ⁇ 1% (wt/wt) KOH in water (solution B).
  • the saturated solution tank was filled with 8623 g of material comprising mixture C, i.e. the saturated potassium hydroxide solution and solid potassium hydroxide prepared in step C.
  • the volume levels in the saturated solution tank were as follows:
  • the 8623 g of saturated potassium hydroxide solution were composed of about 6003 g potassium hydroxide and about 2619 g water.
  • the saturated solution tank ( 1 - 10 ) was a 5 liter plastic beaker.
  • the dilution tank ( 1 - 20 ) was a 2 liter plastic beaker.
  • the transfer system from the saturated solution tank to the dilution tank was a syringe.
  • the mixing of the saturated solution tank ( 1 - 40 ) was done by a circulating pump.
  • the mixing in the diluted solution tank ( 1 - 50 ) was done by a magnetic stirrer. No heat exchangers were used in this experiment.
  • Monitoring the concentration ( 1 - 80 a,b ) was performed by a titration apparatus.
  • the replenishing liquid for the saturated solution tank was DI water.
  • the dilution liquid for the dilution tank was DI water. No special system was used for transferring the prepared electrolyte from the dilution tank to the consumer. The system was operated in a batch mode.
  • the system was “refueled” by adding more solid potassium hydroxide into the saturated solution tank. 4000 g of solid KOH was added. This solid was composed of ⁇ 3600 g of potassium hydroxide, and ⁇ 400 g of water.
  • the levels in the tank were 0 to ⁇ 3500 cc of solid, and ⁇ 3500 cc to ⁇ 4500 cc of solution.
  • Electrolyte for Aluminum-Air Battery that Propels an Electric Vehicle
  • KOH potassium hydroxide
  • the initial state of the saturated solution of the electrolyte production system is considered as including 90.3 kg of KOH.
  • the initial state of the saturated solution of the electrolyte production system is considered as including 90.3 kg of KOH, and 44.1 liters of water, and the dilution liquid tank included 50 liters of water.
  • the solution in the saturated solution tank has a concentration of 52%, and 47.7 Kg of KOH is dissolved in it.
  • the rest of the KOH (42.6 kg) is in a solid form, at the bottom of the tank as precipitate.
  • the electrolyte is used as described in table 3:
  • the system allows the vehicle to drive on electric power with loading of water after every 400 km driven, solid KOH every 800 km, and solid aluminum every 4,000 km
  • Benefits of this system include but are not limited to:

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EP3138152B1 (de) 2014-04-29 2018-10-03 Mahle International GmbH Metall-luft-batterie
DE102014208044A1 (de) 2014-04-29 2015-10-29 Mahle International Gmbh Metall-Luft-Batterie
DE102014208047A1 (de) 2014-04-29 2015-10-29 Mahle International Gmbh Anode und Elektrolyt für eine Metall-Luft-Batterie
US9561737B2 (en) 2014-06-27 2017-02-07 Electro-Motive Diesel, Inc. Mobile aluminum-air battery power system
GB2554724A (en) * 2016-10-06 2018-04-11 Ford Global Tech Llc Metal-air battery for a vehicle

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EP2834871A4 (en) 2015-09-23
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US11515574B2 (en) 2022-11-29
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US20200185801A1 (en) 2020-06-11
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DK2834871T3 (en) 2018-10-22
CA2869370A1 (en) 2013-10-10

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