US3514334A - Method of maintaining aluminum in contact with molten alkali-metal hydroxides and carbonates - Google Patents

Method of maintaining aluminum in contact with molten alkali-metal hydroxides and carbonates Download PDF

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US3514334A
US3514334A US691912A US3514334DA US3514334A US 3514334 A US3514334 A US 3514334A US 691912 A US691912 A US 691912A US 3514334D A US3514334D A US 3514334DA US 3514334 A US3514334 A US 3514334A
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aluminum
carbonates
medium
molten
alkali
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Robert L Novack
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Prototech Inc
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Prototech Inc
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    • CCHEMISTRY; METALLURGY
    • C23COATING 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
    • C23FNON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F15/00Other methods of preventing corrosion or incrustation
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/14Fuel cells with fused electrolytes
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30Hydrogen technology
    • Y02E60/50Fuel cells

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  • ABSTRACT OF THE DISCLOSURE This disclosure deals with the discovery that aluminum can be maintained in continuous contact with molten alkali-metal hydroxide and carbonate media without corrosive attack, by appropriate initial preparation of and maintenance of the molten media in a substantially anhydrous state, while insuring such contact only in such state.
  • the present invention relates to methods of and apparatus for containing alkali-metal hydroxides and carbonates, being more specifically directed to a discovery that enables the utilization of aluminum for such purposes without the corrosive attack thereof.
  • An object of the present invention is to provide a new and improved aluminum container and/ or contacting element for alkali-metal hydroxides and carbonates and a new and improved method of rendering aluminum resistant to corrosive attack by such hydroxides and carbonates at elevated temperatures.
  • an aluminum cup is shown at :1, used for a purpose heretofore considered impossible; namely, as a container for a molten alkali-metal hydroxide or carbonate medium 5 comprising the electrolytic medium of a fuel cell.
  • a tubular Ag-Pd anode 3 is shown disposed in contact with the electrolytic medium 5 for passing, for example, hydrogen fuel into the cell; and a nickel or other cathode electrode 7 is shown disposed in the electrolytic medium 5, in this case operable with the oxidant provided by the apparent conversion of molten hydroxide, for example, into peroxide or superoxide in the region of the cathode 7.
  • cathodes including porous cathodes through which oxidant may be introduced from an external source, may be employed, as may other anodes.
  • oxidant may be introduced from an external source
  • the support 7 for the cathode electrode may also, if desired, be of aluminum, as may the tubular support 3 for the anode 3. In connection with the latter, this is most unusual since aluminum is one of the few metals which is not active as a cathode in peroxide-containing melts and can thus be used at the anode.
  • an aluminum cup 1, 2 /2 inches in diameter by about 4 inches deep has been successfully operated for several months as the container for a potassium hydroxide molten electrolytic medium 5 maintained at a temperature in the before-mentioned temperature range, and intermittently operated as a fuel cell in accordance with the construction illustrated in the drawing; all with no noticeable attack upon the aluminum with its oxide coating.
  • Similar results have also been obtained by immersing aluminum in molten lithium, potassium and sodium carbonates maintained at the above-mentioned temperatures to provide the said substantial equilibrium and anhydrous condition.
  • Other alkali-metal molten hydroxides, including sodium have also been so used with aluminum, all with successful resistance of the aluminum to the molten baths.
  • the invention is not restricted to application in the important fuel cell field, but it is widely applicable wherever it is desired to contact aluminum with such molten alkali-metal hydroxides and carbonates.
  • a method of maintaining an aluminum member in contact with an electrolytic medium consisting essentially of at least one of the group constituted by alkali-metal hydroxides and carbonates, said medium being normally corrosive to said member, and of preventing corrosive attack upon said member by said medium during the utilization of said member, which comprises elevating the temperature of said medium to a temperature sufficient to render the same molten, maintaining said medium at such elevated temperature for a time sufiicient to cause the molten medium to become anhydrous, and continuously maintaining the anhydrous condition of said medium during the utilization of said member and while said member is maintained in contact with said medium.
  • a method of operating an electrochemical cell including the following elements: a cell container, a cell electrode, a support for a cell electrode, and an element for introducing gas into the cell, at least one of said elements being an aluminum member, and of preventing corrosive attack upon said member by a normally corrosive electrolytic medium which contacts said member, said medium consisting essentially of at least one of the group constituted by alkali-metal hydroxides and carbonates, which comprises elevating the temperature of said medium to a temperature sufiicient to render the same molten, maintaining said medium at such elevated temperature for a time sufiicient to cause the molten medium to become anhydrous, and continuously maintaining the anhydrous condition of said medium during the utilization of said member and while said member is in contact with said medium.
  • ALLEN B. CURTIS Primary Examiner H. A. FEELEY, Assistant Examiner US. Cl. X.R. l36-l6l; 204-39

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  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
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  • Sustainable Energy (AREA)
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  • Organic Chemistry (AREA)
  • Fuel Cell (AREA)

Description

May 26, 1970 R. L. NOVACK 3,514,334
METHOD OF MAINTAINING ALUMINUM IN CONTA WI MOLTEN ALKALI-METAL HYDROXI CAR A" Original Filed e 1966 ML UM/A/UM/ MOLTE/V AL/(AU-MEML HYDROX/DE &
ROBERT L. NOVACK, INVENTOR ATTORNEYS United States Patent 3,514,334 METHOD OF MAINTAINING ALUMINUM IN CONTACT WITH MOLTEN ALKALI-METAL HYDROXIDES AND CARBONATES Robert L. Novack, Arlington, Mass., assignor to Prototech Incorporated, Cambridge, Mass., a corporation of Massachusetts Continuation of application Ser. No. 376,917, June 22, 1964. This application Dec. 19, 1967, Ser. No. 691,912 Int. Cl. H01m 27/00 US. Cl. 136-86 4 Claims ABSTRACT OF THE DISCLOSURE This disclosure deals with the discovery that aluminum can be maintained in continuous contact with molten alkali-metal hydroxide and carbonate media without corrosive attack, by appropriate initial preparation of and maintenance of the molten media in a substantially anhydrous state, while insuring such contact only in such state.
This application is a continuation of application 376,- 917 filed June 22, 1964, now abandoned.
The present invention relates to methods of and apparatus for containing alkali-metal hydroxides and carbonates, being more specifically directed to a discovery that enables the utilization of aluminum for such purposes without the corrosive attack thereof.
It has long been accepted that aluminum is readily attacked in aqueous alkali-metal hydroxide solutions, forming a precipitate of aluminum hydroxide or forming aluminates. Similarly, the ready dissolution of aluminum in hot concentrated solutions of alkali-metal carbonates, such as sodium carbonate, has long been known. As a result, the art has considered aluminum a most unsatisfactory metal for use in systems in which it must come into contact with alkali-metal hydroxides or carbonates. In the alkali electrolyte fuel cell field, for example, it has even been reported that aluminum cannot stand up to such electrolyte, particularly at elevated temperatures.
In accordance with the present invention, however, a discovery has been made that, under certain very critical conditions, aluminum may not only withstand attack from alkali-metal hydroxides and carbonates, but it may be beneficially used even as a container for such hydroxides and carbonates and even at elevated temperatures.
An object of the present invention, therefore, is to provide a new and improved aluminum container and/ or contacting element for alkali-metal hydroxides and carbonates and a new and improved method of rendering aluminum resistant to corrosive attack by such hydroxides and carbonates at elevated temperatures.
Other and further objects, including applications to novel fuel cells and the like, will be explained hereinafter and will be more particularly pointed out in connection with the appended claims.
The invention will now be described in connection With the accompanying drawing, the single figure of which illustrates a preferred use of aluminum in a molten alkali-metal hydroxide or carbonate fuel cell or the like.
It has been discovered that if molten alkali-metal hydroxides and carbonates are maintained at temperatures between about 300 C. and 500 C., more or less, and the water content thereof is allowed to decrease until it approaches substantial equilibrium with the moisture in the air or other medium surrounding the melt, aluminum, preferably substantially pure (although aluminum with some impurities and alloys thereof have been found to exhibit some of the resistant characteristics herein 3,514,334 Patented May 26, 1970 ice described), can be placed in direct and continuous contact with the molten alkali-metal hydroxides and carbonates without suffering any appreciable corrosion.
While it is not desired to predicate the invention upon a theory or hypothesis of operation, it being sufiicient to describe the invention as it has been found to work in practice, it appears that the clue to rendering aluminum resistive to alkali-metal hydroxides and carbonates resides in the temperature elevation to the point of driving 013? the water therein sufficiently to attain the substantial equilibrium above-discussed, and the maintenance of the molten alkali-metal hydroxide and/or carbonate in the molten state. Physically, such molten hydroxide and carbonate assumes a substantially clear form when this region of substantial equilibrium is reached. It is this substantially anhydrous molten alkali hydroxide or carbonate that apparently no longer attacks the base metal of the aluminum with whatever oxide coating may be formed thereupon.
Thus, in the embodiment of the drawing, an aluminum cup is shown at :1, used for a purpose heretofore considered impossible; namely, as a container for a molten alkali-metal hydroxide or carbonate medium 5 comprising the electrolytic medium of a fuel cell. In this embodiment, a tubular Ag-Pd anode 3 is shown disposed in contact with the electrolytic medium 5 for passing, for example, hydrogen fuel into the cell; and a nickel or other cathode electrode 7 is shown disposed in the electrolytic medium 5, in this case operable with the oxidant provided by the apparent conversion of molten hydroxide, for example, into peroxide or superoxide in the region of the cathode 7. It is, of course, to be understood that other types of cathodes, including porous cathodes through which oxidant may be introduced from an external source, may be employed, as may other anodes. In the case of the utilization of non-porous nickel, iron or similar cathode electrodes 7, however, operating with the peroxide or superoxide oxidant, it is in some cases desirable to introduce agitation in the region of the cathode, as by blowing air therein. This is illustrated as effected with an inexpensive aluminum tube 9, which, by operation of the cell 5 in the before-described temperature region to a degree such that the water within the medium 5 is decreased until it approaches equilibrium where the water content in the air at the top of the medium 5 (i.e. substantially anhydrous), is rendered resistant to attack by the medium 5.
The support 7 for the cathode electrode may also, if desired, be of aluminum, as may the tubular support 3 for the anode 3. In connection with the latter, this is most unusual since aluminum is one of the few metals which is not active as a cathode in peroxide-containing melts and can thus be used at the anode.
As an example of actual experimental results, an aluminum cup 1, 2 /2 inches in diameter by about 4 inches deep, has been successfully operated for several months as the container for a potassium hydroxide molten electrolytic medium 5 maintained at a temperature in the before-mentioned temperature range, and intermittently operated as a fuel cell in accordance with the construction illustrated in the drawing; all with no noticeable attack upon the aluminum with its oxide coating. Similar results have also been obtained by immersing aluminum in molten lithium, potassium and sodium carbonates maintained at the above-mentioned temperatures to provide the said substantial equilibrium and anhydrous condition. Other alkali-metal molten hydroxides, including sodium, have also been so used with aluminum, all with successful resistance of the aluminum to the molten baths.
Clearly, the invention is not restricted to application in the important fuel cell field, but it is widely applicable wherever it is desired to contact aluminum with such molten alkali-metal hydroxides and carbonates.
Further modifications will occur to those skilled in the art, and all such are considered to fall within the spirit and scope of the invention as defined in the appended claims.
What is claimed is:
1. A method of maintaining an aluminum member in contact with an electrolytic medium consisting essentially of at least one of the group constituted by alkali-metal hydroxides and carbonates, said medium being normally corrosive to said member, and of preventing corrosive attack upon said member by said medium during the utilization of said member, which comprises elevating the temperature of said medium to a temperature sufficient to render the same molten, maintaining said medium at such elevated temperature for a time sufiicient to cause the molten medium to become anhydrous, and continuously maintaining the anhydrous condition of said medium during the utilization of said member and while said member is maintained in contact with said medium.
2. A method as claimed in claim 1 and in which the temperature of said medium is raised to the range substantially 300 degrees to 500 degrees C.
3. A method of operating an electrochemical cell including the following elements: a cell container, a cell electrode, a support for a cell electrode, and an element for introducing gas into the cell, at least one of said elements being an aluminum member, and of preventing corrosive attack upon said member by a normally corrosive electrolytic medium which contacts said member, said medium consisting essentially of at least one of the group constituted by alkali-metal hydroxides and carbonates, which comprises elevating the temperature of said medium to a temperature sufiicient to render the same molten, maintaining said medium at such elevated temperature for a time sufiicient to cause the molten medium to become anhydrous, and continuously maintaining the anhydrous condition of said medium during the utilization of said member and while said member is in contact with said medium.
4. A method as claimed in claim 3 and in which a fuel and an oxidant are introduced into said medium at fuel and oxidant electrodes therein, respectively, an output current is drawn in a circuit connected to said fuel and oxidant electrodes, and said corrosive attack is prevented during the drawing of said current.
References Cited UNITED STATES PATENTS 2,969,315 1/1961 Bacon 136-86 3,138,490 6/1964 Tragert 13686 3,202,547 8/1965 Rightmire et a1. 136-86 3,251,718 5/1966 Hilton 13686 2,244,526 6/ 1941 Mackay 1486.11 3,146,131 8/1964 Linden et a1. 13686 3,294,586 12/1966 Le Duc 136-86 FOREIGN PATENTS 100,100 3/ 1933 Japan.
ALLEN B. CURTIS, Primary Examiner H. A. FEELEY, Assistant Examiner US. Cl. X.R. l36-l6l; 204-39
US691912A 1967-12-19 1967-12-19 Method of maintaining aluminum in contact with molten alkali-metal hydroxides and carbonates Expired - Lifetime US3514334A (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4160067A (en) * 1978-03-13 1979-07-03 Institute Of Gas Technology Molten carbonate fuel cell corrosion inhibition
US4797379A (en) * 1982-08-19 1989-01-10 Energy Research Corporation Electrode structure and method of making same

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2244526A (en) * 1934-11-01 1941-06-03 Rust Proofing Company Of Canad Process of treating metal surfaces
US2969315A (en) * 1956-08-23 1961-01-24 Era Patents Ltd Bipolar electrode for electric batteries
US3138490A (en) * 1961-02-28 1964-06-23 Gen Electric Fuel cell
US3146131A (en) * 1961-03-20 1964-08-25 Inst Gas Technology Appliance for production of direct electric current
US3202547A (en) * 1961-08-04 1965-08-24 Standard Oil Co Electrochemical reaction apparatus
US3251718A (en) * 1961-10-26 1966-05-17 Texas Instruments Inc Screen type fuel cell with foraminous electrolyte carrier
US3294586A (en) * 1962-03-01 1966-12-27 Pullman Inc Fuel cell with movable casing and electrodes and method for operating fuel cell withan anode containing an alkaline earth metal

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2244526A (en) * 1934-11-01 1941-06-03 Rust Proofing Company Of Canad Process of treating metal surfaces
US2969315A (en) * 1956-08-23 1961-01-24 Era Patents Ltd Bipolar electrode for electric batteries
US3138490A (en) * 1961-02-28 1964-06-23 Gen Electric Fuel cell
US3146131A (en) * 1961-03-20 1964-08-25 Inst Gas Technology Appliance for production of direct electric current
US3202547A (en) * 1961-08-04 1965-08-24 Standard Oil Co Electrochemical reaction apparatus
US3251718A (en) * 1961-10-26 1966-05-17 Texas Instruments Inc Screen type fuel cell with foraminous electrolyte carrier
US3294586A (en) * 1962-03-01 1966-12-27 Pullman Inc Fuel cell with movable casing and electrodes and method for operating fuel cell withan anode containing an alkaline earth metal

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4160067A (en) * 1978-03-13 1979-07-03 Institute Of Gas Technology Molten carbonate fuel cell corrosion inhibition
US4797379A (en) * 1982-08-19 1989-01-10 Energy Research Corporation Electrode structure and method of making same

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