WO2012125683A2 - Dispositif de création d'énergie et de stockage d'énergie - Google Patents

Dispositif de création d'énergie et de stockage d'énergie Download PDF

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Publication number
WO2012125683A2
WO2012125683A2 PCT/US2012/029006 US2012029006W WO2012125683A2 WO 2012125683 A2 WO2012125683 A2 WO 2012125683A2 US 2012029006 W US2012029006 W US 2012029006W WO 2012125683 A2 WO2012125683 A2 WO 2012125683A2
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WO
WIPO (PCT)
Prior art keywords
electrolyzer
hydrogen
channel
anode
oxygen
Prior art date
Application number
PCT/US2012/029006
Other languages
English (en)
Other versions
WO2012125683A3 (fr
Inventor
John T. KRACZEK
John Arthur KRACZEK
Clark SKOUSEN
Richard Jensen
Jeff SINGLEY
Frederick Gary DYSON
Paul Freeman
Original Assignee
Maetec, Llc
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.)
Filing date
Publication date
Application filed by Maetec, Llc filed Critical Maetec, Llc
Publication of WO2012125683A2 publication Critical patent/WO2012125683A2/fr
Publication of WO2012125683A3 publication Critical patent/WO2012125683A3/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B15/00—Operating or servicing cells
    • C25B15/08—Supplying or removing reactants or electrolytes; Regeneration of electrolytes
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B1/00—Electrolytic production of inorganic compounds or non-metals
    • C25B1/01—Products
    • C25B1/02—Hydrogen or oxygen
    • C25B1/04—Hydrogen or oxygen by electrolysis of water
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B9/00—Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
    • C25B9/17—Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof
    • C25B9/19—Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof with diaphragms
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B9/00—Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
    • C25B9/70—Assemblies comprising two or more cells
    • C25B9/73—Assemblies comprising two or more cells of the filter-press type
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B9/00—Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
    • C25B9/70—Assemblies comprising two or more cells
    • C25B9/73—Assemblies comprising two or more cells of the filter-press type
    • C25B9/77—Assemblies comprising two or more cells of the filter-press type having diaphragms
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/36—Hydrogen production from non-carbon containing sources, e.g. by water electrolysis

Definitions

  • the present invention is in the technical field of hydrogen and oxygen fuel production and hydrogen and oxygen energy storage.
  • Green energy sources such as wind turbines, water turbines, solar panels, etc. often produce electricity at times of the day, night or week when the electricity is not needed.
  • conventional energy production facilities may make use of electrical storage devices.
  • Conventional electrical storage devices for storing the variable output from wind turbines, solar panels, and/or back up power from utility grids include various kinds of battery systems. Generally these battery systems involve very high costs, as is the case of sodium sulfur batteries, or a relatively short life expectancy. Additionally, such battery systems raise environmental issues when depleted systems are disposed. Other energy storage devices use a hydrogen energy storage loop, but are impractical due to excessive costs and/or very poor efficiencies.
  • Some energy storage devices store hydrogen and oxygen that are generated from the produced electricity using an electrolyzer.
  • An electrolyzer is a device that uses an electrical current to split water into hydrogen and oxygen gases through electrolysis.
  • Conventional electrolyzers are built from expensive materials and/or are generally inefficient because they lose much of the energy of the electricity in the form of heat during electrolysis. Thus, conventional electrolyzers are not cost effective alternatives for converting the energy produced by wind turbines, water turbines, heat panels, and other energy sources into oxygen and hydrogen.
  • the present invention is directed to systems and methods for using generated electricity to create hydrogen and oxygen gasses, which can be stored and used as fuel to create electricity during times when the electricity is needed.
  • embodiments of the present invention include an energy storage device that employs compressed hydrogen and oxygen as the energy storage medium.
  • the energy storage device includes an AC to DC converter, an efficient low-cost electrolyzer, gas filtration and conditioning, gas storage tanks, a fuel cell or combustion generator, a DC to AC inverter with line sense, and an overall system controller.
  • Embodiments of the electrolyzer of the present invention are of a unique design that provides a cost effective alternative for efficiently producing hydrogen and oxygen gases.
  • Figure 1 illustrates a top schematic view of an energy storage device according to one or more embodiments of the present invention
  • Figure 2 illustrates a perspective view of the energy storage device according to one or more embodiments of the present invention
  • Figure 3 illustrates a top view of a containerized version of the energy storage device according to one or more embodiments of the present invention
  • Figure 4 illustrates a perspective view of a containerized version of the energy storage device according to one or more embodiments of the present invention
  • Figure 5 illustrates a perspective view of an electro lyzer according to one or more embodiments of the present invention
  • Figure 6 illustrates an exploded perspective view of the of the electro lyzer of Figure 5 according to one or more embodiments of the present invention
  • Figure 7 illustrates an exploded perspective view of the middle cell of Figure 5 according to one or more embodiments of the present invention
  • Figure 8 illustrates a perspective view of the external plumbing of Figure 5 according to one or more embodiments of the present invention
  • Figure 9 illustrates a perspective view of the front platen of Figure 5 according to one or more embodiments of the present invention.
  • Figure 10 illustrates a perspective view of the front outside gasket of Figure 5 according to one or more embodiments of the present invention
  • Figure 11 illustrates a perspective view of the front anode-cathode plate of Figure 5 according to one or more embodiments of the present invention
  • Figure 12 illustrates a perspective view of a channel gasket of Figure 5 according to one or more embodiments of the present invention
  • Figure 13 illustrates a perspective view of a gas flow media sheet of Figure 5 according to one or more embodiments of the present invention
  • Figure 14 illustrates a perspective view of a scrim sheet of Figure 5 according to one or more embodiments of the present invention
  • Figure 15 illustrates a perspective view of a middle anode-cathode plate of Figure 5 according to one or more embodiments of the present invention
  • Figure 16 illustrates a perspective view of the top channel isolating media of Figure 5 according to one or more embodiments of the present invention
  • Figure 17 illustrates a perspective view of the bottom channel isolating media of Figure 5 according to one or more embodiments of the present invention
  • Figure 18 illustrates a perspective view of the rear anode-cathode plate of Figure 5 according to one or more embodiments of the present invention
  • Figure 19 illustrates a perspective view of the rear outside gasket of Figure 5 according to one or more embodiments of the present invention
  • Figure 20 illustrates a perspective view of the rear platen of Figure 5 according to one or more embodiments of the present invention
  • Figure 21 illustrates a perspective view of alternative cell components of Figure 5 according to one or more embodiments of the present invention.
  • Figure 22 illustrates an exploded perspective view of alternative cell components of Figure 5 according to one or more embodiments of the present invention
  • Figure 23 illustrates an outside perspective view of a channel gasket of alternative cell components of Figure 5 according to one or more embodiments of the present invention
  • Figure 24 illustrates an inside perspective view of a channel gasket of alternative cell components of Figure 5 according to one or more embodiments of the present invention
  • Figure 25 illustrates a perspective view of a gas flow media sheet of alternative cell components of Figure 5 according to one or more embodiments of the present invention
  • Figure 26 illustrates a perspective view of a scrim sheet of alternative cell components of Figure 5 according to one or more embodiments of the present invention
  • Figure 27 illustrates a perspective view of a bridge piece of alternative cell components of Figure 5 according to one or more embodiments of the present invention
  • Figure 28 illustrates a perspective view of a variant of a front platen of Figure 5 according to one or more embodiments of the present invention.
  • Figure 29 illustrates an exploded perspective view of a scrim sheet assembly of Figure 5 according to one or more embodiments of the present invention.
  • the present invention is a system that efficiently converts electricity into a storable energy source, namely hydrogen and oxygen gases, and then converts the stored energy back into electricity when the electricity is needed.
  • a storable energy source namely hydrogen and oxygen gases
  • Figs. 1-2 show an energy storage device 10, having an AC power feed connection 12 and an alternate DC power feed connection 14 positioned inside an electrical breaker panel 16.
  • the AC power feed connection 12 is tied into the AC electrical breaker 18 and the DC power feed connection 14 is tied into the DC electrical breaker 20.
  • a system controller 22 monitors the conditions and inputs then activates valves and switches based on pre programmed operation logic.
  • a rectifier module 24 converts the AC power from the AC electrical breaker 18 to DC power, which is then supplied to the electro lyzer 26.
  • the DC electrical breaker 20 is electrically connected to the electro lyzer 26 through a DC to DC converter 28.
  • the electrolyzer 26 takes the DC power and splits water into its elemental forms, namely hydrogen and oxygen.
  • the electrolyzer recirculation piping 30a-30b and the electrolyzer drain valves 32a-32b are represented.
  • From the electrolyzer 26 the hydrogen and oxygen in a gaseous form travel through a parallel course of components through a hydrogen gas line 34 and an oxygen gas line 36, respectively.
  • the hydrogen and oxygen gases travel through the respective hydrogen and oxygen gas defoaming chambers 38 and 40, gas isolation valves 42 and 44, gas conditioners 46 and 48, gas storage tanks 50 and 52 where the gases are stored.
  • the pressure in the gas storage tanks 50 and 52 is monitored by gas pressure gauges/transmitters 58 and 60.
  • the gasses flow through the respective gas control valves 54 and 56 to the fuel cell 62.
  • the fuel cell 62 converts the hydrogen and oxygen gases back into water, creating electricity in the process.
  • Water leaves the fuel cell 62 through a fuel cell drain valve 64 and is recirculated back to the electrolyzer 26 through a water recirculation line 66 having a recirculation pump 68, and finally through hydrogen and oxygen side water fill valves 70 and 72.
  • Electricity from the fuel cell 62 ties into a grid tie inverter 74 which converts the electricity to AC power and then conducts the electricity to the AC power outlet connection 76 where power is distributed and/or used as desired.
  • the energy storage device 10 is a system that receives either AC or DC electricity coming from a power grid, wind turbines, solar cells, or any other suitable power source.
  • the energy storage device 10 uses the electricity to create hydrogen and oxygen by splitting water.
  • the resultant gases are stored until additional electricity is needed, at which time the energy storage device 10 converts the gases back into electricity that can be used as needed.
  • the process is as follows. An electrical current is provided to the energy storage device 10 through the AC and DC power feed connections 12 and 14.
  • the AC power goes through the AC electrical breaker 18 while the DC power goes through the DC electrical breaker 20. Both breakers are housed in the electrical breaker panel 16.
  • the DC power is applied to the electrolyzer 26 through a DC to DC converter 28.
  • the AC power is first converted to DC power by the rectifier module 24 after which it too is applied to the electro lyzer 26.
  • the system controller 22 monitors all device conditions, pressure, voltage, amperage, and temperature, sending electrical power to the electrolyzer 26 when pre-defined conditions are met, thereby indicating that it is desirable for the electrolyzer to make hydrogen and oxygen gasses for storage.
  • a solution of water and an electrolyte solution are present inside the electrolyzer 26.
  • the electrolyzer 26 splits the water into hydrogen and oxygen gasses.
  • the hydrogen and oxygen gases which are under pressure, rise or bubble to the top of the electrolyzer 26 and travel through a parallel course of components to storage tanks. Specifically, the hydrogen and oxygen gases travel through various components as described above until they are ultimately supplied to the fuel cell 62. These components are described in further detail below.
  • the hydrogen and oxygen gases travel through the hydrogen and oxygen gas lines 34 and 36 to the respective hydrogen and oxygen gas defoaming chambers 38 and 40.
  • the hydrogen and oxygen gas defoaming chambers 38 and 40 allow suds created by the gases to settle, thereby releasing the gases and allowing the electrolyte to circulate back to the bottom of electrolyzer 26 by way of the electrolyzer recirculation piping 30a- 30b, respectively.
  • the diameter of hydrogen and oxygen gas defoaming chambers 38 and 40 is greater than about ten times the cross-sectional surface area of the pipe feeding them.
  • electrolyzer drain valves 32a-32b which are used to drain the electrolyzer 26 for maintenance or repairs.
  • the hydrogen and oxygen gas isolation valves 42 and 44 isolate the electrolyzer 26 from the rest of the components for the reasons of maintenance or repairs. Dependant on the type of fuel cell used the gases next flow through the hydrogen and oxygen gas conditioners 46 and 48 where any moisture and remaining electrolyte is removed before the gases travel to and are stored in the hydrogen and oxygen gas storage tanks 50 and 52 respectively. If the fuel cell used does not require the gases to be conditioned, then the gases go straight to the hydrogen and oxygen gas storage tanks 50 and 52.
  • the present invention contemplates using any suitable number and size of hydrogen gas storage tanks and oxygen gas storage tanks.
  • electrolyzer 26 produces gasses
  • the resulting pressure in the electrolyzer 26 increases, causing the gasses to move into the hydrogen and oxygen gas storage tanks 50 and 52.
  • the pressure is relieved and the gases are metered through the hydrogen and oxygen gas control valves 54 and 56, which are operated by the system controller 22 to supply the gasses to the fuel cell 62.
  • Pressures are read and transmitted to the system controller 22 from the hydrogen and oxygen gas pressure gauges/transmitters 58 and 60.
  • multiple hydrogen and oxygen gas pressure gauges/transmitters 58 and 60 are used throughout the gas lines to allow the system controller 22 to monitor and control the overall system.
  • multiple hydrogen and oxygen gas isolation valves 42 and 44 and gas control valves 54 and 56 can be used throughout the system as needed to control the operation of the system as desired.
  • the fuel cell 62 recombines the hydrogen and oxygen gases to form water and DC electricity. Any excess water created during this process is released through the fuel cell drain valve 64 and pumped by the recirculation pump 68, which is controlled by the system controller 22, back to the electrolyzer 26 through the water recirculation line 66 and hydrogen and oxygen side water fill valves 70 and 72, respectively.
  • the hydrogen and oxygen side water fill valves 70 and 72 introduce the water back into the electrolyzer 26 for the process to continue.
  • Electricity from the fuel cell 62 goes to the grid tie inverter 74 where it converts DC power to AC power.
  • the grid tie inverter 74 also senses the AC wave timing on the electrical grid connection lines and adjusts the DC output from the fuel cell 62 to useful AC electricity. The AC power is then connected to the power grid directly, through an external step up transformer, or to an AC load through the AC power outlet connection 76.
  • the energy storage device 10 shown in Figs. 1-2 is made of multiple metal and composite components.
  • the electrical storage device housing (not shown) can be made of metal, composites, or any other material that can offer the desired protection for the specific application, including shipping containers for standard land or sea shipping that can be modified for the permanent attachment of the internal components and wires for housing the energy storage device 10.
  • the components of the electrical storage device 10 can be placed in the base of an existing wind turbine or any other structure as desired.
  • the electrical breaker panel 16 can be a commercially available metal, composite, or watertight enclosure meeting standard electrical code requirements.
  • the AC electrical breaker 18, DC electrical breaker 20, rectifier module 24, system controller 22, and all other electrical converters, controls and connections are commercially available components, or may be custom built for a particular application as known by those of skill in the art of such components.
  • the hydrogen and oxygen gas storage tanks 50 and 52 may be a composite tank, or may be made of any known or future tank material that will not fail when carrying or storing hydrogen or oxygen gas under pressure.
  • all piping and the hydrogen and oxygen gas defoaming chambers 38 and 40 are constructed out of PVC pipe and fittings, but may also be built out of CPVC, fiberglass reinforced pipe, polypropylene pipe, stainless steel pipe or other piping materials capable of being sealed together by either thread, heat bonding or adhesive and having chemical resistance to corrosion by caustic as well as chemical resistance to pure oxygen.
  • the hydrogen and oxygen gas conditioners 46 and 48, recirculation pump 68, the valves and gauges in one embodiment can be commercially available components.
  • a preferred electro lyzer 26 will be described hereafter, but any electro lyzer or fuel cell that can be built or purchased to meet the user- defined requirements of load, pressure, and efficiency could be used.
  • Fig. 3-4 show an energy storage device 110, having an AC power feed connection 112 and an alternate DC power feed connection 114 positioned inside an electrical breaker panel 116.
  • the AC power feed connection 112 is tied into the AC electrical breaker 118 and the DC power feed connection 114 is tied into the DC electrical breaker 120.
  • a system controller 122 monitors the conditions and inputs then activates valves and switches based on pre programmed operation logic.
  • a rectifier module 124 converts the AC power from the AC electrical breaker 118 to DC power, which is then supplied to the electro lyzer 126.
  • the DC electrical breaker 120 is electrically connected to the electro lyzer 126 through a DC to DC converter 128.
  • the electro lyzer 126 takes the DC power and splits water into its elemental form, namely hydrogen and oxygen. As described above in connection with Figs. 1-2, electrolyte that escapes the electro lyzer 126 is returned to the electro lyzer 126 through recirculation piping 130a- 130b.
  • the electrolyzer 126 also includes electrolyzer drain valves 132a-132b. From the electrolyzer 126, the hydrogen and oxygen gasses travel through a parallel course of components until they are supplied to the fuel cell 162.
  • the hydrogen and oxygen gases travel through hydrogen and oxygen gas defoaming chambers 138 and 140, gas isolation valves 142 and 144, gas control valves 154a and 156a, gas high pressure pumps 184 and 186, gas manifold systems 178 and 180, gas storage tanks 182, gas control valves 154b and 156b, and gas pressure gauges/transmitters 158 an 160 to the fuel cell 162.
  • the fuel cell 162 is used to convert the hydrogen and oxygen gases back into water, creating electricity in the process.
  • Electricity from the fuel cell 162 ties into a grid tie inverter 174 which converts the electricity to AC power and conducts the electricity to the AC power outlet connection 176 where the power is distributed as desired.
  • the energy storage device 110 is sized and configured to be readily shippable. In another embodiment, the energy storage device 110 is assembled and installed as a permanent fixture on site.
  • Figs. 3 - 4 depict an energy storage device 110 that takes either AC or DC electricity coming from a power grid, wind turbines, solar cells, or any other suitable power source and creates hydrogen and oxygen, stores the gases, and then combines the gasses to create electricity that can be used as needed.
  • This variant of an energy storage device 10 of Figs. 1-2 is designed to store larger quantities of hydrogen and oxygen at higher pressures. The process is similar to that described in connection with Figs. 1-2, and is provided hereafter.
  • An electrical current is provided to the energy storage device 110 by way of the AC and DC power feed connections 112 and 114 through the electrical breaker panel 116 where AC and DC electrical breakers 118 and 120 protect the upstream and downstream equipment from being damaged by over amperage.
  • DC power is applied to the electro lyzer 126 through a DC to DC converter 128 while AC power is first converted to DC power by the rectifier module 124 and then applied to the electro lyzer 126.
  • the system controller 122 monitors all device conditions, pressure, voltage, amperage, and temperature, sending DC electrical power to the electro lyzer 126 when pre-defined conditions are met for the electro lyzer to make hydrogen and oxygen gas for storage.
  • the electro lyzer 126 splits water, which is combined with an electrolyte solution, into hydrogen and oxygen gasses.
  • the hydrogen and oxygen gases are under pressure in the electro lyzer 126 and rise or bubble to the top of the electro lyzer 126 where they travel through a parallel course of various components to the fuel cell 162, as described below.
  • the hydrogen and oxygen gases travel through the hydrogen and oxygen gas lines 134 and 136 to the respective hydrogen and oxygen gas defoaming chambers 138 and 140.
  • the hydrogen and oxygen gas defoaming chambers 138 and 140 allow suds created by the gases to settle, thereby releasing the gases and allowing the electrolyte to circulate back to the bottom of electro lyzer 126 by way of the electro lyzer recirculation piping 130a- 130b, respectively.
  • electrolyzer drain valves 132a-132b which are used to drain the electrolyzer 126 for maintenance or repairs.
  • the hydrogen and oxygen gas isolation valves 142 and 144 isolate the electrolyzer 126 from the rest of the components for the reasons of maintenance or repairs.
  • the system controller 122 opens the hydrogen and oxygen gas control valves 154a and 156a, allowing gases to flow to the hydrogen and oxygen gas high pressure pumps 184 and 186.
  • the hydrogen and oxygen gas high pressure pumps 184 and 186 compress the gases and send them to the hydrogen and oxygen gas manifold systems 178 and 180 and to the respective gas storage tanks 182 where the gasses are stored separately and pressure can build up to the limits of the gas storage tanks 182. This is done to maximize the electrical generating capacity of the electrical storage device 110.
  • Hydrogen gases occupy approximately two-thirds of the storage tanks 182 and oxygen gases occupy approximately one-third of the gas storage tanks 182.
  • the present invention contemplates using any suitable number and size of gas storage tanks 182.
  • the system controller 122 automatically turns off the hydrogen and oxygen gas high pressure pumps 184 and 186 and the hydrogen and oxygen gas control valves 154a and 156a.
  • the system controller 122 also reduces the voltage delivered from rectifier module 124 or the DC to DC converter 128 until the current no longer flows to the electrolyzer 126. This "idle" state is maintained until the storage pressure has dropped below a pre-determined level and electrical power is available at the electrical breaker panel 116 to begin gas production again.
  • system controller 122 is connected to a power grid (not shown). In this embodiment, the system controller 122 monitors the power grid and determines when the power grid has the capacity to accept additional power from the energy storage device 110. The system controller 122 then meters the gases through the hydrogen and oxygen gas control valves 154b and 156b to the fuel cell 162. Pressures are read and transmitted to the system controller 122 from the hydrogen and oxygen gas pressure gauges/transmitters 158 and 160. In one embodiment, multiple hydrogen and oxygen gas pressure gauges/transmitters 158 and 160 are used throughout the gas lines to allow the system controller 122 to monitor and control the overall system. Also multiple hydrogen and oxygen gas isolation valves 142 and 144 and gas control valves 154 and 156 can be used throughout the system as needed to control the operation of the system as desired.
  • the fuel cell 162 recombines the hydrogen and oxygen gases to form water and DC electricity. Any excess water created during this process is release through the fuel cell drain valve 164 and pumped by the recirculation pump 168, which is controlled by the system controller 122, back to the electrolyzer 126 through the water recirculation line 166 and hydrogen and oxygen side water fill valves 170 and 172, respectively.
  • the hydrogen and oxygen side water fill valves 170 and 172 introduce the water back into the electrolyzer 126 for the process to continue. Electricity from the fuel cell 162 goes to the grid tie inverter 174 where it converts DC power to AC power.
  • the grid tie converter 174 also senses the AC wave timing on the electrical grid connection lines and adjusts the output from the fuel cell 162 to useful AC electricity.
  • the AC power is then connected to the power grid directly, through an external step up transformer, or to an AC load through the AC power outlet connection 176.
  • the system controller 122 is activated by a user to initiate the process for supplying power.
  • the energy storage device 110 may be made of multiple metal and composite components.
  • the electrical storage device housing (not shown) can be made of metal, composites, or any other material that can offer the desired protection for the specific application, including shipping containers for standard land or sea shipping that can be modified for the permanent attachment of the internal components and wires for housing the energy storage device 110.
  • the components of the electrical storage device 110 can be placed in the base of an existing wind turbine or any other structure as desired.
  • the electrical breaker panel 116 can be a commercially available metal, composite, or watertight enclosure meeting standard electrical code requirements.
  • the AC electrical breaker 118, DC electrical breaker 120, rectifier module 124, system controller 122, and all other electrical converters, controls and connections are commercially available components, or may be custom built for a particular application as known by those of skill in the art of such components.
  • the piping and hydrogen and oxygen gas defoaming chambers 138 and 140 are generally constructed out of stainless steel pipe and fittings, and for high pressure systems are wrapped with carbon fiber or some other composite layer to improve pressure performance, but may also be built out of CPVC, fiberglass reinforced pipe, polypropylene pipe, stainless steel pipe or other piping materials capable of being sealed together by either thread, heat bonding or adhesive and having chemical resistance to corrosion by caustic as well as chemical resistance to pure oxygen.
  • Gas storage tanks 182 are generally a composite tank but may be made of any known or future tank material that will not fail when carrying or storing hydrogen or oxygen gas under pressure.
  • a preferred electro lyzer 126 will be described hereafter, but any electro lyzer or fuel cell that can be built or purchased to meet the user-defined requirements of load, pressure, and efficiency could be used.
  • the recirculation pump 168, the valves and gauges in one embodiment are commercially available components.
  • the grid tie inverter 174 is generally a commercially available unit for solar or wind turbine use, but may be any other suitable grid tie inverter.
  • the hydrogen and oxygen gas high pressure pumps 184 and 186 are commercially available and may preferably use multistage piston or screw compressor systems.
  • a water storage tank for the fuel cell 62 in the electrical storage device 10 of the original invention of Figs. 1-2 may be added to the system.
  • the water storage tank is designed to be an additional supply of water that can make up for losses that can be experienced in the functioning of the electrolyzer 26 and the fuel cell 62.
  • the water storage tank can extend operations of the electrical storage device 10 in remote areas without the need for servicing.
  • the water storage tank can be commercially available and made of a variety of materials such as metal, composites, plastics, or any other suitable material for the purpose of the tank.
  • a number of gas storage tanks 182 of Figs. 3-4 can be used for water storage for the convenience of space. All piping, gauges, and other materials associate with the water storage tank and the functioning of it can all be commercially available.
  • a climate control device is added to the electrical storage device 110 of Figs. 3-4 for use in applications that expose the system to extreme environmental conditions.
  • climate control such as insulation for the electrical storage device housing, heat tracing and insulation for all piping, and even forms of heating and air conditioning, any of which may be used in conjunction with the present invention.
  • Another form of climate control that is specific to the embodiment of the electrical storage device 110 is that of a heat exchanger for the water and electrolyte solution.
  • the purpose of the heat exchanger is to keep the water and electrolyte solution within a tighter range of temperatures, thereby allowing the overall electrical storage device 110 to perform in more extreme environments.
  • the heat exchanger can take on cooling or heating characteristics to accomplish its purpose.
  • Different embodiments include, but are not limited, to circulating the water and electrolyte solution through solar panels to heat or a chiller system to cool.
  • the heat exchanger can be of various forms both commercially available and of future development and can be used in any embodiment of an electrical storage device 10 or 110.
  • the pressures of the output of hydrogen and oxygen gases generated by the electro lyzer 26 are generally from 10 to 200 psi but may be arranged for outputs up to and above 8000 psi when more storage capacity is desired in a smaller area.
  • a general size for an energy storage device is from about 40 inches by 40 inches by 42 inches to approximately 8 feet by 8 feet by 40 feet.
  • Individual energy storage devices and even additional tanks may be grouped to create an even larger storage capacity.
  • An energy storage device can handle energies from 200 to 750 kilowatts depending on the particular need, and can store from 20 to 20,000 kilowatt hours of energy, depending on size.
  • the hydrogen and oxygen gas storage tanks may be configured to be as small as 1 liter to as large as what transportation to an installation site will allow.
  • the device can store electrical energy from variable input sources in a cost effective way.
  • Full charge and discharge cycles of the energy storage device disclosed herein have a very minor impact on the life expectancy of the energy storage device in contrast to lead acid battery or other energy storage devices.
  • lead and acid components are eliminated in the present energy storage device, making the device more environmentally friendly to manufacture, use and dispose of.
  • Use of the present energy storage device can also dramatically improve the usability of wind turbines and solar arrays because the storage device disclosed herein allows the energy produced by the wind turbines and/or solar arrays to be used at any time rather than just when the wind blows or the sun shines.
  • the present energy storage device can be used to store energy from existing power plants during usage lulls and then dispense the stored energy during peak use periods, thereby creating a more efficient use of capital resources and fuels.
  • the electrical storage device can be a buffer from the creation of electricity by most any device to the creation of power by the electrical storage device, the electrical storage device can offer power factor correction, load balancing, and even power purchasing and selling abilities via a smart controller. Other advantages become apparent through the use of the disclosed invention. [0062]
  • the advantage of the first variant of the electrical storage device extends the operations of the electrical storage device in remote areas without the need for servicing.
  • FIG. 5 is a perspective view of an exemplary embodiment of an electrolyzer 310 with external plumbing 346 attached thereto.
  • Fig. 6 is an exploded perspective view of the electrolyzer 310.
  • the electrolyzer 310 includes a front platen 312, a front outside gasket 314, a front cell 330a, a rear cell 330b, a rear outside gasket 334, and finally a rear platen 336.
  • Front cell 330a of electrolyzer 310 as shown in Fig. 6 includes a first anode- cathode plate called the front anode-cathode plate 316, first top and bottom channel isolating media 318a and 320a, respectively, covering the top and bottom of the inside of the front anode-cathode plate 316, a channel gasket 322a with a corresponding gas flow media sheet 324a, a scrim sheet 326a, a channel gasket 322b with a corresponding gas flow media sheet 324b, second top and bottom channel isolating media 318b and 320b, respectively, and a second anode-cathode plate called the middle anode-cathode plate 328.
  • the second anode-cathode plate called the middle anode-cathode plate 328 of the front cell 330a also serves as the first anode-cathode plate of the rear cell 330b.
  • the rear cell 330b includes a first anode-cathode plate called the middle anode-cathode plate 328, first top and bottom channel isolating media 318c and 320c, respectively, covering the top and bottom of the inside of the middle anode-cathode plate 328, a channel gasket 322c with a corresponding gas flow media sheet 324c, a scrim sheet 326b, a channel gasket 322d with a corresponding gas flow media sheet 324d, second top and bottom channel isolating media 318d and 320d, respectively, and a second anode-cathode plate called the rear anode-cathode plate 332.
  • Fig. 7 is an exploded perspective view of a middle cell 330c, any number of which can be inserted between the front cell 330a and rear cell 330b of the electrolyzer 310.
  • the middle cell 330c includes a first anode-cathode plate called the middle anode- cathode plate 328, first top and bottom channel isolating media 318e and 320e, respectively, covering the top and bottom of the inside of the middle anode-cathode plate 328, a channel gasket 322e with a corresponding gas flow media sheet 324e, a scrim sheet 326c, a channel gasket 322f with a corresponding gas flow media sheet 324f, second top and bottom channel isolating media 318f and 320f, respectively, and a second anode- cathode plate called the middle anode-cathode plate 328.
  • the electrolyzer 310 contemplates including any number of middle cells 330c in the electrolyzer 310.
  • the electrolyzer 310 consists of a front cell 330a, a rear cell 330b, and multiple middle cells 330c.
  • the number of cells that may be included in the electrolyzer 310 as shown in Figs. 5-7 is related to the voltage that can be efficiently used by the electrolyzer 310. Voltages that can be used by the electrolyzer 310 range from 2 volts DC to 480 volts DC or more. Amperage supplied to the electrolyzer 310 can range from 1 amp to 3000 amps.
  • the number of middle cells 330c within any particular electrolyzer contemplated as the electrolyzer 310 of the current invention is determined by the voltage.
  • amperage density is between about 5 in 2 per amp and about 12 in 2 per amp.
  • voltage is kept below about 2.4 volts per cell.
  • voltage is kept between about 1.89 volts and about 2.1 volts per cell.
  • the spacing between each anode-cathode plate is consistent throughout the electrolyzer, and is from about 0.03125 inch (1/32 inch) to about 0.26 inch (13/50 inch), and preferably from about 0.060 inch (3/50 inch) to about 0.26 inch (13/50 inch), to maximize the functionality and efficiency of the electrolyzer 310.
  • the spacing between each anode-cathode plate can be varied by one of skill in the art using the principles described herein to configure the disclosed electrolyzer for any particular application.
  • Fig. 8 depicts external plumbing 346a and 346b that attaches to the electrolyzer 310 as shown in Fig. 5.
  • the external plumbing 346a and 346b can be made of metal, plastic, or any other suitable material as determined by one of skill in the art.
  • Circulation piping 354a and 354b will typically range from 1 ⁇ 2 inch to over 2 inches or more in diameter, thereby being configured to handle less than one gallon of water per day to tens of thousands of gallons of water per day depending on the particular application of the electrolyzer 310.
  • the circulation piping 354a and 354b circulates a water/KOH (potassium hydroxide) solution or other suitable electrolyte, hydrogen gases, oxygen gases, and any other substance that is introduced to the system.
  • the external plumbing 346b is a mirror image of the external plumbing 346a, one side being related to the flow of hydrogen gas and the other side for the oxygen gas. The different sides are reversible depending on how the voltage is applied to the electrolyzer.
  • the external plumbing 346a and 346b is attached to the electrolyzer via manifold holes (described below).
  • the external plumbing 346a and 346b is comprised of defoaming chambers 348a and 348b with site glasses 350a and 350b and inspection caps 352a and 352b.
  • Circulation piping 354a and 354b connects the electrolyzer 310 and the defoaming chambers 348a and 348b with the water fill valves 356a and 356b, gas storage valves 358a and 358b, and drain valves 360a and 360b, the functions of which are the same as the corresponding components described in connection with Figs. 1-4.
  • the electrolyzer 310 makes hydrogen and oxygen efficiently.
  • the process is as follows. Water with approximately a 10% - 40% solution of KOH (potassium hydroxide) or other solution which accomplishes the purposes of the electrolyzer 310 (hereafter referred to as "KOH solution”) is introduced by way of the water fill valve 356a and 356b through the external plumbing 346a and 346b to the front platen 312. Electricity is next connected to the front anode-cathode plate 316 and the rear anode-cathode plate 332. Once the electrolyzer 310 is saturated with water and KOH solution, electricity is applied.
  • KOH solution potassium hydroxide
  • the solution of KOH is an electrolyte that provides a method by which electricity can flow through the electrolyzer 310 between the front anode-cathode plate 316 and the rear anode-cathode plate 332.
  • hydrogen and oxygen are broken apart into their elemental form.
  • the hydrogen has a positive charge that flows to the negative electrode while the oxygen has a negative charge that flows to the positive electrode.
  • the gases bubble up along the surface of the anode or cathode plates to which they are attracted inside the gas flow media 324 through the top and bottom channels 344a and 344b respectively in the channel gasket 322 and to the manifold holes 340a-340b.
  • the channel gasket 322 is laid in the electrolyzer 310 in an alternating pattern with the channels 344 alternating from one side to the other. This alternating pattern directs the hydrogen to go to one side of the electrolyzer and one set of the external plumbing 346a, while oxygen is directed to the other side of the electrolyzer and to the other set of the external plumbing 346b. Hydrogen and oxygen gases bubble up to the top of the electrolyzer 310, travel through the respective manifold holes 340a-340b at the top of the electrolyzer 310 to the respective sets of external plumbing 346a and 346b.
  • the gases pass through the respective defoaming chambers 348a and 348b and out the gas storage valves 358a and 358b to storage tanks.
  • the water and KOH solution carried from the electro lyzer 310 by the bubbles of hydrogen and oxygen gas circulate from the defoaming chambers 348a and 348b back down the respective circulation piping 354a and 354b and re-enter the electrolyzer 310 through the manifold holes 340c-340d in the bottom of electrolyzer 310 for the process to continue.
  • the site glasses 350a and 350b allow for a visual inspection of the level of the water and KOH solution and the water fill valves 356a and 356b are used to add water as needed.
  • the inspection caps 352a and 352b can be used for inspections and adding KOH solution as needed.
  • the drain valves 360a and 360b are used to drain the KOH solution from the electrolyzer 310.
  • Fig. 9 depicts the front platen 312 of Fig. 5.
  • the front platen 312 can be made of various types of materials such as wood, metal, composites, etc.
  • the front platen 312 and the rear platen 336 (Fig. 6) are used to press together the front and rear outside gaskets 314 and 334, respectively, with the front, middle, and rear cells 330a, 330b, and 330c as depicted in Figs. 6-7.
  • the front platen 312 has bolt holes 338 around the perimeter that can be used to press the electrolyzer 310 (Fig. 6) together. Any other conventionally known or future method for compressing the electrolyzer 310 together as depicted in Figs. 5-7 is contemplated within the disclosed invention.
  • the front platen 312 ranges from approximately 1/32 of an inch to several inches in thickness.
  • the front platen 312 is also slightly larger in height and width than the channel gasket, scrim, and middle anode-cathode plate.
  • the front platen 312 is shorter by an inch or greater than the front and rear anode-cathode plates 316 and 332, respectively, to facilitate attaching electrical connections to the front and rear anode-cathode plates 316 and 332.
  • External plumbing 346a and 346b (Figs. 5 and 8) is attached to the outside of the front platen 312 at the manifold holes 340a-340d.
  • the manifold holes 340a-340d located in each corner are used to introduce the water and KOH solution, and to retrieve the hydrogen and oxygen gases for storage.
  • the manifold holes 340a-340d are 1 ⁇ 2 inch or larger in diameter to match the size of the external plumbing 346a and 364b.
  • Fig. 10 depicts the front outside gasket 314 of the electrolyzer 310 of Figs. 5- 6.
  • the front outside gasket 314 is made of polypropylene or any other suitable material that exhibits sealing properties and resists degradation caused by KOH or other caustic solutions.
  • the front outside gasket 314 is an electrical insulator and is primarily needed if the front platen 312 is made of a material that conducts electricity.
  • the front outside gasket 314 has manifold holes 340a-340d located in each corner to allow for the transfer of water, KOH solution, and gases.
  • the front outside gasket 314 is slightly smaller in height and width than the front platen 312 and rear platen 336 to allow for the chosen form of clamping the electro lyzer 310 together.
  • the front outside gasket 314 is approximately the same size as the channel gaskets 322, middle anode-cathode plates 328 and scrim sheets 326. In one embodiment, the front outside gasket 314 ranges from approximately 1/32 of an inch to approximately 1 ⁇ 4 of an inch in thickness.
  • Fig. 11 depicts the front anode-cathode plate 316 shown in Fig. 6.
  • the front anode-cathode plate 316 is made of a nickel steel alloy, 316 stainless.
  • the present invention contemplates that the front anode-cathode plate 316 may be made of any suitable electrically conductive material(s) that is not highly susceptible to oxidation or alkali corrosion.
  • the front anode-cathode plate 316 has four manifold holes 340a-340d corresponding to those in the front platen 312 and front outside gasket 314.
  • the front anode-cathode plate 316 is slightly smaller in height and width than the front platen 312 to allow for the chosen form of clamping the electro lyzer 310 together, and is approximately the same size as channel gaskets, front outside gaskets, and scrim sheets. However, in one embodiment the top of the front anode-cathode plate 316 is taller than the channel gaskets, front outside gaskets, and scrim sheets by an inch or greater to facilitate attaching electrical connections to the front anode-cathode plate 316.
  • the surfaces of the front anode-cathode plate 316 may be lightly sanded to remove contaminants and to give it a texture. In one embodiment, the thickness of the front anode-cathode plate 316 ranges from approximately 1/32 of an inch to approximately 1 ⁇ 4 of an inch in thickness, but may be thicker or thinner depending on the size and configuration of a particular electrolyzer.
  • Fig. 12 depicts a representative example of a channel gasket 322 identified as 322a-322f of Figs. 6-7.
  • the channel gasket 322 is made of polypropylene or another suitable material that exhibits sealing properties and resists degradation caused by KOH or other caustic solutions.
  • the thickness of channel gasket 322 generally ranges from about 1/32 of an inch to about 1 ⁇ 4 of an inch, but may be thicker or thinner depending on the size and configuration of a particular electrolyzer.
  • Channel gasket 322 is slightly smaller in height and width than the front platen 312 and rear platen 336 to allow for the chosen form of clamping the electrolyzer 310 together.
  • the channel gasket 322 is approximately the same size as the middle anode-cathode plate 328 and scrim sheet 326.
  • Channel gasket 322 has manifold holes 340a-340d in each corner.
  • the channel gasket 322 also has a series of top channels 344a and bottom channels 344b that are cut in a switch-back pattern to facilitate the flow of water, KOH solution, and hydrogen or oxygen gases.
  • a piece of gas flow media 324 (Fig. 13) is inserted into the center cut out 342 portion of the channel gasket 322.
  • the channel gaskets 322 are arranged in the electrolyzer 310 in an alternating pattern with the top and bottom channels 344a and 344b alternating from one side to the other, as can be seen in Figs. 6-7.
  • Fig. 13 depicts the gas flow media sheet 324 that is made of a material called green flow or another loosely woven plastic mesh or other material that creates a conduit or path to guide the gasses as they rise to the top of the channel gasket 322 while maintaining a desired space between the anode-cathode plates and the scrim, as shown in Figs. 6-7.
  • the gas flow media sheet 324 fits into the center cut out 342 and channels 344a and 344b of the channel gasket 322, and it is approximately the same thickness as the channel gasket 322.
  • Fig. 14 depicts a representative example of a scrim sheet 326 identified as 326a-326c of Figs. 6-7.
  • the scrim sheet 326 enables mechanical control of gases via surface tension, but also allows acid and base sides of cells to bleed back and forth, preventing corrosion of components.
  • the scrim sheet 326 may be made of polypropylene felt or any other suitable material that has absorption properties for water, KOH solutions and other caustic solutions, and resists degradation caused by KOH or other caustic solutions.
  • the scrim sheet 326 absorbs the water and KOH solution and also acts as a barrier to separate the channels 344a and 344b of the alternating channel gaskets 322 (Fig. 12).
  • the scrim sheet 326 has manifold holes 340a-340d in each corner.
  • the scrim sheet 326 is slightly smaller in height and width than the front platen 312 and rear platen 336 to allow for the chosen form of clamping the electrolyzer 310 together.
  • the scrim sheet 326 is approximately the same size as the channel gasket and middle anode-cathode plate. In one embodiment, the scrim sheet 326 ranges in thickness from approximately 1/32 of an inch to approximately 1 ⁇ 4 of an inch, but may be thicker or thinner depending on the size and configuration of a particular electrolyzer.
  • Fig. 15 depicts the middle anode-cathode plate 328 shown in Figs. 6-7.
  • the middle anode-cathode plate 328 is made of a nickel steel alloy, 316 stainless.
  • the present invention contemplates that the middle anode-cathode plate 328 may be made of any suitable electrically conductive material(s) that is not highly susceptible to oxidation or alkali corrosion.
  • Middle anode-cathode plate 328 has the same four manifold holes 340a-340d as found in the front platen 312, front outside gasket 314, and other internal components of electro lyzer 310 as described above.
  • the surfaces of the middle anode-cathode plate 328 may be lightly sanded to remove contaminants and to give it a texture.
  • the middle anode-cathode plate 328 is slightly smaller in height and width than the front platen 312 and rear platen 336 to allow for the chosen form of clamping the electro lyzer 310 together.
  • the middle anode-cathode plate 328 is approximately the same size as the channel gasket 322 and scrim sheet 326. In one embodiment, the middle anode-cathode plate 328 ranges in thickness from approximately 1/32 of an inch to approximately 1 ⁇ 4 of an inch, but may be thicker or thinner depending on the size and configuration of a particular electro lyzer.
  • Fig. 16 depicts an example of the top channel isolating media 318 similar to those shown as 318a-318f in Figs. 6-7.
  • the top channel isolating media 318 has manifold holes 340a and 340b that correspond to the manifold holes 340a and 340b as found in the front platen 312, front outside gasket 314, and other internal components of electro lyzer 310 as described above (Figs. 6-7).
  • the top channel isolating media 318 isolates the top channels 344a of the channel gaskets 322a-322f (Figs. 6-7 and 12).
  • top channel isolating media 318 may be made from any suitable material so long as it is not electrically conductive. It is not important whether the non-conductive property is due to the type of material, or some other coating or treatment of the material. In one embodiment, the top channel isolating media 318 is preferably as thin as possible.
  • the top channel isolating media 318 is as wide as the anode-cathode plates 316, 328, and 332, and tall enough to cover the top channels 344a of the channel gaskets 322a-322f when manifold holes 340a- .40b of the top channel isolating media 318 are aligned with the corresponding manifold holes 340a-340b of the channel gaskets 322a-322f (Figs. 6-7).
  • the top channel isolating material 318 wraps into the manifold holes 340a-340b to complete the isolation.
  • Fig. 17 depicts an example of the bottom channel isolating media 320 similar to those shown as 320a-320f in Figs. 6-7.
  • the bottom channel isolating media 320 has manifold holes 340c and 340d that correspond to the manifold holes 340c and 340d as found in the front platen 312, front outside gasket 314, and other internal components of electro lyzer 310 as described above (Figs. 6-7).
  • the bottom channel isolating media 320 isolates the bottom channels 344b of the channel gaskets 322a-322f (Figs. 6-7 and 12).
  • the bottom channel isolating media 320 may be made from any suitable material so long as it is not electrically conductive. It is not important whether the non-conductive property is due to the type of material, or some other coating or treatment of the material. In one embodiment, the bottom channel isolating media 320 is preferably as thin as possible.
  • the bottom channel isolating media 320 is as wide as the anode-cathode plates 316, 328, and 332, and tall enough to cover the bottom channels 344b of the channel gaskets 322a-322f when manifold holes 340c-340d of the bottom channel isolating media 320 are aligned with the corresponding manifold holes 340c-340d of the channel gaskets 322a-322f.
  • the bottom channel isolating material 320 wraps into the manifold holes 340c-340d to complete the isolation.
  • Fig. 18 depicts the rear anode-cathode plate 332 as shown in Fig. 6.
  • the rear anode-cathode plate 332 is made of a nickel steel alloy, 316 stainless.
  • the present invention contemplates that the rear anode-cathode plate 322 may be made of any suitable electrically conductive material(s) that is not highly susceptible to oxidation or alkali corrosion.
  • the rear anode-cathode plate 322 is slightly smaller in height and width than the front platen 312 allowing for the chosen form of clamping the electro lyzer 310 together, and is approximately the same size as channel gaskets, front outside gaskets, and scrim sheets.
  • the rear anode-cathode plate 332 extends above the channel gaskets, front outside gaskets, and scrim sheets by an inch or greater to facilitate attaching electrical connections to the rear anode-cathode plate 332.
  • the surfaces of the rear anode-cathode plate 332 may be lightly sanded to remove contaminants and to give it a texture.
  • the rear anode-cathode plate 332 does not need to have manifold holes 340a-340d as shown on the front anode-cathode plate 316 (Fig. 11) but may have them for ease of manufacturing, assembly or other need.
  • the thickness of the rear anode-cathode plate 332 ranges from approximately 1/32 of an inch to approximately 1 ⁇ 4 of an inch in thickness, but may be thicker or thinner depending on the size and configuration of a particular electro lyzer.
  • Fig. 19 depicts the rear outside gasket 334 shown in Fig. 6.
  • the rear outside gasket 334 is made of polypropylene or any other suitable material that exhibits sealing properties and resists degradation caused by KOH or other caustic solutions.
  • the rear outside gasket 334 is an electrical insulator and is primarily needed if the rear platen 336 is made of a material that conducts electricity.
  • the rear outside gasket 334 is the same size as the front outside gasket 314.
  • the rear outside gasket 334 does not need to have manifold holes 340a-340d as shown on the front outside gasket 334 (Fig. 10) but may have them for ease of manufacturing, assembly or other need.
  • the rear outside gasket 334 ranges from 1/32 of an inch to 1 ⁇ 4 of an inch in thickness, but may be thicker or thinner depending on the size and configuration of a particular electrolyzer.
  • Fig. 20 shows the rear platen 336 of Fig. 5.
  • the rear platen 336 can be made of various types of materials such as wood, metal, composites, etc.
  • the rear platen 336 and the front platen 312 (Fig. 6) are used to press together the front and rear outside gaskets 314 and 334, respectively, with the front, middle, and rear cells 330a, 330b, and 330c as depicted in Figs. 6-7.
  • the rear platen 336 has bolt holes 338 around the perimeter that can be used to press the electrolyzer 310 together. Any other conventionally known or future method for compressing the electrolyzer 310 together as depicted in Figs. 5-7 is contemplated within the disclosed invention.
  • the rear platen 336 does not need to have manifold holes 340a-340d as shown on the front platen 312 (Fig. 9) but may have them for ease of manufacturing, assembly or other need.
  • the rear platen 336 ranges from approximately 1/32 of an inch to several inches in thickness.
  • the rear platen 336 is also slightly larger in height and width than the channel gasket, scrim, and middle anode-cathode plate.
  • the rear platen 336 is shorter by an inch or greater than the front and rear anode-cathode plates, to facilitate attaching electrical connections to the front and rear anode-cathode plates.
  • FIG. 5 The construction details of the invention as shown in Figs. 5- 6 are as follows. A small amount of sealant is placed around the manifold holes 340a-340d of the inside of the front platen 312 and the outside of the front anode-cathode plate 316. Provided the front platen 312 is made of a non-conducting material then the front outside gasket 314 may not be needed. The front anode-cathode plate 316 is placed on the front platen 312 and a top and bottom channel isolating media 318a and 320a covering the top and bottom respectively of the inside of the front anode-cathode plate 316 is applied.
  • the channel gasket 322a is laid down on the front anode-cathode plate 316.
  • the orientation of the channel gasket 322a is positioned and noted.
  • Each subsequent channel gasket 322 used in electrolyzer 310 will be alternated in orientation with respect to the immediately proceeding channel gasket 322.
  • the gas flow media sheet 324a is placed inside the center cutout 342 of the channel gasket 322a with the scrim sheet 326a placed on top of the channel gasket 322a and gas flow media sheet 324a.
  • a second channel gasket 322b is laid down in an orientation that is opposite that of the prior channel gasket 322a, with a gas flow media sheet 324b placed inside the center cutout 342 of the channel gasket 322b.
  • the middle anode-cathode plate 328 is laid down with a top channel isolating media 318b and 318c covering the top of both sides of the middle anode-cathode plate 328, and a bottom channel isolating media 320b and 320c covering the bottom of both sides of the middle anode-cathode plate 328.
  • the steps used to construct the front cell 330a may be repeated to construct multiple middle cells 330c using additional similar components, starting at the first layer of the channel gasket 322c and gas flow media sheet 324c.
  • the rear cell 330b shown in Fig.
  • the rear anode-cathode plate 332 with a top and bottom channel isolating media 318f and 320f covering the top and bottom respectively of the inside of the rear anode-cathode plate 332 is put in place .
  • the rear platen 336 is made of a non-conducting material then the rear outside gasket 334 may not be needed.
  • the rear platen 336 is laid down and the two platens 312 and 336 are bolted together through the bolt holes 338 and tightened to apply the appropriate pressure.
  • the outside perimeter edges of the electrolyzer 310 are sealed. This seal may be formed using a sealant or any other appropriate method of sealing the outside perimeter edges of the electrolyzer. Once sealed, the external plumbing 346 is assembled and attached to the electrolyzer 310 as depicted in Fig. 1 and Fig. 4.
  • FIG. 21 is a perspective view of an exemplary embodiment of alternative cell components 400 that may be included in an electrolyzer 310
  • Fig. 22 is an exploded perspective view of the alternative cell components 400.
  • the basic alternative cell components 400 include a channel gasket 422a with four manifold holes 440a-440d and the center cutout 442.
  • a gas flow media sheet 424a is sized and configured to fit in the center cutout 442 of the channel gasket 422a.
  • Top and bottom bridge pieces 476a and 476b respectively are inserted into the bridge piece indentations 478a and 478b (see Fig.
  • Alternative cell components 400 also include a channel gasket 422b, having a center cutout 442, and a gas flow media sheet 424b sized and configured to fit in the center cutout 442 of the channel gasket 422b.
  • Channel gasket 422b also has manifold holes 440a-440d that match the manifold holes 440a-440d of the channel gasket 422a.
  • Channel gaskets 422a and 422b are identical, but are oriented with identical surfaces facing toward one another such that the channels 444a and 444b of channel gasket 422a are opposite one side to the other of channels 444a and 444b of channel gasket 422b.
  • Channel gaskets 422a and 422b further include grooves forming the top channel 444a and the bottom channel 444b (Fig. 24).
  • Two bridge pieces 476c and 476d which are inserted into the bridge piece indentations 478c and 478d are used to hold the scrim sheet 426 tightly against the face of the opposite channel gasket 422a.
  • the alternative cell components 400 can be made up of the same or different materials as described above, with the intent of being a unit that can be easily inserted in between the appropriate anode-cathode plates to facilitate manufacturing the electrolyzer described herein.
  • Channel gasket o-ring grooves 472 may be cut around the perimeters of the outside of the channel gaskets 422a and 422b, and manifold o-ring grooves 470a-470d may be cut around each of the manifold holes 440a-440d so that o-ring type of gaskets can be used in connection with these parts to replace or reduce the use of silicon or other sealants.
  • Fig. 23 depicts the outside of the channel gasket 422a shown in Fig. 22.
  • the outside of channel gasket 422b shown in Fig. 22 is the same as the outside of channel gasket 422a.
  • the channel gaskets 422a and 422b are made of polypropylene or any other suitable material that exhibits sealing properties and resists degradation caused by KOH or other caustic solutions.
  • the channel gaskets 422a and 422b are designed to be slightly smaller than the front platen of the electrolyzer into which the channel gaskets 422a and 422b are to be placed, and are designed to be approximately the same size as a middle anode-cathode plate of the respective electrolyzer.
  • the channel gaskets 422a and 422b have manifold holes 440a-440d located in the corners thereof. There is a center cut out 442 of the channel gaskets 422a and 422b in a rhombus-like shape designed to channel the flow of gasses to the channels 444a-444b shown in Fig. 24.
  • the channel gaskets 422a and 422b range from approximately 1/32 of an inch to approximately 1 ⁇ 4 of an inch in thickness, but may be thicker or thinner depending on the size and configuration of a particular electrolyzer into which channel gaskets 422a and 422b are to be inserted.
  • An o-ring groove called the channel gasket o- ring groove 472 may be cut around the outside perimeter of channel gaskets 422a and 422b for an o-ring to be placed therein.
  • O-ring grooves called manifold holes o-ring groove 470a-470d may also be cut around the manifold holes 440a-440d to facilitate the placement of o-rings in the manifold holes 440a-440d for the purpose of replacing or reducing the use of silicon in the construction.
  • Fig. 24 depicts the inside of the channel gasket 422b shown in Fig. 22.
  • the inside of channel gasket 422a, also shown in Fig. 22, is the same as the inside of channel gasket 422b.
  • Channel gaskets 422a and 422b have a series of channels 444a and 444b cut in a switch-back pattern on the inside to facilitate the flow of water, KOH solution, and hydrogen or oxygen gases.
  • the deeper cut section of the channels 444a and 444b are the bridge piece indentations 478a and 478b which are designed to except a bridge piece 476 of Fig. 27.
  • the series of channels 444a and 444b do not extend all the way through the thickness of the channel gaskets 422a and 422b.
  • the inside of channel gaskets 422a and 422b also have a recessed portion called the scrim sheet indentation 474 extending around the perimeter of the center cutout 442.
  • the scrim sheet indentation 474 is sized and configured to receive a scrim sheet 426, which is described below in connection with Fig. 26.
  • Fig. 25 depicts a gas flow media sheet 424 that is also depicted as gas flow media sheets 424a and 424b in Fig. 22.
  • the gas flow media sheet 424 is made of a material called green flow or another loosely woven plastic mesh or other material.
  • the gas flow media sheet 424 creates a conduit or path to guide the gasses as they raise to the top of the channel gaskets 422a and 422b (Fig. 22) while maintaining a desired space between the anode cathode plates and the scrim sheet 426.
  • the alternative cell components 400 are to be placed between anode-cathode plates for use in an electrolyzer.
  • the gas flow media sheet 424 is sized and configured to fit into the center cut out 442 of the channel gaskets 422a and 422b and may only slightly overlap the series of channels 444a and 444b of channel gaskets 422a and 422b (Fig. 24). In one embodiment, the gas flow media sheet 424 is approximately the same thickness as the channel gasket into which it is placed for use.
  • Fig. 26 depicts the scrim sheet 426 that is also shown in Fig. 22.
  • the scrim sheet 426 may be made of polypropylene felt or any other suitable material that has absorption properties for water, KOH solutions and other caustic solutions, and resists degradation caused by KOH or other caustic solutions.
  • the scrim sheet 426 absorbs the water and KOH solution and it also acts as a barrier to separate the channels 444a and 444b of the channel gaskets 422a and 422b.
  • the scrim sheet 426 is rectangular in shape, similar to the channel gaskets 422a and 422b.
  • the scrim sheet 426 is sized to cover the gas flow media sheet 424a and 424b when the gas flow media sheet 424a and 424b are placed in the center cutouts 442 of channel gaskets 422a and 422b, respectively.
  • the scrim sheet 426 is further sized and configured to overlap at least a portion of the series of channels 444a and 444b in channel gaskets 422a and 422b.
  • the scrim sheet 426 is sized and configured to fit into the scrim sheet indentation 474 of the channel gaskets 422a and 422b, each scrim sheet indentation 474 being one half of the thickness of scrim sheet 426.
  • the scrim sheet 426 ranges in thickness from approximately 1/32 of an inch to approximately 1 ⁇ 4 of an inch, but may be thicker or thinner depending on the size and configuration of a particular electrolyzer with which scrim sheet 426 is used.
  • Fig. 27 shows a representative bridge piece 476 of bridge pieces 476a-476d shown in Fig. 22.
  • the bridge piece 476 may be made of polypropylene or any other suitable material that resists degradation caused by KOH or other caustic solutions.
  • a bridge piece 476 is used to hold the scrim sheet 426 tightly against the face of the opposite channel gasket 422a or 422b that the scrim sheet 426 is mated to.
  • bridge pieces 476a-476d is placed in each of the upper and lower channels 444a and 444b for the channel gaskets 422a and 422b in the groove that abuts the center cutout 442 called the bridge piece indentations 478a and 478b.
  • each groove of the upper and lower channels 444a and 444b that abuts the center cutout 442 serves as a recess to receive one of the bridge pieces 476a-476d called the bridge piece indentations 478a-478d.
  • the bridge pieces 476a-476d are orientated such to allow the flow of gasses into the upper and lower channels 444a and 444b.
  • the channel gaskets 422a and 422b are placed on a flat surface with the inside of each of channel gaskets 422a and 422b facing up.
  • the gas flow media sheets 424a and 424b are placed in the center cutouts 442 of the channel gaskets 422a and 422b.
  • the bridge pieces 476a-476d are placed into each of the bridge piece indentations 478a-478d of the upper and lower channels 444a and 444b for each of the channel gaskets 422a and 422b.
  • the scrim sheet 426 is next inserted into the scrim sheet indentation 474 of channel gasket 422a.
  • channel gasket 422a and 422b are then placed together and bonded.
  • the alternative cell components 400 are complete and ready to be assembled into an electrolyzer.
  • An o-ring type of gasket made of Viton or any other suitable material that has sealing properties and resists degradation caused by KOH or other caustic solutions can be used in the place of or in addition to a sealant that is applied to the outside perimeter edge of the electrolyzer and the manifold holes 440a-440d.
  • the o- ring type of gasket is applied to the channel gasket o-ring groove 472 that goes around the perimeter of the outside of the channel gasket 422a and 422b.
  • the o-ring type of gasket is also applied to the manifold o-ring grooves 470a-470d that go around the manifold holes 440a-440d on the outside of the channel gaskets 422a and 422b.
  • Fig. 28 depicts a perspective view of an exemplary embodiment of a front platen 512 with grooves that is a variant of the front platen 312 of the electrolyzer 310 (Fig. 6).
  • the front platen 512 with grooves can be made of any number various suitable materials, including wood, metal, composites, etc.
  • the font platen 512 has manifold o-ring grooves 570a-570d configured to receive an o-ring cut into the front thereof.
  • Bolt holes 538 are used to receive bolts (not shown) that secure the front platen 512 with grooves to a rear platen (not shown). When the bolts (not shown) are tightened, the front platen 512 with grooves is drawn toward the rear platen (not shown) thereby compressing the various components (not shown) located between the front platen 512 with grooves and the rear platen (not shown).
  • the front platen 512 works in the same way as the front platen 312 of the electrolyzer 310 shown in Fig. 6, with the added feature of the manifold o-ring grooves 570a-570d.
  • the manifold o-ring grooves 570a-570d allow for an o-ring to be used in the place of or in addition to a sealant.
  • Fig. 28 The construction details of Fig. 28 are substantially the same as for the front platen 312 described in connection with the electrolyzer 310 of Fig. 6, with the addition of cutting the manifold o-ring grooves 570a-570d.
  • an o-ring type of gasket made of Viton or any other suitable material that has sealing properties and resists degradation caused by KOH or other caustic solutions is inserted into each of the manifold o-ring grooves 570a-570d.
  • Fig. 29 depicts an exploded perspective view of an exemplary embodiment of a scrim sheet assembly 680 that is a variant of the scrim sheet 326 of the electrolyzer 310 of Fig. 6.
  • the scrim sheet assembly 680 consists of three parts made of two different materials; scrim sheet 626 and two fabric sheets 682a and 682b.
  • the scrim sheet 626 in one embodiment can be used by itself as it is the same scrim sheet 326 of Fig. 6.
  • the fabric sheets 682a and 682b are made of silk or any other suitable fabric material that has absorption properties for water, KOH solutions and other caustic solutions, and resists degradation caused by KOH or other caustic solutions.
  • the fabric sheets 682a and 682b aid in the retention of water and KOH solution in the scrim sheet 626 causing the scrim sheet assembly 680 to be more effective than just the scrim sheet 326 of Fig. 6.
  • the scrim sheet assembly 680 serves the same purpose and is similar in size to the scrim sheet 326 of Fig. 6.
  • the scrim sheet assembly 680 has manifold holes 640a-640d in each corner.
  • Fig. 29 The construction details of Fig. 29 are substantially the same as for the scrim sheet 326 described in connection with the electro lyzer 310 of Fig. 6, with the addition of placing a fabric sheet 682a and 682b on either side of the scrim sheet 626.
  • the fabric sheets 682a and 682b are inserted on both sides of the scrim sheet 326 of Fig. 6.
  • the electrolyzers disclosed herein have numerous advantages. For example, the electrolyzers of the present invention are more efficient at using electricity to make hydrogen and oxygen than conventionally known electrolyzers. Because the electrolyzers of the present invention use cells that are arranged in series, the electrolyzer can receive higher voltages than conventional electrolyzers, such as AC 480, thereby eliminating the need to use a step down transformer. The ability to use higher voltages translates into the capacity for higher power utilization as well as a lower overall amperage density. This configuration results in reduced energy loss in the form of heat that is generated as a byproduct. Fairly common lower-cost materials can also be utilized in the electrolyzers of the present invention without sacrificing efficiency or durability. The combination of high efficiency output and lower material costs allow the electrolyzers disclosed herein to be a very cost effective way of producing hydrogen and oxygen from water.
  • the present invention is a device to store and produce energy with an efficient, cost effective electrolyzer.
  • the energy storage device described herein is configured for a given set of input voltages.
  • the AC power feed connection 12 is connected to one set of feed voltage, such as 120, 240, 480 volts or some other pre-determined voltage as desired.
  • the DC power feed connection 14 is configured to receive 12, 24, or 48 volts DC or some other pre-determined voltage as desired.
  • the electrolyzer 26 has a number of cells such that there is one to every two volts being supplied to the electrolyzer 26. The cells are also sized to meet the amperage requirements of the particular installation.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Electrolytic Production Of Non-Metals, Compounds, Apparatuses Therefor (AREA)
  • Fuel Cell (AREA)

Abstract

L'invention concerne un dispositif qui stocke de l'énergie électrique par conversion de l'énergie électrique en hydrogène gazeux et oxygène gazeux puis utilisation de l'hydrogène et de l'oxygène gazeux pour générer de l'électricité selon les besoins. L'invention comprend des connexions d'alimentation à courant alternatif (AC) et à courant continu (DC) pour alimenter en électricité un dispositif de stockage d'énergie. L'électrolyseur utilise cette électricité avec de l'eau et crée de l'hydrogène et de l'oxygène qui sont stockés dans des réservoirs jusqu'à ce que l'on en nécessite. Des soupapes de commande envoient de façon dosée les gaz stockés à une pile à combustible, laquelle reconvertit l'hydrogène gazeux et l'oxygène gazeux en électricité. La sortie de la pile à combustible est ensuite adressée à un onduleur de couplage au réseau pour une introduction dans un réseau électrique comme courant alternatif (AC) ou est utilisée pour fournir de l'électricité directement à un dispositif électrique ou à un système électrique tel que désiré.
PCT/US2012/029006 2011-03-15 2012-03-14 Dispositif de création d'énergie et de stockage d'énergie WO2012125683A2 (fr)

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US201161453036P 2011-03-15 2011-03-15
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017020824A1 (fr) * 2015-08-05 2017-02-09 林信涌 Appareil électrolytique
US20230279836A1 (en) * 2022-03-01 2023-09-07 Keith Charles Avery Grid Decoupled Wind Powered Hydrogen Generation and Storage

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Publication number Priority date Publication date Assignee Title
CN1019590B (zh) * 1990-09-03 1992-12-23 张学明 高效水电解制氢氧装置
US6474330B1 (en) * 1997-12-19 2002-11-05 John S. Fleming Hydrogen-fueled visual flame gas fireplace
KR100632181B1 (ko) * 2003-06-26 2006-10-12 김석현 전기분해조의 수,산소가스 분리격막 제조방법

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Title
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017020824A1 (fr) * 2015-08-05 2017-02-09 林信涌 Appareil électrolytique
US11021800B2 (en) 2015-08-05 2021-06-01 Hsin-Yung Lin Electrolytic device
US20230279836A1 (en) * 2022-03-01 2023-09-07 Keith Charles Avery Grid Decoupled Wind Powered Hydrogen Generation and Storage

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