WO2011028233A2 - Systems and methods for sustainable economic development through integrated full spectrum production or renewable material resources using solar thermal - Google Patents

Systems and methods for sustainable economic development through integrated full spectrum production or renewable material resources using solar thermal Download PDF

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Publication number
WO2011028233A2
WO2011028233A2 PCT/US2010/002260 US2010002260W WO2011028233A2 WO 2011028233 A2 WO2011028233 A2 WO 2011028233A2 US 2010002260 W US2010002260 W US 2010002260W WO 2011028233 A2 WO2011028233 A2 WO 2011028233A2
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WIPO (PCT)
Prior art keywords
hydrogen
material resource
carbon
electrolyzer
source
Prior art date
Application number
PCT/US2010/002260
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English (en)
French (fr)
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WO2011028233A3 (en
Inventor
Roy E. Mcalister
Original Assignee
Mcalister Roy E
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Priority claimed from PCT/US2010/024498 external-priority patent/WO2010096504A1/en
Priority claimed from PCT/US2010/024497 external-priority patent/WO2010096503A1/en
Priority claimed from US12/707,656 external-priority patent/US8075749B2/en
Application filed by Mcalister Roy E filed Critical Mcalister Roy E
Priority to EP10814051.8A priority Critical patent/EP2470311A4/en
Priority to US12/857,554 priority patent/US8808529B2/en
Priority to CN201080048872.5A priority patent/CN102712020B/zh
Priority to PCT/US2010/002260 priority patent/WO2011028233A2/en
Publication of WO2011028233A2 publication Critical patent/WO2011028233A2/en
Publication of WO2011028233A3 publication Critical patent/WO2011028233A3/en

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N5/00—Exhaust or silencing apparatus combined or associated with devices profiting from exhaust energy
    • F01N5/02—Exhaust or silencing apparatus combined or associated with devices profiting from exhaust energy the devices using heat
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F03G7/00—Mechanical-power-producing mechanisms, not otherwise provided for or using energy sources not otherwise provided for
    • F03G7/04—Mechanical-power-producing mechanisms, not otherwise provided for or using energy sources not otherwise provided for using pressure differences or thermal differences occurring in nature
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    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/22—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by decomposition of gaseous or liquid organic compounds
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    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
    • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
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    • C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
    • C10L3/06—Natural gas; Synthetic natural gas obtained by processes not covered by C10G, C10K3/02 or C10K3/04
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    • C25B1/00—Electrolytic production of inorganic compounds or non-metals
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    • 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
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21C—MINING OR QUARRYING
    • E21C50/00—Obtaining minerals from underwater, not otherwise provided for
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02G—HOT GAS OR COMBUSTION-PRODUCT POSITIVE-DISPLACEMENT ENGINE PLANTS; USE OF WASTE HEAT OF COMBUSTION ENGINES; NOT OTHERWISE PROVIDED FOR
    • F02G5/00—Profiting from waste heat of combustion engines, not otherwise provided for
    • F02G5/02—Profiting from waste heat of exhaust gases
    • F02G5/04—Profiting from waste heat of exhaust gases in combination with other waste heat from combustion engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F03B—MACHINES OR ENGINES FOR LIQUIDS
    • F03B13/00—Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates
    • F03B13/12—Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates characterised by using wave or tide energy
    • F03B13/14—Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates characterised by using wave or tide energy using wave energy
    • F03B13/16—Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates characterised by using wave or tide energy using wave energy using the relative movement between a wave-operated member, i.e. a "wom" and another member, i.e. a reaction member or "rem"
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    • F03B13/1885—Adaptations of machines or engines for special use; Combinations of machines or engines with driving or driven apparatus; Power stations or aggregates characterised by using wave or tide energy using wave energy using the relative movement between a wave-operated member, i.e. a "wom" and another member, i.e. a reaction member or "rem" where the other member, i.e. rem is fixed, at least at one point, with respect to the sea bed or shore and the wom is tied to the rem
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    • F03G3/00—Other motors, e.g. gravity or inertia motors
    • F03G3/08—Other motors, e.g. gravity or inertia motors using flywheels
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    • H01M8/0656—Combination of fuel cells with means for production of reactants or for treatment of residues with means for production of gaseous reactants by electrochemical means
    • H—ELECTRICITY
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    • H01M8/184—Regeneration by electrochemical means
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    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
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    • C01B2203/0211—Processes for making hydrogen or synthesis gas containing a reforming step containing a non-catalytic reforming step
    • C01B2203/0216—Processes for making hydrogen or synthesis gas containing a reforming step containing a non-catalytic reforming step containing a non-catalytic steam reforming step
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Definitions

  • Prior art waste-to-energy technologies provide severely limited capabilities if not counterproductive results for overcoming the growing problem of climate changes due to greenhouse gas accumulations in the global atmosphere. In summary, prior art technologies are too expensive, too wasteful, and too polluting.
  • a system for providing a renewable source of material resources comprising: a first source of renewable energy; first stream of materials from a first materials source; an electrolyzer coupled to the first source of renewable energy and the first stream of materials, wherein the electrolyzer is configured to produce a first material resource by electrolysis; a processor for further processing or use or the material resource to produce a second material resource, wherein the processor comprises a solar collector and where the solar collector is configured to provide heat to the first materials resource for disassociation; and a material resource storage coupled to the electrolyzer for receiving the material resource from the electrolyzer or providing the material resource to the processor for further processing or use.
  • a system for providing a renewable source of material resources comprising: a first source of renewable energy; first stream of materials from a first materials source; an electrolyzer coupled to the first source of renewable energy and the first stream of materials, wherein the electrolyzer is configured to produce a first material resource by electrolysis; a processor for further processing or use or the material resource to produce a second material resource, wherein the processor comprises a solar collector and where the solar collector is configured to provide heat to the first materials resource for disassociation; and a material resource storage coupled to the electrolyzer for receiving the material resource from the electrolyzer or providing the material resource to the processor for further processing or use.
  • a method for providing a renewable source of a material resource comprising: providing a first source of renewable energy; providing a first stream of materials from a first materials source; providing an electrolyzer coupled to the first stream of materials and the first source of renewable energy, wherein the electrolyzer produces a material resource from the first stream of materials through electrolysis, and providing the material resource to a first processor for further processing or use.
  • FIG 1 depicts process steps of the invention.
  • FIG 2 is a longitudinal sectional view of an embodiment that operates in accordance with the principles of the present invention.
  • FIG 3 is a longitudinal section of a magnified view of a portion of an embodiment of a component provided in Figure 1.
  • FIG 4 is a sectional view of an embodiment that operates in accordance with the principles of the invention.
  • FIG 5 is a partial sectional view of an embodiment that operates in accordance with the principles of the invention.
  • FIG 6 depicts process steps for operation in accordance with the principles of the invention.
  • FIG 7 is a schematic view of an embodiment that operates in accordance with the principles of the invention.
  • FIG 8 depicts operations in accordance with the principles of the invention.
  • FIG 9 depicts components that operate in accordance with the principles of the invention.
  • FIG 10 is a schematic of embodiments of the invention.
  • FIGS 12-15 are flowcharts of various embodiments in accordance with aspects of the disclosure.
  • FIG IB shows an electrolytic cell in accordance with an embodiment of the present invention.
  • FIG 2B shows a magnified view of a portion of the embodiment of Figure 1.
  • FIG 3B shows a variation of the embodiment of Figure 2.
  • FIG 4B shows an electrolytic cell in accordance with an embodiment of the present invention.
  • FIG 5B a magnified view of an alternative embodiment for a portion of electrolytic cell of Figure 4.
  • FIG 6B shows a cross-section of a spiral electrode for use in a reversible fuel-cell.
  • FIG 7B shows a system for converting organic feedstocks such as those produced by photosynthesis into methane, hydrogen, and or carbon dioxide.
  • FIG 8B shows a system for converting organic feedstocks such as those produced by photosynthesis into methane, hydrogen, and or carbon dioxide.
  • FIG 9B shows a system for converting organic feedstocks such as those produced by photosynthesis into methane, hydrogen, and or carbon dioxide.
  • FIG 10B shows a method for manufacturing an electrode in accordance with an embodiment of the disclosure..
  • Patent Applications filed concurrently herewith on August 16, 2010 and titled: METHODS AND APPARATUSES FOR DETECTION OF PROPERTIES OF FLUID CONVEYANCE SYSTEMS (Attorney Docket No. 69545-8003US);
  • FIG. 1 shows a process 16 in which biomass including municipal, farm, and forest wastes such as forest slash and diseased and/or dead trees are cut, pulled, or otherwise harvested and delivered at step 2.
  • biomass wastes are chipped or otherwise subdivided into bits and pieces for the purpose of efficient transport and compaction by a conveyer such as a belt, ram, or screw conveyer.
  • a conveyer such as a belt, ram, or screw conveyer.
  • step 6 subdivided biomass wastes are dried and converted by regenerative dissociation to produce
  • Step 8 provides for separation of vapors and gases such as methane and or hydrogen from carbon dioxide.
  • Step 10 provides for shipment of typically methane-rich gases by pipelines or other transport methods such as those utilized by the natural gas industry.
  • Step 12 provides for production of hydrogen and carbon products from such pipeline deliveries of methane-rich gases.
  • Step 14 provides use of hydrogen in engines and/or fuel cells to power motor vehicles, to provide heat, for shaft work and electricity generation, for chemical process applications, and to produce fertilizers.
  • Job development and investor confidence is bolstered by establishment of renewable sources of methane that can be delivered by low cost transport through pipelines. Further improvement is provided by development of the "carbon age” that is facilitated by conversion of methane to carbon products as hydrogen is used for clean energy applications.
  • Figure 2 shows embodiment 200 of method and apparatus for regeneratively producing methane and/or hydrogen by dissociation of biomass in which subdivided materials such as various cellulosic materials and lignocellulosic tissues are de-aired, dried, and heated to release the desired gases as shown.
  • the system of Figure 2 provides important improvements in thermal efficiency and depression of carbon dioxide formation. These improvements are provided by countercurrent drying and elimination of air, moisture, and other oxygen donors prior to extraction of carbon, hydrocarbons such as methane, and/or hydrogen as designated in the process train shown in Figure 1.
  • Ultimately such wastes are heated sufficiently in an anaerobic environment to release desirable gases, carbon, and solid residues such as mineral oxides and other compounds.
  • Equation 1 The process is summarized by Equation 1, which is not balanced for any particular type, amount, or ratio of lignin, cellulose, or other biomass feedstock. Therefore, Equations 1 and 2 generalize the versatility of the process shown in Figure 1 and illustrate the qualitative conversion of organic feedstocks that contain carbon, hydrogen, and oxygen into valuable supplies of methane, hydrogen, and sequestered carbon.
  • FIG. 2 Shown in Figure 2 is a system embodiment for rapid conversion of biomass wastes into gases such as methane, hydrogen, carbon dioxide and carbon monoxide.
  • rotating tube 214 is driven by suitable speed reduction system 204 and 206 by engine 202 which may be a rotary, piston, or turbine engine depending upon the size of the system and throughput desired.
  • Engine 202 is preferably fueled by the fuel conditioning, injection, and ignition system 220 as disclosed in the U.S. Patent Application 08/785,376, which is incorporated herein. Waste heat from the engine cooling system and/or exhaust gases is preferably transferred to materials in hopper 250 by countercurrent turns of helical heat exchange tubing 244 and 245 that are joined to hopper 250 at respective zones that derive the maximum amount of heat recovery from engine 202.
  • speed reduction components such as sprockets and chain or drive gear 206 and bearing support assembly 208 and 212 are
  • Rotating tube 214 is supported similarly and thermally isolated at the opposite end by insulated bearing and support assembly 224 and 226 as shown.
  • Insulator pack 230 provides insulation to prevent radiative and conductive heat gain by bearing 212 and other areas where protection from heat is desired.
  • a relatively small portion of the methane and/or hydrogen and/or carbon monoxide generated as summarized by Equations 1 and 2 is delivered to engine 202 and to the burner nozzle of combustor assembly 220 through control valve 222 as shown in Figure 2. Sufficient air is provided to assure complete combustion of fuel values that are present with minimal objectionable emissions in both applications. Hot products of combustion are circulated past spiral heat exchange tubing 216 for the purpose of transferring heat to organic materials that travel in counterflow direction by extrusion action of fins 218 on the exterior of rotating tube 214 as shown.
  • the overall process of the invention will also be achieved by other material conveyance and compaction means and will be facilitated in some applications by a unidirectional ram delivery and compaction system instead of by the helical conveyer shown.
  • the essential steps being accomplished by compaction and heat addition to eliminate air and moisture, creating a plug seal of advancing material derived from the feedstock, heating the advancing material to achieve the desired pressure and temperature conditions for dissociation to produce the desired chemical derivatives selected from substance options such as carbon, one or more vaporous hydrocarbons, fuel alcohols, and gases such as ethane, methane, hydrogen, and oxides of carbon, extraction of the desired chemical species in a zone that utilizes derivatives and/or remnants of the advancing material to seal or help seal the zone that provides for removal of desired chemical species.
  • Relatively extended operation can be provided with greatly reduced carbon production as may be preferred for purposes of achieving desired carbon to hydrogen ratios of the chemical species produced.
  • This extended operation can be provided on an intermittent basis, such as between times that carbon is intentionally produced to aid in sealing the zone before collection of desired chemical species and/or the zone after such collection.
  • This is a feature of some embodiments of the invention and it enables carbon to be transported as a constituent of fluids that are delivered by pipeline to storage including repressurization of depleted natural gas reservoirs, to industrial plants for making carbon- enhanced durable goods, and for other purposes. After successive expulsion of air and moisture biomass material is converted to the product gases shown in Equation 1 and a much lower volume of solid residues.
  • the amount of solid residue is about 2 to 10% of the original mass of organic waste.
  • Such residues are important sources of trace minerals that are preferably utilized to revitalize soils and assure rapid growth of replacement stands of healthy forests, gardens, aquaculture, and/or other groundcover. This expedites greenhouse gas reduction, sequestration of carbon and hydrogen, and economic development. Reforested areas serve as sustainable sources of lignocelluloses for continued production of renewable methane, hydrogen and sequestered carbon as disclosed herein.
  • combustion gases from burner assembly 220 may be circulated within tubular flights 216 which are constructed to connect through holes in tube 214 with helical flight tubes 218 to provide for more rapid transfer of heat from combustor 220 to feedstock materials progressing along the outside of flights 218 within containment tube 236.
  • Gases such as methane, hydrogen and carbon dioxide that are released from heated organic feedstocks by the thermal dissociation process are allowed to pass into annular space between helical fins 238 and insulated tube 241 to flow in countercurrent direction to the flow of feedstock being heated by rotating tube assembly 214. This provides for further heat conservation as heat is regeneratively added to feedstocks within tube 236 that are progressively compacted and dissociated by heat transfer to enhance pressure production as shown.
  • Combustion gases such as water vapor, nitrogen, oxygen, and carbon dioxide reaching the hopper area by travel through the interior of tube 214 and/or tubular fins 216 and/or 218 enter helical heat transfer tubing 246 to provide further countercurrent energy addition to feedstock materials progressing through hopper 250 as shown.
  • Gases that are produced such as methane, hydrogen and carbon dioxide and/or carbon monoxide reaching the area of hopper 250 by passage through holes 230 and the annular area between tube 236 and tube 241 and/or hollow fin 238 are circulated through tubing 248 which is wound adjacent to helical tubing 246 for efficient countercurrent heat transfer to materials progressing to rotating tubular screw conveyer 214 as shown. Insulation 242 and 260 prevent heat loss to the outside.
  • Mixtures of product gases such as carbon dioxide and carbon monoxide that may be produced are separated from methane and/or hydrogen by pressure swing or temperature absorption and/or the system shown in Figure 4. Such mixtures of product gases are provided at a suitable margin above the desired pressure by controlling the speed of rotation of rotary conveyer 214 and thus the compaction of solids that are delivered to the thermal dissociation stage.
  • pressure sensor 270 sends pressure data to process controller 272 for maintaining the speed of feed conveyer 256, extrusion conveyer 214, and the heat rate of combustor assembly 220 to achieve desired throughput, conversion temperature, and pressure of delivered product gases.
  • Pressure regulator 274 provides the final adjustment of product gas delivery from regenerative converter 200.
  • One aspect of the present disclosure is conversion of low cost heat into potential energy as stored energy and the utilization of such pressure to facilitate separation processes, and energy regeneration. Pressurized mixtures are separated while retaining desirable pressurization of selected gases. Such pressurized supplies of refined quality gas are used to power engines including internal combustion engines and engines with external heat supplies.
  • Such energy conversion, refinement and pressurization are also utilized to deliver refined gases to distant markets by pipeline or pressurized tank cars or by
  • an embodiment of the present invention provides self-reinforcing structures of tubular construction. Strengthening is provided by helical reinforcement structures that combine heat exchange, strengthening, rigidizing, conveying, and heat resisting benefits in modular structures that can be built by rapid assembly processes. This greatly expedites deployment of the remedies needed in waste management and reduces the delivered system cost compared to past approaches.
  • This provides for efficient separation of carbon compounds such as carbon dioxide or carbon monoxide from gases such as methane and/or hydrogen.
  • Mixtures of product gases are delivered through tube 404 as shown in Figure 4 to be exposed to water or other absorber fluid selections in pressure vessel 402 for selective separation of carbon dioxide and/or carbon monoxide.
  • Methane and/or hydrogen are thus delivered to collection tube 408 at the pressure maintained in pressure vessel 402.
  • the pressurized absorption fluid is delivered by 410 to nozzle manifold 426 for delivery to heat exchangers such as 414, 416, 418, 420, 422, 424, etc., as shown where heat from the exhaust of engine 202 may be delivered to the heat exchangers shown along with heat released by combustion by burner 444 of portions of the produced gas along with waste gases such as carbon monoxide that is released through 458 by subsequent expansion of the pressurized fluid. Additional heat may also be supplied by solar collector 442 or by resistance or induction heaters using wind or wave energy where such resources are abundant.
  • Heated fluids are then expanded across turbines 430, 432, 434, 436, 438, 440, etc., as shown for recovery and/or conversion of energy to further improve overall efficiency.
  • Additional improvements in overall efficiency are provided for generation of electricity by a suitable generator such as alternator 280 and/or alternator 428. It is preferable to utilize hydrogen to cool these generators and reduce windage losses. After perfuming these functions, hydrogen is then used to fuel engine 202 or as a carbon-free fuel in combustor 444 and/or 220.
  • Equation 3 A general summary of the overall reactions for production of methane from typical organic wastes such as glucose, lignin, and cellulosic feedstocks by the embodiments described is shown in Equation 3.
  • This chemical process variation is favored in instances that it is desired to rapidly convert damaged forests into pressurized supplies of methane, ethane, and hydrogen that are shipped to distant market by pipeline and to then utilize the pipeline to continue delivery of such gases at reduced rates as a function of desired rates of forest thinning, scheduled harvesting, and maintenance programs.
  • Pipeline capacity established by this approach becomes an important storage system for meeting daily and seasonal variations in market demand. It is generally desired for the resultant pipeline gas to provide about 900 BTU/scf., after removal of carbon dioxide, particulates, ash, sulfur dioxide, and water by the embodiments of Figure 2 and Figure 4. [0061] With most wastes, the initial output without recycling hydrogen ranges from
  • the gas mixture produced by operation of the embodiment of Figure 2 at approximately 1,000 PSI and 1025°F (69 Atmospheres, 550°C) varies as shown in Table 1 with the type of wastes being converted, the dwell time, and related parameters of operation.
  • a new formulation provides for compression ignition to replace diesel fuel and includes adsorbed hydrogen in activated carbon suspensions in methanol.
  • Such gas mixtures are be rapidly produced and can be supplemented with higher energy constituents such as methanol, carbon suspensions in methanol, or propane etc., to achieve virtually any desired energy content of the resulting hydrogen-combustion characterized combustion mixture in combined fuel applications. It is often desired to redirect hydrogen and/or methane produced by the reaction into the reaction zone by injection through manifold 239 at a rate sufficient to produce the desired ratios of methane and ethane to provide pipeline quality gas or feedstocks for chemical synthesis.
  • methanol as a readily storable and transportable liquid fuel and chemical precursor from the embodiment of Figure 2.
  • Methanol or "wood alcohol” can be extracted by heating lingocellulosic wastes through partial combustion or by anaerobic heating processes. Equations 4 and 5 summarize the output of methanol that can be achieved by selection of different anaerobic operating temperatures, pressures, and catalysts.
  • Equation 6 At higher feed rates and/or lower heat release rates from combustor 220, the charge does not reach the higher temperatures that produce the gases shown in Equation 1 and thus the process produces methanol. It is preferred to separate carbon monoxide from methanol by cooling the methanol vapors to form liquid methanol and to utilize the separated carbon monoxide to fuel engine 202, to release heat through combustion by burner assembly 220, and to form hydrogen by the reaction with water as summarized in Equation 6.
  • Hydrogen produced by the reaction summarized in Equation 6 may be used to produce methanol as shown in Equation 5, to improve operation of engine 202, to improve the yield of methane and/or ethane in converter 200 and/or as a heating fuel in converter 200 as shown.
  • each of the reaction systems shown herein may be further improved by the use of homogeneous and heterogeneous catalysts and application of adaptive controls to improve or optimize the desired results.
  • the reaction zone between manifold 239 and gas stripper ports 240 it is contemplated to utilize catalyst selections that enhance methane and ethane formation by reactions that facilitate the action of hydrogen to build reactive components that synthesize to form such compounds.
  • Catalysts including chromia and other ceramics with rare earth constituents, the platinum metal group, nobelized nickel, and intermetallics of transition metals are applicable. This provides an unexpected and significant reduction of equipment cost and complexity compared to prior art approaches.
  • lanthanide-ruthenium preparations Fischer-Tropsch catalysts, and copper, copper intermetallics, and/or copper alloys to enhance methanol synthesis from carbon monoxide and hydrogen along with production of methanol by partial oxidation of methane.
  • Figure 3 illustrates separation of methanol from carbon monoxide and shipment of methanol to market by delivery pump 298.
  • embodiment 300 preferably incorporates vortex separation of denser from lighter components and provides for mixtures of carbon monoxide and methanol to enter vessel 302 by tube 304 from regenerative pump/motor 312.
  • Pump/motor 312 provides pumping action on such vapors if the delivery pressure is not adequate to achieve the delivery rate desired and provides recovery of pressure energy if the desired delivery pressure is less than the supply pressure from the system of Figure 2 or another suitable converter 320.
  • Cooling to condense methanol is provided by heat exchange circuit 306, which is symbolically shown and preferably utilizes ground water or cooling tower fluid as a heat sink. Water in cooling circuit 306 is preferably maintained at a higher pressure by pump 296 than the vapors that enter chamber 302 and thus any containment failure of the cooling circuit does not cause cooling water contamination. Cooling water that exits separator 302 from 324 may be used as a heated water supply or returned to the ground water system, cooling tower, or evaporation pond as appropriate for the application. After sufficiently cooling the gas mixture to create denser vapors and droplets of methanol near the walls of vessel 302, less dense carbon monoxide is extracted by central tube 308. Condensed methanol may be delivered by pump 298 for further processing to remove water and/or absorbed gases depending upon the purity desired.
  • Methanol and pipeline gas mixtures of methane, ethane, and hydrogen may be interchangeably shipped to market by the same or additional pipelines.
  • the same pipeline it is preferred to changeover from one chemical type to the other by proven technologies such as the use of a pressure propelled separation slug or by pump down to clear the pipeline before refilling with the next selection to be delivered.
  • Figure 5 illustrates an embodiment similar to the system of Figures 1 and 2 that includes a cylinder compacter 500 for conversion of biomass such as sawdust, manure, and wood chips.
  • This system operates essentially the same as the embodiment of Figure 2 except compaction of biomass is cyclically provided by a reciprocating ram.
  • Ram piston 502 is forced by hydraulic cylinder 506 to reciprocate in stationery cylinder 518 to compact biomass that has been dried and preheated by countercurrent heat exchange in hopper 250.
  • Biomass is loaded by conveyer 256 into cylinder 518 when ram 502 is in the position shown.
  • Engine 202 drives hydraulic pump 504 to deliver pressurized working fluid through lines 510 and 51 1 to actuate cylinder 506.
  • ram 502 forces the biomass into a dense charge that is further compacted as it moves around cone 512 of heater 516 which may be stationery or rotated to enhance throughput and maintain the compaction of biomass that is progressing through the conversion process.
  • Numerous tubes in positions typical to 249 allow expulsion of air and water vapor while further serving as a material check-valve to prevent backward flow of material that is advanced by the action of ram 502.
  • Countercurrent heat exchange from combustion gases from burner assembly 220 that travel through helical heat exchanger fins 216 and 218 raise the temperature of the biomass sufficiently to cause the dissociation reactions summarized in Equations 1, 3, 4, and 5 in response to coordination and control by controller 272.
  • organic materials are converted into fluids such as methane, ethane, propane, methanol, ethanol, hydrogen, hydrogen sulfide, carbon monoxide, and carbon dioxide and improved for replacement of fossil fuels by removal of objectionable levels of hydrogen sulfide, carbon monoxide, and carbon dioxide by the regenerative embodiment of Figure 4 or by another suitable selective removal process such as pressure swing absorption, temperature swing absorption, solution absorption, and membrane separation.
  • This is provided by countercurrent heat exchange from sources such as combustion of a portion of one or more fuel constituents from such fluids, heat exchange from higher temperature to lower temperature substances before, during, and after production, and by heat exchange with energy conversion devices such as internal combustion engines, external combustion engines, expansive motors, and fuel cells.
  • Figure 6 shows process steps 60 for converting methane from landfills, sewage treatment plants, waste disposal operations including those based on the embodiments of Figures 1, 2, 3, 4, and 5 along with other methane sources into hydrogen and carbon as summarized in Equation 2.
  • Hydrogen combusts seven to nine times faster compared to hydrocarbons such as gasoline, fuel alcohols, methane, and diesel fuel. This enables improved efficiency and lower carbon or no carbon emissions by turbine, rotary combustion, and reciprocating engine operations in which hydrogen or hydrogen-characterized fuels such as mixtures of hydrogen and methane, hydrogen and methanol, or hydrogen and carbon monoxide are injected and ignited.
  • Improvements in thermal efficiency by such operations are particularly important for intermittent combustion engines such as rotary combustion engines and reciprocating two- or four-stroke engines such as 202 whereby direct injection and/or ignition is provided close to, at, or after top dead center to reduce or avoid heat loss and hackwork during compression. This assures much greater efficiency in the conversion of fuel potential energy to work energy during the power stroke of the engine.
  • intermittent combustion engines such as rotary combustion engines and reciprocating two- or four-stroke engines such as 202 whereby direct injection and/or ignition is provided close to, at, or after top dead center to reduce or avoid heat loss and hackwork during compression.
  • This assures much greater efficiency in the conversion of fuel potential energy to work energy during the power stroke of the engine.
  • By combusting fast burning hydrogen-characterized fuel within surplus air in the combustion chamber considerably greater operating efficiencies are achieved compared to engines with conventional arrangements to utilize propane, natural gas or diesel fuels.
  • step 62 of Figure 6 methane that has been produced and purified to the desired degree by the embodiments of Figures 1, 2, 3, 4, and 5 is transported by bulk carrier or pipeline to a suitable destination such as an industrial park. Methane is then preheated in step 64 from ambient temperature to a suitable temperature such as about 1200°C (2200°F) by countercurrent heat exchange from hydrogen and/or carbon that is produced by dissociation. Sufficient heat addition in step 66 is provided by radiation and/or contact with a heated substance such as graphite, iron oxide, aluminum oxide, magnesium oxide, various carbides or other ceramics to cause carbon to be precipitated on or near such heated substance selections and hydrogen is released as summarized by Equation 2.
  • a heated substance such as graphite, iron oxide, aluminum oxide, magnesium oxide, various carbides or other ceramics to cause carbon to be precipitated on or near such heated substance selections and hydrogen is released as summarized by Equation 2.
  • Step 68 provides for collection of such hot hydrogen for countercurrent heat exchange with advancing methane as described regarding step 64.
  • step 70 carbon that is formed by dissociation of methane is collected as a deposit or as a powder or flake material that is stripped or exfoliated from the heated substrate used in step 66.
  • step 72 provides for a portion of the carbon and/or the hydrogen that is coproduced in step 66 to be combusted to heat or assist with heat addition to produce the desired pressure and temperature for dissociation of methane.
  • Alternative sources of heat addition for accomplishing dissociation of methane by step 66 include concentrated solar energy, electric induction heating of a conductive ceramic such as graphite or zirconium oxide, resistance heating of such substrates and radiative heating of such substrates from a suitable incandescent source, various varieties of plasma heating including plasma involving hydrogen and/or methane, and/or by combustion of a suitable fuel including the methane or the products of methane dissociation such as hydrogen and or carbon.
  • Apparatus for the method provided in steps 62, 64, 66, 68, 70, and/or 72 include various types of fluidized beds, helical screw or piston induced flow reactors, plasma chambers with carbon collection provisions and features, and improved carbon-black production furnaces.
  • Particularly important benefits of some embodiments of the invention include hydrogen production from hydrocarbons such as methane with much lower energy addition than required to dissociate water and that valuable forms of carbon are coproduced.
  • Dissociation of hydrocarbon feedstocks to produce hydrogen and products such as derived by the disclosures in the U.S. Patent Application 09/370,431 provide high combined values for carbon products and hydrogen.
  • Figure 7 shows another particularly efficient system for facilitating the method.
  • FIG. 7 shows components of a process system 700.
  • a hydrocarbon such as methane is delivered by pipe 702 to refractory tubular barrel 704 within which refractory conveyer screw 710 is rotated to move particles and/or substrate materials 71 1 of preferred geometry and size to receive carbon that is dissociated from methane and deposited or precipitated as the methane is heated by radiation, conduction etc., according to the process summarized in Equation 2.
  • Hydrogen that is coproduced is ducted through holes 708 of hollow screw conveyer 710 to the interior bore as shown.
  • Helical screw 710 serves as an energy exchange system for conductive and radiative heat along with performing mechanical work to rapidly accomplish the reactions summarized by Equation 2.
  • Heat addition provided by suitable heat source 706 causes dissociation of the preheated methane. Heat may also be added by combustion of hydrogen within the hollow center of refractory screw assembly 710 as shown. Oxygen or another oxidant such as air is delivered through rotary union 718 is used for such combustion. Oxygen is preferably provided by air separation or electrolysis according to the copending patent applications. Hydrogen is delivered by conduit 717 through rotary union 719 as shown.
  • speed reduction components such as sprockets and chain or drive gear 732 and bearing support assembly 730 are preferably thermally isolated from rotating screw assembly 710 by a torque-conveying thermal insulator assembly 728.
  • insulating support of bearing and rotary union 716 assembly with 718 is provided to minimize heat transfer from screw assembly 710.
  • Insulator pack 724 provides heat-transfer blocking to prevent radiative and conductive heat losses and other areas where protection from heat is needed.
  • a relatively small portion of the methane and/or hydrogen and/or carbon monoxide generated as summarized by Equations 1 and 2 is delivered to an engine generator assembly similar to 202 and 280 as shown in Figure 2 to provide heat and electricity for support operations including electric drive motor 736, electrolyzer and/or air separator 744. pump or compressor 746, and generator 712 as shown. [0081] It is preferred to provide progressively reduced pitch of helical flights and/or to reduce the cross-sectional area between rotating screw 710 and stationery tube barrel 704 in zones that serve as plug seals for the purpose of constantly compacting solid materials that are entrained within, as shown.
  • Insulation system 724 facilitates efficient countercurrent heat exchange between hydrocarbons such as methane advancing toward seal 714 and carbon and/or hydrogen advancing toward seal 726.
  • Gear or sprocket drive 732 is thermally isolated from drive motor 736 and bearings 716 and 730 are designed for heat isolation and/or elevated temperature service.
  • Screw conveyer 710 and barrel 704 are made of refractory metals or ceramic material selections such as graphite, carbides, nitrides, intermetallics, and metallic oxides.
  • Heat addition at 706 may be by concentrated solar energy, catalytic or flame combustion, or by electrical heating such as plasma, resistance or inductive principles preferably using renewable electricity.
  • FIG. 8 illustrates the overall process 800 in which photosynthesis provides organic material typically containing carbon, hydrogen, and oxygen in step 862.
  • Step 864 provides anaerobic digestion or pyrolysis or partial oxidation to produce fuel gases such as methane and oxides of carbon. Separation of the oxides of carbon such as carbon dioxide from fuel gases is provided in step 866.
  • step 868 Appropriate filter, pressure swing adsorption, temperature swing adsorption, or selective absorption as disclosed in the copending patent application is provided by the system depicted as 868.
  • pressurizer 870 is utilized which includes selections such as a electrolysis pressurization, mechanical pump or compressor operation, or pressurizing release from adsorptive and/or metal hydride systems.
  • methane is preheated by countercurrent heat exchanges with hydrogen and carbon prior to final heat addition for dissociation as shown.
  • Subsequent provisions for heat addition are selected to specialize products made from carbon derived from preheated methane in step 874 as shown.
  • FIG. 9 shows details of embodiment 900 including solar concentration mirror 912 concentrated radiation receiver 914, stationery receiver tube 922 and rotary screw conveyer and extruder tube 924 in which integral helical screw flights 926 force reactive ingredients such as organic material into zone 930 where it is rapidly heated to a high temperature by concentrated solar energy.
  • Sufficient concentration of solar energy is readily achieved by parabolic, spherical, or arrayed heliostatic mirrors to produce typical operating temperatures of 500°C to 2500°C as facilitated by the physical and chemical properties provided by the material and configuration specifications of containment tube 922.
  • Stationery base 904 houses a drive system and provides transfer of materials to and from reactor 914.
  • Fuels and feedstocks such as landfill methane for reactor 914 are delivered by connection to pipeline 918.
  • a fluid feedstock such as constituents of sewage are processed by reactor 914 it is preferred to provide delivery by connection to pipeline 915.
  • Electricity produced or delivered is transferred by cable group 917.
  • Hydrogen and/or other fluids produced by reactor 914 are delivered to pipeline 916 for storage and distribution to contract sales.
  • Stage 906 rotates around a central vertical axis to provide sun tracking of reactor 914, which is assembled with mirror 912. Coordinated rotation around horizontal axis 909 in support 910 as shown is provided to track the sun and produce point focused solar energy that is reflected from mirror assembly 912.
  • Organic solids and semisolids to be heated are loaded into hopper 908, which feeds such materials into screw conveyer 924 a portion of which is shown in Figure 10.
  • Supplemental heating or replacement of solar heat for zone 930 by partial combustion of produced hydrogen and/or carbon monoxide is preferably accomplished by delivering oxygen through tube 937 within bore 931 of tube 932 from electrolyzer 907.
  • An important synergistic benefit is provided by operation of heat engine 903 on landfill methane and/or hydrogen for driving electricity generator 905.
  • Surplus electricity generating capacity is used to produce oxygen and hydrogen in electrolyzer 907.
  • Hydrogen produced by such operation can readily be stored in pipeline 916 for contract sales and oxygen can be used to greatly improve the process efficiency of heat generation by partial combustion of fuel produced by reactor 914 and/or in fuel cell power generation applications.
  • Tube 922 thus performs the functions of containing organic feedstocks in an anaerobic condition and transferring energy such as solar energy to biomass that is conveyed into the concentrated heating zone 930 to facilitate the reactions summarized as follows:
  • H 2 S is preferably reacted with iron to form iron sulfide or collected in carbon produced by the process as hydrogen is released. It is preferred to collect fixed nitrogen typically as ammonia and sulfur as iron sulfide and to utilize these substances as soil nutrients along with mineral ash collected by some embodiments of the invention.
  • Solids such as carbon and ash 936 are extracted from zone 930 by the rotating motion of screw tube 932 along flights 934 as shown.
  • High temperature insulation 940 is preferably used to cover the end of receiver 914 as shown and insulated area 942 provides heat conservation along the countercurrent exchange of heat made between carbon rich solids being extracted by screw conveyer 932 and biomass moving towards the heated zone 930 of the receiver and reactor assembly.
  • insulator sleeve 948 is used to cover zone 930 and is preferably supported and guided to and from the stored position shown by telescoping tube guides, which are not shown.
  • countercurrent pre-heating are preferably vented through louvers or holes 944 to allow extraction through collection tube 946.
  • this water generally contains fixed nitrogen and other soil nutrients and preferably is utilized to replenish soil tilth and productivity.
  • the biomass may be pre-treated to remove ash forming materials such as calcium, magnesium,
  • Ash ingredients of biomass are often wastefully impounded in landfills or allowed to escape to the oceans as effluent is dumped from sewage and garbage disposal operations.
  • ash is readily collected and returned to useful applications as a soil nutrient. This may be accomplished by a combination of mechanical separation and dissolution of the biomass in a suitable solvent to separate ash components.
  • Another embodiment provides anaerobic digestion of biomass such as carbohydrates and cellulose according to the following general reactions: n(C 6 Hi 0 O 5 ) + n H 2 0 + HEAT 3 -> n(C 6 Hi 2 0 6 ) Equation 9 n(C 6 Hi 2 0 6 ) 3n(CFLt) + 3nC0 2 + HEATio Equation 10
  • Soil nutrients captured in the aqueous liquor remaining after the processes shown are efficiently transferred to depleted soils by various techniques including addition to irrigation water.
  • Carbon dioxide is readily removed from the products of the process by cooling to produce phase change separation or by adsorption in a suitable solvent such as water.
  • Carbon dioxide is soluble in water to the extent of about 21.6 volumes of gas per volume of water at 25 atmospheres pressure and 12°C (54°F). Increasing the pressure and/or decreasing the temperature increases the amount of carbon dioxide dissolved per volume of water. After separation of carbon dioxide from methane, lowering the pressure or increasing the temperature releases dissolved carbon dioxide.
  • Apparatus 920 of assembly 914 for carrying out these endothermic reactions can readily seal the reaction zone 930 with carbon rich material that is compacted by extruder flights 926 along the inlet to zone 930 and with carbon rich material along extruder flights 934 of the outlet of zone 930 so that the hydrogen and other gases passing out through bore 931 may be pressurized to the desired extent and maintained by a rotary union and pressure regulation means on the outlet of bore 931.
  • Types of carbon that may be produced vary greatly depending upon market demand and the corresponding temperature and pressure at which the process of carbon sequestration is accomplished.
  • Methane delivered to manufacturing stage 874 may be processed as needed to produce fibers, carbon black, diamond-like plating on suitable substrate, graphite crystals and in many other forms corresponding to the copending disclosures in U.S. Patent Applications 08/921,134; 08/921, 134 and 09/370,431.
  • screw conveyer 932 would be designed as the feed path and preheater with hydrogen being delivered through bore 931 and carbon produced by the reaction in zone 930 conveyed by appropriately designed extruder 924 in countercurrent heat exchange with incoming feedstock.
  • This arrangement provides for countercurrent heating of the incoming feedstock from inside and from the outside before reaching zone 930 by parallel flows of products passing in the opposite direction of feedstock.
  • Carbon formed by the reaction is carried by screw conveyer 932 in countercurrent heat exchange with tube 924 to preheat the incoming methane and thus increase the overall efficiency and rate that solar energy completes the process reactions.
  • Hydrogen produced is collected in bore 931 of tube conveyer 932 and heat is removed in countercurrent heat exchange with reactants passing towards zone 930.
  • Renewable hydrogen produced can be used fuel cells or in heat engines that actually clean the air and provide cleaner exhaust than the ambient atmosphere.
  • conveyance of reactants in processes shown would be by numerous other means in addition to screw conveyers as shown.
  • Illustratively biomass could be forced to the reaction zone by a reciprocating plunger in place of screw conveyer 924 and carbon can be extracted from the hot end by other extraction methods including a chain drive conveyer in place of screw conveyer 932.
  • reaction temperature may be adjusted usually to reduced temperature or the throughput rate of ingredients increased.
  • Useful compounds such as hydrogen, carbon, methanol, biodiesel and turpentine may be produced and collected in tube bore 931 as summarized in the equations or a portion of a typical biomass waste feedstock with the average compound formula shown:
  • the rate of biomass travel into zone 930 and the rate of extraction of solid residues by helical conveyer 932 is preferably controlled by a computer that responds to adaptively control the process in response to instrumentation of the pressure, temperature, and other indicators of the kind and quality of products desired in the gas, vapor and solid residue streams.
  • Carbon monoxide may be decomposed or converted to desired forms of sequestered carbon by disproportionation as shown by the process summarized in Equation 8:
  • Disproportionation as summarized in Equation 13 is exothermic and can be provided under various combinations of temperature and pressure conditions including operations at 10-40 Atmospheres pressure at 500°C to 800°C.
  • Carbon monoxide produced by the processes summarized can be converted into numerous products to meet market demand as selected from processes requiring
  • some embodiments of the invention offer a practical process for sequestration of carbon from the atmosphere consisting of photosynthesis, collection of photosynthesized biomass, and heating the biomass to yield products selected from the group including carbon, hydrogen, methanol, turpenes, and ash.
  • Biomass wastes that are ordinarily allowed to rot into the atmosphere and which contribute to carbon dioxide and/or methane buildup can now be utilized to efficiently produce hydrogen, carbon products and soil nutrients.
  • Figure 12 shows a preferred embodiment in which a hydrogen internal combustion engine is the electricity source and heat source for the system, (not shown is that oxygen and potable water are also by products of the system).
  • Figure 12 emphasizes that once the process begins, it is self-sustaining in that a relatively small amount of hydrogen is used to power the system.
  • Energy efficiency is obtained by the relation between biodigester and electrolyzer. Energy efficiency is further obtained by the specialization of the solar thermal dish technology: cracking methane into its constituents: hydrogen and carbon.
  • cracking of methane would not occur at night.
  • distributable mass scale renewable energy production of hydrogen fuel is thereby achieved.
  • distributable mass scale renewable resource production carbon (undifferentiated carbon fiber or carbon ash) is thereby achieved.
  • distributable mass scale manufacturing of differentiated, specialized carbon is thereby achieved by use of distinct apparatus.
  • a Recursive formula is a formula that is used to determine the next term of a sequence using one or more of the preceding terms.
  • Use of some embodiments of the invention within a system of production yields an economic multiplier effect on (a) the biomass feedstock, (b) the methane feedstock, and (c) on the carbon; then methane / hydrogen is used to harvest more renewable energy and renewable material resource; then carbon turned into a durable good that harvests more (a) and (b) and produce more (c).
  • the disclosure embodies the mathematics of economic "sustainability.”
  • Figure 12 does not necessarily illustrate the economic implication of mass scale storage. Energy production that is both distributable (many locations) and scalable (capable of large quantity production) is an improvement over methods which are distinctly local and non-scalable.
  • Figure 13 shows a preferred embodiment in which the solar thermal concentrator system is the electricity source and heat source for the system.
  • Figure 14 shows a preferred embodiment in which the electricity source and heat source is not specified so as to make room for future variability and adaptability of the system.
  • Figure 15 shows a flow chart for a process of renewable energy production.
  • an electrolytic cell comprising a containment vessel; a first electrode; a second electrode; a source of electrical current in electrical communication with the first electrode and the second electrode; an electrolyte in fluid communication with the first electrode and the second electrode; a gas, wherein the gas is formed during electrolysis at or near the first electrode; and a separator; wherein the separator includes an inclined surface to direct flow of the electrolyte and the gas due to a difference between density of the electrolyte and the combined density of the electrolyte and the gas such that the gas substantially flows in a direction distal to the second electrode.
  • an electrolytic cell comprising a containment vessel; a first electrode; a second electrode; a source of electrical current in electrical communication with the first electrode and the second electrode; an electrolyte in fluid communication with the first electrode and the second electrode; a gas, wherein the gas is formed during electrolysis at or near the first electrode; a gas extraction area; and a separator wherein separator comprises two inclined surfaces forming a "V" shape; wherein the separator directs flow of the electrolyte and the gas due to a difference between density of the electrolyte and the combined density of the electrolyte and the gas such that the gas substantially flows in a direction distal to the second electrode, and wherein the separator is further configured to promote circulation of the electrolyte between the first electrode, the gas extraction area, and the second electrode to provide fresh electrolyte to the first electrode and the second electrode.
  • an electrolytic cell comprising a containment vessel; a first electrode; a second electrode; a source of electrical current in electrical communication with the first electrode and the second electrode; an electrolyte in fluid communication with the first electrode and the second electrode; a gas, wherein the gas is formed during electrolysis at or near the first electrode; and a separator; wherein the separator includes an inclined surface to direct flow of the electrolyte and the gas due to a difference between density of the electrolyte and the combined density of the electrolyte and the gas such that the gas substantially flows in a direction distal to the second electrode.
  • an electrolytic cell and method of use is provided.
  • An electrolytic cell may be used in many applications, it is described in this embodiment for use in the production of hydrogen and oxygen.
  • An electrolytic cell according to the present embodiment provides for reversible separated production of pressurized hydrogen and oxygen and tolerates impurities and products of operation.
  • the embodiment further provides the option for operating an electrolysis process which comprises the steps of supplying a substance to be dissociated that is pressurized to a much lower magnitude than desired for compact storage, applying an electromotive force between electrodes to produce fluid products that have less density than the substance that is dissociated and restricting expansion of the less dense fluid products until the desired pressure for compact storage is achieved.
  • This and other embodiments can improve the energy utilization efficiency of dwellings such as homes, restaurants, hotels, hospitals, canneries, and other business facilities by operation of heat engines or fuel cells and to utilize heat from such sources to cook food, sterilize water and deliver heat to other substances, provide space heating or to facilitate anaerobic or electrically induced releases of fuel for such engines or fuel cells.
  • heat engines or fuel cells can be operated by operation of heat engines or fuel cells and to utilize heat from such sources to cook food, sterilize water and deliver heat to other substances, provide space heating or to facilitate anaerobic or electrically induced releases of fuel for such engines or fuel cells.
  • aspects of the embodiments disclosed herein can apply to other types of electrochemical cells to provide similar advantages.
  • the present embodiment provides more efficient mass transport including rapid ion replenishment processes and deliveries to desired electrodes by pumping actions of low-density gases escaping from a denser liquid medium as described herein. This assures greater electrical efficiency, more rapid dissociation, and greater separation efficiency along with prevention of undesirable side reactions. Increasing the rate and efficiency of ion production and delivery to electrodes increases the system efficiency and current limit per electrode area.
  • a container 4b such as a metallic tube serves as a containment vessel is shown.
  • the container 4b may also serve as an electrode as shown in Figure IB.
  • a porous electrode such as cylindrical conductive wire screen electrode 8b is coaxially located and separated from tubular electrode 4b by an electrolytic inventory of liquid such as an acid or base. Liquid electrolyte occupies the interior space of container 4b to the liquid-gas interface in insulator 24b.
  • a layer of plated, plasma sprayed, or composited electrode material on a dielectric sleeve or a conductive cylindrical inner liner electrode 4b' may be provided within container 4b to serve as an electrically separated element of the assembly to enable convenient replacement as a maintenance item or to serve as one of a number of segmented electrode elements for purposes of optional polarity, and/or in series, parallel, or series-parallel connections.
  • electrode 8b may be considered the electron source or cathode such that hydrogen is produced at electrode 8b, and electrode 4b may be considered the anode such that oxygen is produced at electrode 4b.
  • Container 4b may be capable of pressurization.
  • Pressurization of the electrolytic cell 2b can be accomplished by self-pressurization due the production of gas(es) during electrolysis, by an external source such as a pump or by any combination thereof.
  • Separator 10b is configured to be liquid permeable but to substantially prevent gas flow or transport from the cathode side of the separator to the anode side of the separator and vice versa, include substantially preventing the flow of gas dissolved in the electrolyte or after nucleation of gas bubbles.
  • electrode 8b may be configured to act as separator 10b such that a distinct separator is not necessary.
  • separator 10b may include the electrode 8b or electrode 8b may include separator 10b.
  • separator 10b may also include the anodic electrode 4b or anodic electrode 4b may include separator 10b.
  • Insulator 24b is shaped as shown and as needed to separate, collect and/or extract gases produced by electrodes such as 4b and 8b including utilization in combination with separator 10b.
  • insulator 24b has a central conical cavity within which gases released on electrode 8b are collected. Concentrically surrounding this central cavity is an annular zone that collects the gases released from the surfaces of electrode 4b' or from the inside of container electrode 4b.
  • a catalytic filter 48b may be placed in the upper collection passage of 24b as shown. Oxygen that manages to reach catalytic filter 48b including travel by crossing separator 10b can be catalytically induced to form water by reacting with hydrogen, which may then return to the electrolyte. The vast excess of hydrogen can serve as a heat sink to prohibit the heat released by this catalytic reaction from affecting the electrolytic cell. Purified hydrogen is supplied at fitting 26b as shown. Similarly it may be preferred to provide a catalytic filter 49b in the upper region of the circumferential annulus that collects oxygen as shown, for converting any hydrogen that reaches the oxygen annulus into water. Oxygen is removed at fitting 22b as shown. Alternatively, the catalytic filters may be placed at, near or inside fittings 22b and 26b.
  • a suitable electrolyte such as an aqueous solution of sodium bicarbonate, sodium caustic, potassium hydroxide, or sulfuric acid and is maintained at the desired level as shown by sensor 50b that detects the liquid presence and signals controller 52b to operate pump 40b to add water from a suitable source such as reservoir 42b as needed to produce or maintain the desired inventory or pressure.
  • Controller 52b is thus responsive to temperature or pressure control sensor 58b which may be incorporated in an integrated unit with liquid level sensor 50b or, liquid inventory sensor 51b and control pumps 36b and 40b along with heat exchanger 56b which may include a circulation pump of a system such as a radiator or heater (not shown) to receive or deliver heat.
  • heat exchanger 56b which may include a circulation pump of a system such as a radiator or heater (not shown) to receive or deliver heat.
  • a heating or cooling fan maybe utilized in conjunction with such operations to enhance receipt or rejection of heat from sources associated with the electrolytic cell 2b.
  • electrolytic cell 2b can be operated with considerable variation of the water inventory. At times that surplus electricity is not available or it is turned off, hydrogen and oxygen supplies may be extracted from container 4b and the system is allowed to return to ambient pressure. Ambient pressure water can then be added to fully load the system, which can be provided to have a large annular volume around the circumference of insulator 24b as may be desired to facilitate such cyclic low-pressure filling and electrolysis operations to deliver hydrogen or oxygen at the desired high pressure needed for pressure or chemical energy to work conversions, compact storage, and provide rapid transfers to vehicles, tools, or appliance receivers.
  • the system may be pressurized as desired and remains pressurized until the inventory of water in solution is depleted to the point of detection by sensors 50b or 51 b which enables controller 52b to either interrupt the electrolysis cycle or to add water by pressure pump 40b from reservoir 42b as shown. It may be preferable to add water across a valve such as check valve 44b as shown to allow multiple duties or maintenance on pump 40b as needed.
  • Figure 2B shows one embodiment of the separator 10b of Figure IB in which the separator includes two inclined surfaces 14b forming a "V" shape.
  • the electrolyte is water based
  • electrons are added to porous electrode 8b such as a woven wire cylinder through connection 32b and are removed from container 4b through electrical connection 6b to continuously convert hydrogen ions into hydrogen atoms and subsequently diatomic molecules that can nucleate to form bubbles on or near electrode 8b.
  • Hydrogen and oxygen bubbles are typically much less dense than water based electrolytes and are buoyantly propelled upward.
  • Oxygen bubbles are similarly propelled upward and separated from hydrogen by the geometry of coaxial separator 10b as shown in the magnified section view of Figure 2B.
  • the configuration shown in Figure 2B may be used in any application in which the flow of gas formed during operation of the electrolytic cell 2b is desirable. Further, said separator configuration may be employed in other configurations of electrochemical cells known in the art. Alternatively, if the materials formed during electrolysis is of a higher density than the electrolyte, separator 10b may be inverted forming a " ⁇ " shape.
  • separator 10b may be comprised of a slanted "/" or " ⁇ " shapes to deflect the less dense material away from the more dense material.
  • separator 10b which efficiently separates gases by deflection from the surfaces 12b' and 14b which are inclined against oxygen and hydrogen entry, flow, or transmission as shown.
  • separator 10b may include a helical spiral that is composed of an electrically isolated conductor or from inert dielectric material such as 30% glass filled ethylene-chlorotrifluoroethylene in which the cross section of the spiraled strip material is in a "V" configuration as shown to serve as an electrical insulator and gas separator.
  • Separator 10b may be of any suitable dimensions including very small dimensions and with respect to surface energy conditions sufficient to allow the liquid electrolyte to pass toward or away from electrode 8b while not allowing passage of gases because of the buoyant propulsion and upward travel of the gas.
  • An alternative embodiment applicable in, for example, relatively small fuel cells and electrolyzers, is provided by a multitude of closely-spaced flattened threads with the cross section shown in Figure 2B in which such threads are woven or adhered to threads that provide mostly open access of liquids and are disposed in the mostly vertical direction on one or both sides of the "V" shaped threads. This allows the overall liquid-porous but gas-barrier wall thickness of separator 10b that is formed to be about 0.1 mm (0.004") thick or less.
  • Upward buoyant propulsion deflects gas bubble collisions on the inclined surfaces 12b and 14b.
  • This feature overcomes the difficulties and problems of the prior art conventional approaches that cause inefficiencies due to one or more of electrical resistance, fouling, stagnation, corrosion, and polarization losses.
  • some configurations can promote electrolyte circulation in concentric layers due to the buoyant pumping action of rising bubbles that produces flow of electrolyte upward and, as the gas(es) escape at the top of the liquid, the relatively gas-free and denser electrolyte flows toward the bottom as it is recycled to replace the less dense electrolyte mixed with bubbles or including dissolved gas.
  • a heat exchanger 56b may be operated as needed to add or remove heat from electrolyte that is circulated from the top of container 4b to the bottom as shown.
  • Pump 36b may be used as needed to increase the rate of electrolyte circulation or in conjunction with pump 40b to add make up water.
  • high current densities are applied, including systems with rapid additions of organic material.
  • pump 36b which returns relatively gas free electrolyte through fitting 28b through line 34b to pump 36b to return to container 4b through line 38b and fitting 16b as shown. It may be preferred to enter returning electrolyte tangentially at fitting 16b to produce a swirling delivery that continues to swirl and thus synergistically enhances the separation including the action by separator 10b that may be utilized as described above.
  • hydrogen is about fourteen times less dense and more buoyant than the oxygen and tends to be readily directed at higher upward velocity by separator 10b for pressurized collection through filter 48b at fitting 26b.
  • separator 10b for pressurized collection through filter 48b at fitting 26b.
  • the velocity of electrolyte travel is increased by pump 36b to enhance swirl separation and thus prevents gases produced on an anode from mixing with gases produced by a cathode.
  • separator 10b can be designed to improve electrolyte flow during electrolysis.
  • separator 10b can be configured to promote the spiral flow of ions in liquid electrolyte inventories traveling upward from port 16b to port 28b. This assures that each portion of the electrodes receives freshly replenished ion densities as needed for maximum electrical efficiency.
  • Such electrode washing action can also rapidly remove bubbles of hydrogen and oxygen as they form on the respective electrodes of the
  • FIG. 3B shows the edge view of representative portions of component sheets or helical strips of another aspect of separator 10b for providing electrical isolation adjacent electrodes including flat plate and concentric electrode structures while achieving gas species separation as described above.
  • sheets 12b' and 14b' form a cross section that resembles and serves functionally as that of separator 10b.
  • Flat conductive or non-conductive polymer sheet 12b' is prepared with multitudes of small holes on parallel centerlines that are inclined to form substantial angles such as shown by first angle 15b of approximately 35° to 70° angles with the long axis of sheet 12b' as shown.
  • Polymer sheet 14b' is similarly prepared with multitudes of small holes on parallel centerlines that are substantially inclined as shown by second angle 15b' to form approximately 35° to 70° angles with the long axis of sheet 14b' as shown.
  • angles 15b and 15b' can be varied depending on the material to be separated during the electrolysis process. For example the angles could be declined, for electrolysis of compounds that have no gaseous constituent or only one gaseous constituent. If a compound such as A1 2 0 3 is dissociated by electrolysis in cryolite-alumina electrolyte to form aluminum and oxygen, the aluminum is more dense than the cryolite- alumina electrolyte and the aluminum separating cathode electrode or associated separator would be configured (by, e.g., declined angles) to send the aluminum downward and away from the oxygen traveling upward.
  • a compound such as A1 2 0 3 is dissociated by electrolysis in cryolite-alumina electrolyte to form aluminum and oxygen
  • the aluminum is more dense than the cryolite- alumina electrolyte and the aluminum separating cathode electrode or associated separator would be configured (by, e.g., declined angles) to send the aluminum downward and away from the oxygen traveling upward.
  • Multitudes of such small holes with diameters of about 1/12 to 1/3 of the sheet thickness dimension can readily be made in sheets 12b' and 14b' by suitable technologies including laser drilling, hot needle piercing, or by high-speed particle penetrations.
  • Sheets 12b' and 14b' each of which are typically about 0.025 to 0.25 mm (.001" to 0.10") thick can be held together by welding or otherwise bonding, thread ties, elastic bands, or one or more spiral wraps of conductive or nonconductive wire on the resulting outside diameter to form as an assembly with electrode 8b. Sheets 12b' and 14b' may also be joined occasionally or continuously by adhesives or by thermal or solvent fusion.
  • tubular constructions of the assembled gas barrier sheets may be formed with the appropriate diameter for embodiments 2b or 100b by adhering or welding the butt seam or by providing an overlapped seam that performs as the intended separation gas barrier.
  • electrolytes For electrolysis of water, a variety of electrolytes are suitable.
  • potassium hydroxide may be used with low carbon steel for the containment vessel 4b.
  • Extended life with increased corrosion resistance may be provided by nickel plating cylinder 4b or by utilization of a suitable stainless steel alloy.
  • increased containment capacity can be provided by overwrapping cylinder 4b with high- strength reinforcement such as glass, ceramic, or carbon filaments or a combination thereof.
  • Electrode 8b may be made of woven nickel or type 316 stainless steel wires.
  • Separator 10b may be made from about 30% glass filled ethylene-chlorotrifluro- ethylene strip.
  • the embodiment can operate in conjunction with the embodiments of copending patent application including Serial No. 09/969,860, which is incorporated herein by reference.
  • Anaerobic digestion processes of organic materials that ordinarily produce methane can be controlled to produce an electrolyte that releases hydrogen at considerably lower voltage or by a reduced on-time of a pulse-width modulated duty cycle and resulting electricity expenditure than that required to dissociate water.
  • Acidity or pH of the organic solution that is produced by microbial digestion can be maintained by a natural bicarbonate buffered interaction.
  • the bicarbonate buffer may be supplemented by co-production of carbon dioxide in the digestion process.
  • the process may be generalized for various steps in anaerobic digestion processes of organic compounds by illustrative digestion of a simple carbohydrate or glucose that may have many competing and complementary process steps such as:
  • pH control near 7.0 may be needed.
  • pH of about 7.0, and 35-37°C (99°F) methanogenesis is favored.
  • Most domestic wastewater contains biowastes with both macro and
  • micronutrients required by the organisms that provide methanogenesis may inhibit operations of methane-forming microorganisms.
  • increased production of fuel values from organic substances can be accomplished by application of an electric field to cause dissociation of substances such as acetic acid (CH 3 COOH) that are produced by bacterial breakdown of glucose and other organic compounds and by other acid-production processes that yield hydrogen ions.
  • substances such as acetic acid (CH 3 COOH) that are produced by bacterial breakdown of glucose and other organic compounds and by other acid-production processes that yield hydrogen ions.
  • Initialization and maintenance of the exothermic decomposition of acids such as acetic acid may be accomplished at lower voltage applications or by intermittent or occasional electrolysis instead of continuous electrolysis as typically required to decompose water.
  • selected catalysts including modifications to Raney-Nickel catalysts, nickel-tin-aluminum alloys, selections from the platinum metal group, platinum-nickel and other platinum- transition metal single crystal alloy surfaces, and various organic catalysts utilized in conjunction with the electrode systems set forth herein further improve the rate and/or efficiency of hydrogen production.
  • each cell may require about 0.2 to 2 volts depending upon the aqueous electrolyte chosen or biochemically produced from organic substances so a home-size 6-volt photovoltaic source could have 3 to 30 cells in series and an industrial 220-volt service may have about 100 to 1 ,000 electrode cells connected in series.
  • Product gases could readily be delivered by parallel or series collection arrangements.
  • support and flow control feature 18b may be by an insulating or non-insulating material selection.
  • the problem of regenerative braking of vehicles or power-plant spin-down in which sudden bursts of large amounts of energy must be quickly converted into chemical fuel potential is addressed.
  • a conventional fuel cell for truck, bus, or train propulsion cannot tolerate high current densities that are suddenly applied to the fuel cell electrodes.
  • This embodiment overcomes this limitation and provides extremely rugged tolerance of high current conditions while achieving high electrolysis efficiency without the problems of PEM degradation or electrode-interface failures that regenerative PEM fuel cells suffer. Because of the rugged construction and extremely ample opportunities for cooling that are provided, extremely high current operations are readily accommodated. Conversely, this embodiment readily starts up and operates efficiently in severe cold or hot conditions without regard for various PEM-related difficulties, limitations, and failures.
  • the embodiment in order to achieve much higher return on investment in energy conversion systems such as a hydroelectric generating station, wind farm, system of wave generators, or conventional power plants, the embodiment allows off-peak electricity to be quickly and efficiently converted into hydrogen and oxygen by dissociation of water or hydrogen and carbon dioxide by dissociation of substances generated by anaerobic digestion or degradation of organic matter.
  • a compact version of the embodiment can occupy a space no larger than a washing machine and convert off-peak electricity that might otherwise go to waste into enough hydrogen to operate two family size vehicles and provide the energy requirements of the home.
  • some embodiments provided herein provide more efficient mass transport including rapid ion replenishment processes and deliveries to desired electrodes by pumping actions of low-density gases escaping from denser liquid medium. This assures greater electrical efficiency, more rapid dissociation, and greater separation efficiency along with prevention of undesirable side reactions. Increasing the rate and efficiency of ion production and delivery to electrodes increases the system efficiency and current limit per electrode area.
  • electrolytic cell 100b is shown that is particularly beneficial in applications in which it is not desired to apply voltage or to pass current through the inside walls of containment vessel 102b.
  • the embodiment also facilitates series connections of bipolar or multiple electrode sets or cells such as 1 10b and 1 14b within the electrolytic cell 100b to simplify gas collection and voltage matching needs.
  • electrode assemblies 1 10b and 1 14b may be formed from numerous nested truncated conical components or one or both electrodes may be formed as a helical electrode as described above. Electrodes 1 10b and 1 14b may be of the same, similar or different configurations. In another aspect, electrode 1 14b may be assembled from nested truncated conical sections or it may be a spiral electrode that continuously encircles electrode 1 10b.
  • Electrodes 1 10b and 1 14b to prevent short circuits may be accomplished by various means including by controlled tolerances for the operating dimensions and/or by the use of dielectric threads or filaments placed between electrodes 1 10b and 1 14b and/or by another form of separator 10b or 1 1 lb as disclosed regarding Figures 2B and 5B.
  • the electrolytic cell 100b may be pressurized. Pressure containment is provided by upper and lower caps 104b and 106b as shown. Insulators 120b and 122b are supported by caps 104b and 106b as shown.
  • the circuit components and hardware for electrical and fluid connections are illustrative and can be accomplished by penetrations through caps 104b and 106b as needed to meet specific application needs.
  • both electrodes 1 10b and 1 14b are formed to have inclined surfaces that direct the substance produced such as gas released to respective collection zones as shown.
  • electrode 1 10b may receive electrons that are supplied through connection 108b, which is sealed in cap 106b by plug seal 132b. Electrons are thus taken from electrode 1 14b through plug seal 130b, which provides insulation of contact 124b as a gas such as carbon dioxide or oxygen is released on electrode 1 14b.
  • Such gases are thus propelled by buoyant forces and travel more or less upward as delivered by electrode 1 14b and along the inside wall of container 102b.
  • Hydrogen is propelled upward as delivered by electrode 1 10b and within the center core formed by numerous turns or conical layers of electrode 1 10b and collected as shown at insulator 120b.
  • Purified hydrogen at design pressure is delivered by pressure fitting 1 16b.
  • Catalytic filter 134b may be used to convert any oxidant such as oxygen that reaches the central core to form water.
  • a similar catalytic filter material may be used to produce water from any hydrogen that reaches the outer collection annulus in insulator 120b as shown.
  • Pressurized filtered oxygen is delivered by pressure fitting 1 18b.
  • one or more gas collection vessels may be in fluid communication with electrolytic cell 100b to collect gas formed during electrolysis.
  • the gas collection vessel can be implemented to capture the gas at an elevated pressure prior to substantial expansion of the gas.
  • the gas collection vessel can be further configured to capture work as the gas expands according to methods known in the art.
  • the gas collection vessel can be configured to provide gas at pressure for storage, transport or use wherein the gas is desired to be delivered at an elevated pressure. It is further contemplated that said aspect can be implemented in various electrochemical cells.
  • a gas expander may be included at, near or inside fitting 22b, fitting 26b or in a gas collection vessel in fluid communication with fitting 22b or fitting 26b.
  • a gas expander may be included at, near or inside fitting 1 16b, 1 18b or in a gas collection vessel in fluid
  • a method and apparatus for electrolysis to pressurize a fluid coupled with a device to extract work from such pressurized fluid is provided.
  • the fluid may be pressurized liquid, liquid-absorbed gas, vapor or gas. Conversion of pressurized fluid to vapor or gas may occur in or after fitting 1 16b and a device to convert the pressure and flow from such fittings could be selected from a group including a turbine, generator, vane motor, or various piston motors or an engine that breathes air and injects pressurized hydrogen from 1 16b.
  • conversion of pressurized fluid to vapor or gas could be in or after fitting 1 18b and a device to convert the pressure and flow from such fittings could be selected from a group including a turbine, generator, vane motor, or various piston motors or an engine that expands and/or combusts pressurized fluid such as oxygen from 1 18b.
  • an apparatus and method to overcome the high cost and power losses of a transformer and rectifier circuit is provided. This is accomplished by adjusted matching of load voltage with source voltage by series connection of electrode cells or electrodes within a cell, such as connecting the negative polarity of a DC source to the lowest three turns of electrode 1 10b to the next three turns of electrode 1 14b to the next three turns of electrode 1 10b to the next three turns of electrode 1 14b and to the next three turns of electrode 1 10b et seq.
  • Turns and/or stacks of truncated cones may be adjusted to develop the area needed to match the source amperage.
  • the pumping action developed by the some embodiments of the invention provides for delivery of nutrients to microorganisms that, depending upon the relative scale of operations, are hosted in suitable media such as carbon cloth, activated carbon granules, expanded silica, graphite felt, coal, charcoal, fruit pits, wood chips, shredded paper, saw dust, and/or mixtures of such selections that are generally located within portions of electrode 1 10b and/or between portions of electrode 1 14b and container 102b.
  • suitable media such as carbon cloth, activated carbon granules, expanded silica, graphite felt, coal, charcoal, fruit pits, wood chips, shredded paper, saw dust, and/or mixtures of such selections that are generally located within portions of electrode 1 10b and/or between portions of electrode 1 14b and container 102b.
  • Corresponding functions and benefits include thermal stabilization of the system, circulation of feedstocks and removal of products such as carbon dioxide and production of hydrogen from acids that may be produced by the incubation, nutrition, and growth of such
  • the embodiment can be optimized for high current densities to deliver commensurately higher electrolyte fluid flow rates through one or more holes or grooves 139b, which direct fluid at a tangent to the annular space between electrodes 1 10b and 1 14b.
  • Electrolyte flows upward along the helical spaces formed by the electrodes and is replenished by electrolyte entering helical paths provided by 1 10b and 1 14b from the annular space between 1 10b and 1 14b.
  • the angular momentum of the electrolyte entering the space between electrodes 1 10b and 1 14b increases the impetus of bubble lift pumping by electrolytic products such as hydrogen and oxygen respectively produced on electrodes 1 10b and 1 14b and adds to such momentum.
  • This circulation of electrolyte is highly beneficial for purposes of assuring rapid replacement of ions that become hydrogen and oxygen atoms or other gases such as carbon dioxide upon charge exchanges to and from electrodes 1 10b and 1 14b and for removing such gases for collection and removal with minimum electrical polarization loss during electrolysis.
  • very high current densities are readily accepted to efficiently electrolyze the circulated fluid.
  • further accommodation of high current densities is provided by the vast cooling capacity of the design resulting from improved electrolyte circulation, which prevents harmful stagnation of products of electrolysis and/or phase changes such as steam nucleation, and reduction of effective electrode areas.
  • electrodes 1 10b and 114b may constitute spring forms that can be advantageously operated at a resonant frequency or perturbed by various inducements including piezoelectric drivers, rotating eccentrics, and the action of bubble formation and the acceleration thrust by less-dense mixtures of electrolyte and bubbles as higher density electrolyte inventories are delivered to the surfaces of electrodes 1 10b and 1 14b by the pumping action that results.
  • electrodes 1 10b and 1 14b vibrate at natural or induced frequencies to further enhance dislodgement of bubbles from surfaces including nucleation sites and thus enable higher current densities and greater energy-conversion efficiency.
  • FIG. 5B shows a representative section view of a set of electrodes 1 10b' and 1 14b' for operation in conjunction with an electrically insulative spacer 1 1 1b between 1 10b' and 1 14b' including selections such as insulator 10b shown in Figure 2B that includes a helical flow delivery configuration for various applications or electrolytes.
  • concentric electrode 1 10b', spacer 1 1 lb, and electrode 1 14b' provides a very rugged, self- reinforcing system for enabling efficient dissociation of fluids such as water, liquors from anaerobic digesters, or seawater with improved efficiency and resistance to fouling.
  • Electrodes 1 0b' and 1 14b' may be constructed from conductive carbon papers, cloth, or felt; woven or felt carbon and metal filaments, graphite granules sandwiched between woven carbon or metal filaments; or metal-plated polymers or metallic sheet stocks such as mild steel, nickel plated steel, or stainless steel that are drilled more or less as previously disclosed with multitudes of holes on parallel centerlines that are inclined as shown for respective separations of hydrogen from co-produced gases such as oxygen, chlorine, or carbon dioxide depending upon the chemical make up of the electrolyte.
  • Electrode 1 10b', spacer 1 1 lb, and electrode 1 14b' are utilized in concentric electrode deployments such as shown in Figure 4B, hydrogen is delivered to port 1 16b and depending upon the substance undergoing dissociation, products such as oxygen, chlorine or carbon dioxide delivery is provided at port 1 18b.
  • products such as oxygen, chlorine or carbon dioxide delivery is provided at port 1 18b.
  • Electrode 1 14b is illustrated in the section with gas 152b flowing along spiral grooves formed by corrugating the strip stock that is used to form the spiral and provide delivery of oxygen for fuel-cell operation and in electrolysis operation to deliver oxygen to annulus 136b and fitting 1 18b.
  • gas 152b flowing along spiral grooves formed by corrugating the strip stock that is used to form the spiral and provide delivery of oxygen for fuel-cell operation and in electrolysis operation to deliver oxygen to annulus 136b and fitting 1 18b.
  • the same configuration works well for electrode 1 10b in fuel-cell and electrolysis modes for conversion of organic acids into carbon dioxide and hydrogen and in the electrolysis mode and assures plentiful gas delivery to the desired collection or source ports as previously described.
  • improved electrode performance is provided by facilitating the growth and maintenance of microorganisms that convert aqueous derivatives of organic substances such as carbonic, acetic, butyric and lactic acids along with compounds such as urea into hydrogen.
  • microbe productivity is facilitated by preparing such electrode surfaces with topographical enhancements that increase the effective surface area including high aspect ratio filaments or whiskers that reduce electrical resistance to the substrate electrode and help hold microbes and biofilm in place along with the desired film substances provided by digestive processes.
  • the specific features of the electrode and/or separator such as the topographical treatments or enhancement, promote turbulence, including cavitation or super cavitation, of the electrolyte at a desired location which in turn promotes nucleation at the location.
  • the specific configuration of the electrode and/or separator can inhibit turbulence, including cavitation or super cavitation at a desired location, for example, the point of electron transfer, which in turn inhibits nucleation at that location.
  • elements including these features can be implemented at any location in the electrolytic cell at which nucleation is desired.
  • these same features and principles can be applied to a gas collection vessel or similar in fluid communication with the electrolytic cell, or to fluid communication with passages or valves there between.
  • Suitable filaments and or whiskers include metals or doped semiconductors such as carbon, silicon or nano-diameter filaments of carbon or boron nitride to provide increased surface area, reduce ion-transport and ohmic loses, increased microbe productivity and more effective nucleation activation for more efficient carbon dioxide release. Such filaments may also be utilized to anchor graphite granules that further improve microbe productivity, enhanced efficiency of enzyme and catalyst utilization, and related beneficial hydrogen ion production processes. Similarly, at the electrode where hydrogen ions are provided with electrons to produce hydrogen atoms and nucleate bubbles of diatomic hydrogen, filaments and whiskers may be utilized to increase the active area and reduce the voltage required for the overall process.
  • filaments grown from metals such as tin, zinc, nickel, and refractory metals deposited from vapor or grown from plating on suitable substrates such as iron alloy electrodes have been found to provide reduced electrical resistance and improved process efficiency.
  • Such filaments or whiskers may be made more suitable for biofilm support and process enhancement by addition of conducive surfactants and or surface plating with suitable substances such as carbon, boron nitride, or silicon carbide deposited by sputtering or from decomposition of a substance such as a carbon donor from illustrative precursors such as acetylene, benzene, or paraffinic gases including methane, ethane, propane, and butane.
  • FIG. 4B and variation thereof can provide advantageous separation of low density gaseous derivatives of fluid dissociation including hydrogen separation from organic liquors as summarized in Equations 1 -6 to deliver hydrogen or selections of hydrogen-enriched mixtures to port 1 16b while carbon dioxide or carbon dioxide enriched mixtures including fixed nitrogen components are delivered to port 1 18b.
  • hydrogen may be delivered to port 1 16b but the system may be operated to include methane and carbon dioxide.
  • carbon dioxide delivered to port 1 18b may include methane and other gases of greater density than hydrogen.
  • An unexpected but particularly beneficial arrangement for production of vigorous anaerobic colonies of microbes that produce the desired conversion of organic feedstocks to hydrogen and/or methane is provided by adding media such as colloidal carbon, carbon filaments including nanostructures, exfoliated carbon crystals, graphene platelets, activated carbon, zeolites, ceramics and or boron nitride granules to the electrochemical cell.
  • media such as colloidal carbon, carbon filaments including nanostructures, exfoliated carbon crystals, graphene platelets, activated carbon, zeolites, ceramics and or boron nitride granules
  • Such media may be doped or compounded with various agents to provide enhanced catalytic productivity.
  • desirable functionality may be provided by doping with selected agents having electron structures more or less like boron, nitrogen, manganese, sulfur, arsenic, selenium, silicon, tellurium, and or phosphorous. Circulation induced by the gases released by the electrolysis process can promote sorting of such
  • porous and/or exfoliated substrates of polymers, ceramics or activated carbon may adsorb conductive organic catalysts such as co-tetramethoxyphenylporphirine (CoTMPP) or poly(3,4- ethylenedioxythiophene) (PEDOT) and or favorably orient and present other catalytic substances including enzymes and graft polymers that may also be utilized to incorporate and present catalytic substances including additional enzymes.
  • CoTMPP co-tetramethoxyphenylporphirine
  • PEDOT poly(3,4- ethylenedioxythiophene)
  • Suitable substances or graft polymers may include those of conventional, dendrimers, fiberforms, and other organic functional materials to minimize or replace platinum and other expensive catalysts and conductors. Such replacement substances and their utilization includes mixtures or staged locations with respect to the fluid circulation resulting from some embodiments disclosed herein.
  • Variously specialized conductive and or catalytic structures include acicular deposits and fibers that may be grown or attached to the electrodes 4b, 8b, 1 10b, or 1 14b and/or to overlaid carbon felts or woven structures or dispersed into developing biofilms.
  • conductive and/or catalytic functionalities may be provided by filaments that retain and present hydrogenase and other enzymes, CoTMPP and or other catalysts such as poly (3, 4-ethylenedioxythiophene) (PEDOT) as fibers that are synthesized from aqueous surfactant solutions as self-organized thin-diameter, nanofibers with an aspect ratio of more than 100 and provide low resistance to charge conductivity.
  • PEDOT poly (3, 4-ethylenedioxythiophene)
  • Synthesis in aqueous solutions including anionic surfactant sodium dodecyl sulfate (SDS) can be adapted to produce various configurations by changing the
  • Preparations include graft polymers and end caps of organometallic alkoxides, metal alkyls and application of the catalytic benefits of acetic acid and a polymeric catalyst containing COOH end group.
  • Special function and bifunctional end groups along with mixtures of end groups may be chosen to produce multi-functional characteristics including catalytic functions, reactive stabilizers, grafting agents, and promoters of dispersion polymerization.
  • specialized activation of carbon or other substrates by hydrogen and or enzymes produced by anaerobic microorganisms provides a locally hydrogen-rich environment to enhance or depress methane production and enhance additional hydrogen production from various organic substances.
  • supplemental felts and or woven screens may commensurately collect or distribute electrons in conjunction with electrodes 4b, 8b, 1 10b, and or 1 14b and or separators 10b or 1 lb and help anchor or preferentially locate granules, filaments, and or other structures to reduce pressure losses or more equally distribute liquor flows and facilitate microbial functions in the desired energy conversion operations.
  • Carbon is consumed as summarized in Equation 8 including carbon that may be supplied as a constituent or a carbonaceous substance mixed with liquor from an anaerobic digester or electrolyzer or as a result of various manufacturing outcomes.
  • carbon may include scrap from grinding, machining, electro-discharge- machining (EDM), and various thermochemical operations to produce electrodes, electrode coatings on electrodes including tank liners, or particles, or filaments, or flocculants, or selected carbides by thermal dissociation and reaction processes, including colloidal or other suspensions as an outcome of various degrees of dehydrogenization of organic substances.
  • EDM electro-discharge- machining
  • Such carbon and/or carbon-donor feedstocks may be renewably supplied by bacteria, phytoplankton, or larger algae that receive carbon dioxide and other nutrients from the liquor supplied or by circulation of carbon dioxide to hydroponic and or soil-supported plants. It is advantageous to utilize such forms of carbon with high surface to volume ratios and to provide a voltage gradient to zones where they are delivered for the purpose of driving the reaction indicated and for delivering hydrogen ions to electrode surfaces including complementary conductive media such as filaments and conductive filter substances for production, nucleation, and release of hydrogen bubbles to increase the overall rate of hydrogen production.
  • Suitable provisions for increasing active surfaces and or flocculants include those with organic constituents such as bacteria, proteins, simple and complex sugars, cellulose, thermally dissociated cellulose, live and dissociated phytoplankton along with various forms of colloidal carbons, activated carbons, and carbides.
  • organic constituents such as bacteria, proteins, simple and complex sugars, cellulose, thermally dissociated cellulose, live and dissociated phytoplankton along with various forms of colloidal carbons, activated carbons, and carbides.
  • phytoplankton and or larger algae may be grown, dried, mixed with a binder such as corn syrup, thermally dehydrogenated to various extents and milled to provide finely divided flocculants.
  • activated carbon feedstocks may be milled to provide finely divided particles that are utilized as enzyme receivers or flocculent media or it may be used in conjunction with the previously disclosed substances to enhance the desired production or efficiency of enzymes, to support incubation of desired microorganisms, or to increase hydrogen or methane production and or consumption of carbon to produce hydrogen ions for electrolysis as indicated by Equation 8.
  • Applications of some embodiments include large community waste disposal operations to nano-size electrolyzers, include improvements to conventional waste digesters from which solutions or "liquor" containing organic substances is supplied for production of hydrogen and/or methane and or carbon dioxide and other plant nutrients.
  • some embodiments can provide rapid and efficient conversion of byproducts produced by anaerobic digesters and convert hydrogen ions into hydrogen and overcome acid degradation of the methane production operations.
  • liquor from an anaerobic digester is utilized to produce hydrogen and carbon dioxide to provide beneficial restoration and or maintenance of pH near 7.0 instead of more acidic conditions that may stymie methane production systems. This enables increased overall energy conversion efficiency as it overcomes the requirement for expensive provisions for addition of chemical agents to adjust the pH in digesters.
  • an electrolyzer such as disclosed herein may be applied to provide rapid conversion of acids that are typically produced by anaerobic digestion including applications with municipal waste water and landfills along with wastes form slaughter houses, dairies, egg farms, and other animal feeding centers or similar.
  • Production of methane is slowed or inhibited if acids that are produced by anaerobic conditions cause the pH to fall much below 7.
  • acids can form if the feed rate of organic material exceeds the capacity of the methanogenic colony of microorganisms.
  • By extracting hydrogen from such acids the rate of organic material processing by anaerobic digestion can be increased.
  • the combination of methane and hydrogen provides much greater net energy production per ton of wastes, and the wastes are processed faster to increase the capacity of the process.
  • a particularly useful embodiment of the some embodiments is in waste-to- energy applications that utilize organic substances such as sewage along with hydrolyzed garbage, farm wastes, and forest slash in the anaerobic electro-digestion process summarized in Equations 1-6 to produce hydrogen with minimal or no oxygen production.
  • the rugged configuration and recirculation operations enable great tolerance for dissolved solids including organic solids and particles in anaerobic process liquors that are utilized as electrolytes. Production of hydrogen without commensurate release of oxygen as would be released by electrolysis of water facilitates higher efficiency and safety for utilization of the waste-sourced hydrogen as a cooling gas in electrical equipment such as an electricity generator.
  • electrolyzer system 900b as shown in Figure 7B provides for tissue and/or cellular disruption of biomass by enzyme, mechanical, thermal, acoustic, electrical, pressure and/or chemical actions and processes in conditioner 950b to enable faster or more complete processing, digestion and/or support of incubator purposes. Fluid including such disrupted cells from conditioner 950b and related feedstocks that are produced by converter 902b is circulated to electrolyzer 914b through annular distributor 922b of base 910b as shown.
  • Anaerobic microorganisms are supported by media 940b and 942b and receive liquid recirculated from hydrogen separator 904b through conduit 910b and liquid recirculated from carbon dioxide separator 906b through conduit 908b as shown.
  • Electrode 918b and/or media 942b releases hydrogen and electrode 916b and/or media 940b releases carbon dioxide.
  • Electromotive bias is provided to electrodes 916b and 918b through circuit 926b by source 924b which may range from 0.1 to about 3 VDC depending upon the compound dissociation requirement and occasional needs for increased voltage to overcome insulating films that form.
  • Hydrogen is ducted to collection and delivery to separator 904b by travel along the more or less conical surface 925b, which may be a conductive surface depending upon the desired series/parallel variations or contained and supported by insulator 930b as shown.
  • liquors are mingled in distributor annulus 922b and travel upwards to provide process reactants and nutrients to microorganisms hosted in activated carbon cloth and/or granules 940b and 942b and or conductive felts that encase and substantially retain such granules proximate to electrode 916b and or 918b.
  • Smaller particles and filaments may be added to infiltrate locations throughout the electrolyzer system to enhance electrical charge conductivity, enzyme, and catalytic functions including those previously disclosed.
  • Separator 902b may be a reverse osmosis membrane or a cation or anion exchange membrane or it may be constructed according to the embodiments shown in Figures 2B, 3B, 4B, or 5B and in some instances such separators may be used in conjunction with each other as may be desired to provide for various liquor circulation pathways and/or to produce hydrogen and carbon dioxide at different pressures or with a pressure differential between hydrogen and carbon dioxide.
  • electrode 916b along with adjacent felt and or media 940b operate as electron sources to produce hydrogen from ions delivered from liquors that are circulated by the action of gas production lifts, convection currents, or by pump deliveries as shown.
  • carbon dioxide is released as hydrogen ions are produced from acids delivered from 902b and 950b or that are produced by microorganisms hosted in fibrous or granular media 942b and associated felt materials that are electrically biased by electrode 918b to be opposite to electrode 916b as shown.
  • Another exemplary option results if electrons are supplied by electrode 918b to produce hydrogen that is collected by insulator 930b for delivery to gas collector 904b as shown.
  • electrode 916b and the media electrically associated with it are electron collectors as carbon dioxide is released to provide pumping in the fluid circuit shown as carbon dioxide is delivered past insulator 930b to collector 906b as shown.
  • system 900b can be used for converting organic feedstocks such as those produced by photosynthesis into methane, hydrogen, and/or carbon dioxide and/or by microorganisms.
  • liquors that typically include acids such as acetic and butyric acids along with compounds such as urea are dissociated in electrolyzer 914b.
  • Electrolyzer 914b provides current at sufficient voltage to produce hydrogen from such compounds and acids and may provide operation as a digester and an electrolyzer, or may be operated within an anaerobic digester (not shown) or may utilize liquors produced by anaerobic digestion in 914b as shown.
  • Such operation is particularly useful for converting organic wastes from a community and or industrial park for purposes of supplying the community with fuel and feed stocks for manufacturing carbon enhanced durable goods.
  • an arrangement of one or more electrically conductive electrodes for utilization in an electrolyzer is shown as including flat sheets (not shown) or concentric electrodes 1002b, 1003b, 1004b, or 1005b, as shown that may be electrically connected as mono-polar or di-polar components of an electrolyzer.
  • conductive electrodes provide extensive surfaces as high surface to volume materials such as spaced graphene or layers of other thicknesses (e.g., carbon and/or BN "filters")- This serves the purpose of hosting microbes that decompose various organic materials including volatile fatty acids to release electrons and protons for production of hydrogen at cathode surfaces and can be implemented for use with any of the above embodiments.
  • the essential enzymes that microbes produce to decompose volatile fatty acids and various other organic are added to activated carbon or polymer particles or filaments that are incorporated in the high surface to volume materials that comprise electrodes 1002b, 1004b, 1006b, 1008b.
  • any microbe, enzyme or promoter described here can be incorporated into said surface.
  • enzymes or other materials or promoters are depleted, degraded, or destroyed supplemental amounts of such enzymes, materials or promoters may be added as needed.
  • This system allows optimization of the prmotoers, including allowing microbes to thrive at a location that is separated but to provide such enzymes to be utilized in the operation of the electrolyzer as shown.
  • the essential enzymes, microbes or promoters are artificially produced as duplicates or variously altered "designer enzymes" which are grafted to suitable natural polymers such as cellulose or lignocellulose or to various factory produced polymers or compounds.
  • systems for detection of chemically active substances and identification of the presence, capability, and viability of such substances or enzymes for the purpose of enabling an adaptive control system that adjusts the operating conditions including the amounts of chemically active nutrients and other operating conditions for purposes of optimizing the operation of maintained enzyme systems can be used with the present embodiments.
  • said systems can be implemented with any of the embodiments disclosed herein.
  • Hydrogen that is produced at elevated pressure can be delivered to compact, pressurized storage without incurring the capital cost, maintenance, or energy expense to operate a multistage hydrogen gas compressor.
  • Hydrogen that is produced at elevated pressure can be directly admitted into a pressurized pipeline for transmission to market.
  • Hydrogen that is produced at elevated pressure can be used to pressurize other reactants to enable or accelerate reactions.
  • Illustratively pressurized hydrogen can be added to nitrogen in a suitable reactor to produce ammonia or other products.
  • a system 1 100b is shown including elevated pressure electrolyzer 1 102b, which may receive pressurized electrolyte and/or precursor fluids that form suitable electrolytes within electrolyzer 1 102b from suitable pump 1 1 14b.
  • Pressurized hydrogen is produced as a result of the action of microbes and/or otherwise maintained enzymes on one or more electrodes depicted such as 1002b, 1004b, 1006b, 1008b etc., or 1 104b along with voltage applied across taps 1 106b and 1 124b as shown. Elevated pressure hydrogen is delivered to a suitable application through conduit 1 122b by pressure regulator 1 120b.
  • Pressurized electrolyte containing carbon dioxide flows through fluid motor-generator 1 126b to produce work by harnessing the kinetic energy of the flowing electrolyte and the expansion of carbon dioxide to ambient pressure as it is diverted to a suitable carbon dioxide use such as a hydroponic system or greenhouse 1 130b for growing algae switch grass, kudzu or various other crops 1 132b and/or 1 134b. Electrolyte that has been depleted of carbon dioxide is recycled by pump 1 1 14b through three way valve 1 1 12b.
  • Biomass including materials grown in 1 130b is ground or otherwise made into a slurry of activated substances consisting of broken cellular material that is produced by suitable mechanical, acoustic, chemical, thermal or radiation treatment in processor 1 136b.
  • activated organic feedstock is added to accumulator 1 108b for suitable passage through filter 1 1 10b and passage through three-way valve 1 1 12b to pump 1 1 14b for entry into pressure electrolyzer 1 102b as shown.
  • controller 1 101 b Operation of system 1 100b is provided by controller 1 101 b in response to pressure, temperature, and pH sensors 1 142b, 1 144b, 1 146b along with chemically active agent sensors 1 140b and 1 150b as shown. This enables corrective substances to be added through port 1 1 18b for purposes of providing the maintained enzyme conditions desired for optimized performance.
  • suitable electrodes include systems that are formed from circular or other cross sections of wire such as square or rectangular or various "star" shapes or flat strip for providing plastically formed woven embodiments or helical embodiments as disclosed herein.
  • Material selections such as iron or other transition metal based alloys are then heat treated to carburize and produce various amounts of carbon in solid solution including saturated zones that are further defined or grown by additional heat treatment to enable growth of such saturated zones particularly near the surface.
  • the carbon zones that develop accelerate the deposition of additional carbon as a carbon donor such as a hydrocarbon or carbon monoxide is decomposed on such surfaces. Equations 10 and 1 1 show such overall processes of providing heat to the substrate being heat treated in an amount that is equal or greater than the heat of formation of the carbon donor:
  • initial preparation and the orientation of the carbon rich zones that approach saturation conditions are modified by hot or cold working the embodiment to provide sufficiently uniform orientation of the carbon crystalline structure to provide a significantly epitaxially influenced deposit of the subsequent carbon deposition.
  • the oriented carbon thus deposited such as predominantly edge exposed or as graphene layers that are more parallel to the original surface are competitively tested to provide support of the desired microbial processes. This allows "designer carbon" to be selected for each type of microbial process desired.
  • the manufacture of carbon/steel electrodes for use in the embodiments disclosed herein is disclosed.
  • These electrodes can include surface treated carbon for attachment to selective enzymes, microbes or other promoters for improved operation of the electrolyzer.
  • a steel or steel alloy substrate is saturated with carbon.
  • the grains of the saturated carbon are aligned by, for example, heat treating through induction to provide a desired grain orientation for the carbon as shown in phase I.
  • Other known heat treating method may be employed.
  • the electrode can also be subjected to liquid cooling to prevent damage to the electrode or provide other benefits.
  • the electrode is then shaped through known processes, including pinch rolling.
  • the shaping can be implemented in a manner to further align, flatten or modify the oriented carbon grains as desired.
  • carbon is then deposited on the electrode through known carbon deposition techniques including vapor deposition, by which the carbon is deposited or grown on the surface of the electrode.
  • the carbon can be deposited or grown in a manner to further enhance the grain orientation or selectively deposit the carbon at selected locations on the electrode depending on the desired use of the electrode.
  • the enzyme, microbe, or promoter can be deposited at one location and another enzyme, microbe or promoter can be deposited at another location for controlled use of the enzyme, microbe and promoter.
  • the electrode with the deposited carbon can be further treated through heating by induction or other means to further align or orient the grains, and which again can include liquid cooling. This process can be repeated until the desired carbon amount and/or grain orientation and/or grain location is achieved.
  • the electrode upon completion of the surface treatment, the electrode is then exposed to one or more enzymes, microbes or promoters selected for the particular application of the electrode, for example enzymes that enhance the production of desired compounds during electrolysis such as hydrogen.
  • enzymes for example enzymes that enhance the production of desired compounds during electrolysis such as hydrogen.
  • the method can target specific locations of the electrode.
  • different treatment conditions can be applied to different locations such that different enzymes can be deployed or different enzyme densities can be implemented at different locations depending on the desired configuration or use of the electrode.
  • an electrode is manufactured to include carbon constructs having an affinity for particular enzymes, microbe or promoters, and to bond the enzymes, microbes or promoters to the electrodes at desired locations to permanently or substantially retain the enzymes at the desired locations for use during electrolysis or other operation of the electrode.
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US12/857,554 US8808529B2 (en) 2009-02-17 2010-08-16 Systems and methods for sustainable economic development through integrated full spectrum production of renewable material resources using solar thermal
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PCT/US2010/024498 WO2010096504A1 (en) 2009-02-17 2010-02-17 Apparatus and method for controlling nucleation during electrolysis
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US12/707,656 US8075749B2 (en) 2009-02-17 2010-02-17 Apparatus and method for gas capture during electrolysis
US12/707,653 US8172990B2 (en) 2009-02-17 2010-02-17 Apparatus and method for controlling nucleation during electrolysis
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US12/707,651 US8075748B2 (en) 2009-02-17 2010-02-17 Electrolytic cell and method of use thereof
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