WO2024044812A1 - An electrolyser output treatment system - Google Patents

An electrolyser output treatment system Download PDF

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Publication number
WO2024044812A1
WO2024044812A1 PCT/AU2023/050832 AU2023050832W WO2024044812A1 WO 2024044812 A1 WO2024044812 A1 WO 2024044812A1 AU 2023050832 W AU2023050832 W AU 2023050832W WO 2024044812 A1 WO2024044812 A1 WO 2024044812A1
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WO
WIPO (PCT)
Prior art keywords
electrolyser
filtration chamber
gaseous fuel
treatment system
output treatment
Prior art date
Application number
PCT/AU2023/050832
Other languages
French (fr)
Inventor
Richard Arthur CONNORS
Matthew Stephen BAILEY
Hassan SHAFIQ
Original Assignee
Dcarb Australia Pty Ltd
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
Priority claimed from AU2022902479A external-priority patent/AU2022902479A0/en
Application filed by Dcarb Australia Pty Ltd filed Critical Dcarb Australia Pty Ltd
Publication of WO2024044812A1 publication Critical patent/WO2024044812A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D47/00—Separating dispersed particles from gases, air or vapours by liquid as separating agent
    • B01D47/02—Separating dispersed particles from gases, air or vapours by liquid as separating agent by passing the gas or air or vapour over or through a liquid bath
    • B01D47/021—Separating dispersed particles from gases, air or vapours by liquid as separating agent by passing the gas or air or vapour over or through a liquid bath by bubbling the gas through a liquid bath
    • 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
    • C25B15/00—Operating or servicing cells
    • C25B15/02—Process control or regulation
    • 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
    • C25B15/085—Removing impurities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D47/00—Separating dispersed particles from gases, air or vapours by liquid as separating agent
    • B01D47/02—Separating dispersed particles from gases, air or vapours by liquid as separating agent by passing the gas or air or vapour over or through a liquid bath
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/20—Mixing gases with liquids
    • B01F23/23—Mixing gases with liquids by introducing gases into liquid media, e.g. for producing aerated liquids
    • B01F23/231—Mixing gases with liquids by introducing gases into liquid media, e.g. for producing aerated liquids by bubbling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/20—Mixing gases with liquids
    • B01F23/23—Mixing gases with liquids by introducing gases into liquid media, e.g. for producing aerated liquids
    • B01F23/237—Mixing gases with liquids by introducing gases into liquid media, e.g. for producing aerated liquids characterised by the physical or chemical properties of gases or vapours introduced in the liquid media
    • B01F23/2376—Mixing gases with liquids by introducing gases into liquid media, e.g. for producing aerated liquids characterised by the physical or chemical properties of gases or vapours introduced in the liquid media characterised by the gas being introduced
    • B01F23/23761—Aerating, i.e. introducing oxygen containing gas in liquids
    • B01F23/237612—Oxygen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F23/00—Mixing according to the phases to be mixed, e.g. dispersing or emulsifying
    • B01F23/20—Mixing gases with liquids
    • B01F23/23—Mixing gases with liquids by introducing gases into liquid media, e.g. for producing aerated liquids
    • B01F23/237—Mixing gases with liquids by introducing gases into liquid media, e.g. for producing aerated liquids characterised by the physical or chemical properties of gases or vapours introduced in the liquid media
    • B01F23/2376—Mixing gases with liquids by introducing gases into liquid media, e.g. for producing aerated liquids characterised by the physical or chemical properties of gases or vapours introduced in the liquid media characterised by the gas being introduced
    • B01F23/23764—Hydrogen
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B13/00—Oxygen; Ozone; Oxides or hydroxides in general
    • C01B13/02—Preparation of oxygen
    • C01B13/0203—Preparation of oxygen from inorganic compounds
    • C01B13/0207—Water
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N17/00—Investigating resistance of materials to the weather, to corrosion, or to light
    • G01N17/02—Electrochemical measuring systems for weathering, corrosion or corrosion-protection measurement
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N31/00—Investigating or analysing non-biological materials by the use of the chemical methods specified in the subgroup; Apparatus specially adapted for such methods
    • G01N31/22—Investigating or analysing non-biological materials by the use of the chemical methods specified in the subgroup; Apparatus specially adapted for such methods using chemical indicators
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N31/00—Investigating or analysing non-biological materials by the use of the chemical methods specified in the subgroup; Apparatus specially adapted for such methods
    • G01N31/22—Investigating or analysing non-biological materials by the use of the chemical methods specified in the subgroup; Apparatus specially adapted for such methods using chemical indicators
    • G01N31/221—Investigating or analysing non-biological materials by the use of the chemical methods specified in the subgroup; Apparatus specially adapted for such methods using chemical indicators for investigating pH value

Definitions

  • the present invention relates to an electrolyser output treatment system including a filtration chamber connected to an electrolyser and a flash back valve connected to the filtration chamber configured to open when the gaseous fuel in the filtration chamber exceeds a designated pressure.
  • the present invention involves the filtration chamber filtering electrolytes produced from an aqueous solution that is used by the electrolyser to produce hydrogen and oxygen and the flash back valve venting gasses to atmosphere if pressure in the filtration chamber exceeds a designated pressure.
  • Hydrogen and oxygen gas can be produced by the electrolysis of water by an electrolyser, such as a wet cell electrolytic generator or a dry cell electrolytic generator. Water, however, is a relatively poor conductor of electric current.
  • a chemical like potassium hydroxide, sulfuric acid, or sodium hydroxide is typically added to the water to form an aqueous solution with electrolytes that optimises the production of hydrogen and oxygen gas by the electrolyser.
  • Chemicals like potassium and sodium hydroxide make the water highly corrosive and potentially harmful to people and to devices that ultimately use the produced hydrogen and oxygen gas such as combustion engines.
  • one existing type of electrolyser for producing hydrogen and oxygen gas is a wet cell electrolytic generator.
  • plates forming an anode and a cathode are submerged into a tank containing an aqueous solution with an electrolyte such as sodium hydroxide in water.
  • electrolyte such as sodium hydroxide in water.
  • These wet cell generators may typically require 1 to 2 litres of electrolyte per tank and most designs of this type require 6 to 12 two-litre tanks, meaning that the total electrolyte may be in 10 to 20 litres of aqueous solution.
  • the wet cell electrolytic generators work under pressure to produce the hydrogen and oxygen gas which can result in safety issues.
  • the resultant hydrogen and oxygen gas may pool at the top of the tank which could conceivably be ignited by a static electrical charge.
  • the tanks also continually generate hydrogen and oxygen gas long after the generator is turned off.
  • Another existing type of electrolyser for producing hydrogen and oxygen gas is a dry cell electrolytic generator.
  • the generator may have a series of flat conductive plates between which circulates a pumped aqueous solution of electrolyte such as sodium hydroxide in water. These plates are sandwiched between insulating gaskets and their electric connections are located on the outside of the plates thus eliminating the possibility of a spark igniting the gas produced within the tanks.
  • the resultant gas is passed to a central gas tank and may pool in components of the electrolyser which can still result in safety issues.
  • Both types of existing electrolysers use an aqueous ionic solution for producing hydrogen and oxygen gas which may contain say ten to twenty five percent of an electrolytic solution such as sodium hydroxide, potassium hydroxide or similar chemical.
  • an electrolytic solution such as sodium hydroxide, potassium hydroxide or similar chemical.
  • Sodium hydroxide solution is very caustic and corrosive, and the electrolysis may produce caustic gasses in the resultant hydrogen and oxygen gas. These caustic gasses are deleterious to devices that ultimately use the hydrogen and oxygen gas such as combustion engines.
  • an electrolyser output treatment system including: a filtration chamber having a first end and a second end, the filtration chamber being connected to an electrolyser at the first end and is configured to filter gaseous fuel produced by the electrolyser and to output the gaseous fuel at the second end; and a flash back valve connected to the filtration chamber and is configured to open when the gaseous fuel in the filtration chamber exceeds a designated pressure and at least partially vent the gaseous fuel to atmosphere to reduce pressure in the filtration chamber.
  • the gaseous fuel includes hydrogen and oxygen.
  • the hydrogen and oxygen gas may be used in a combustion engine in a continuous injection process at a certain volume to enhance engine fuel efficiency, or in short service cycles of 30 minutes to 90 minutes at higher delivery rates to dislodge and burn off built up layers of carbon that plague internal combustion engines. Both application methods bring significant benefits to engines.
  • the gaseous fuel could be just hydrogen.
  • the flash back valve vents the gaseous fuel and the explosive gasses to atmosphere to prevent an explosion.
  • the flash back valve includes a sealing means connected to a stabilising rod and a biasing means, whereby the sealing means is biased to a closed position by the biasing means and the sealing means moves to an open position when the gaseous fuel in the filtration chamber exceeds the designated pressure.
  • the sealing means is a ball valve and the biasing means is a spring.
  • the flash back valve thus prevents excess gaseous fuel, such as hydrogen and oxygen, from pooling in the filtration chamber. Further, if the gaseous fuel did ignite in the filtration chamber, the flash back valve would vent the high pressure wave away from the filtration chamber to prevent a potentially fiery explosion, and then the spring would reseal the ball valve.
  • the flash back valve further includes a plurality of vent holes for venting the gaseous fuel and or pressure wave to atmosphere.
  • the flash back valve includes a clear housing so operation of the flash back valve can be visually inspected.
  • the filtration chamber contains fluid, and the fluid is configured to filter the gaseous fuel and to prevent ingress of a spark, flame or pressure wave following operation of the flash back valve.
  • electrolysers use an aqueous solution for producing hydrogen and oxygen gas which may contain an electrolytic solution such as sodium hydroxide.
  • the fluid in the filtration chamber is thus configured to filter electrolytes from an aqueous solution used by the electrolyser to produce the gaseous fuel that made their way into the filtration chamber. That is, the fluid filters caustic gasses produced by the electrolyser from the addition of the electrolytic solution to water.
  • the fluid is configured to neutralise its pH resulting from contamination by electrolytes in the filtration chamber.
  • the fluid is configured to change colour when contaminated by the electrolytes in the filtration chamber beyond its operating capability.
  • the fluid in the filtration chamber is indicator fluid and the filtration chamber is configured to provide a visible indicator of production of the gaseous fuel.
  • the gaseous fuel here forms bubbles in the indicator fluid indicative of a rate of production of the gaseous fuel.
  • the electrolyser may be configured to produce between 5 and 20 litres per minute of gaseous fuel and, at 20 litres per minute, four times the bubbles in the indicator fluid are formed than at 5 litres per minute.
  • the filtration chamber includes a pH sensor and the system is configured to prevent the gaseous fuel from being outputted at the second end following sensed pH in the filtration chamber exceeding a threshold value.
  • the threshold value is 7 to 14.
  • the fluid includes naturally occurring plant dyes or synthetically manufactured chemicals that change colour when exposed to chemicals or gases of a specific acidic or basic nature.
  • a typical example is a swimming pool chlorine test kit used to keep swimming pools in a pH range that discourages algae growth.
  • Figure 1 is a representation of an electrolyser system including an electrolyser output treatment system according to an embodiment of the present invention
  • Figure 2 is a representation of a flash back valve of an electrolyser output treatment system according to an embodiment of the present invention
  • Figure 3 is a representation of an electrolyser output treatment system according to another embodiment of the present invention.
  • Figure 4 is a flow chart of operation of an electrolyser output treatment system according to another embodiment of the present invention.
  • an example of at least part of an electrolyser system 10 is shown in Figure 1 including an electrolyser output treatment system 11 which is shown in more detail in Figure 3.
  • the electrolyser system 10 here includes an electrolyser 12 configured to be controlled by a controller 13 to produce gaseous fuel.
  • the electrolyser 12 produces hydrogen and oxygen gaseous fuel which is outputted to be used by devices such as a combustion engine (not shown) via a gaseous passage 14 and subsequent hoses (not shown).
  • the hydrogen may be used by the combustion engine as fuel and in doing so may clean various components of the combustion engine.
  • the electrolyser 12 is a dry cell type electrolyser which uses an aqueous solution for producing the hydrogen and oxygen gas which contains an electrolytic solution, such as sodium or potassium hydroxide, to aid in the electrolysis of water.
  • an electrolytic solution such as sodium or potassium hydroxide
  • the dry cell type electrolyser 12 reaches maximum output within 3 minutes regardless of ambient temperature and stops generating gas within 3 seconds of being turned off.
  • the electrolyser 12 requires one or more power supplies with built in safety features such as circuit and power regulation logic, and has a control panel for controlling the controller 13. The control panel enables the operator to select different modes of operation of the electrolyser 12 such as 4 different rates of production of the gaseous fuel.
  • the electrolyser 12 is a wet cell type electrolyser which also uses the same aqueous solution.
  • the aqueous solution is stored in a tank (not shown) of the dry cell type electrolyser 12 that is made from a non-metal composite material so that it cannot rust, leak, or corrode. Further, the tank is configured to exceed heat and chemical resistance criteria for operation within the electrolyser 12.
  • the tank in this example is a 300ml barrel.
  • the tank also has sensors and one or more electrolyte pumps to automatically keep the electrolyte balance in the aqueous solution at an optimal level, circulates the solution to dislodge gas bubbles forming at the electrolyser plates and to dissipate heat, and can shut down the system 10 if the solution level falls below and prescribed level.
  • the aqueous solution in the tank can also be pumped through radiator cooling fins to dissipate heat.
  • the system 10 includes the electrolyser output treatment system 11 to treat the hydrogen and oxygen produced by the electrolyser 12 to prevent any electrolyte from being outputted with the gaseous fuel and to prevent any gasses produced from the electrolytes in the aqueous solution being electrolysed from being outputted and, for example, entering a combustion engine.
  • the electrolyser output treatment system 11 includes filtering stages include a filtration chamber 16 that is configured to filter the gaseous fuel.
  • the filtration chamber 16 is elongate is shape and has a first end connected to the gaseous passage 14 of the electrolyser 12 and a second, opposed end connected to an output passage 19.
  • the output passage 19 is, in this example, connected to a combustion engine for burning the produced hydrogen.
  • the filtration chamber 16 filters electrolytes in the resultant gaseous fuel outputted from the electrolyser 12 from being outputted to the combustion engine via the passage 19.
  • the filtration chamber 16 is a bubbler barrel containing fluid 18.
  • the fluid is configured to filter the gaseous fuel so as to output a higher purity of hydrogen and oxygen.
  • the aqueous solution includes an electrolytic solution such as sodium hydroxide, and the fluid filters electrolytes from being outputted with the hydrogen and oxygen gas produced by the electrolyser 12.
  • the fluid 18 is configured to neutralise its pH resulting from contamination by electrolytes in the filtration chamber 16.
  • the electrolyser output treatment system 11 further includes a flash back valve 20 connected to the filtration chamber 16 that is configured to open when the hydrogen and oxygen produced from the electrolyser 12 in the filtration chamber 16 exceeds a designated pressure for the filtration chamber 16. Further, it is configured to open if the hydrogen in the filtration chamber 16 or the attached delivery hoses is ignited by, for example an engine backfire or other unintended spark event. That is, when the pressure in the filtration chamber 16 exceeds the designated pressure, such as if an explosion event occurs, the flash back valve 20 vents the pressure wave in the filtration chamber 16 to atmosphere to reduce pressure in the filtration chamber 16. The fluid 18 would then prevent ingress of a spark, flame or pressure wave into the filtration chamber 16 following operation of the flash back valve 20.
  • the electrolyser output treatment system 11 further includes a pH sensor 43 in the filtration chamber 16.
  • the pH sensor 43 is used as a preventative measure to avoid any KOH leaching out of the system 1 1 into the unit it is connected to via the passage 19.
  • the pH sensor 43 will indicate KOH leaching by changing its value towards the basic region, e.g., 7 to 14.
  • the controller 13 upon receipt of the signal from the pH sensor 43 that KOH has been detected, can prevent the resultant gaseous fuel from being outputted via the passage 19 via activation of a valve (not shown). This will avoid any leaching by having a real-time value of pH for the gas output of the system 1 1 .
  • FIG. 2 shows the flash back valve 20 in more detail.
  • the flash back valve 20 includes a screw thread 22 for attachment to the filtration chamber 16 at one end of an elongate shaped flash back valve 20.
  • the screw thread 22 provides for ease of removal, inspection and maintenance.
  • an end cap 24 configured to retain a biasing means 26 in the form of a spring.
  • the spring 26 biases a sealing means 28 in the form of a ball valve in the closed position within a seat 25.
  • the flash back valve 20 also includes washers and rubber seals assembled in such a way that the flash back valve 20 does not jam during operation or leak.
  • the ball valve 28 is connected to a stabilising rod 30 so that the ball valve 28 moves to an open position when the gaseous fuel in the filtration chamber exceeds the designated pressure.
  • the flash back valve 20 thus prevents excess hydrogen and oxygen from pooling in the filtration chamber 16 and acts as a low pressure relief valve in case, for example, the operator accidentally starts the system before plugging the delivery hose into the output port 19. Further, as mentioned, if the hydrogen and oxygen in the filtration chamber 16 did ignite then the flash back valve 20 would vent the high pressure wave away from the filtration chamber 16 via vent holes 32 for venting the gaseous fuel and or pressure way to atmosphere, and then the spring 26 would reseal the ball valve 28. That is the flash back valve 20 reacts very quickly to dissipate a supersonic pressure wave generated by the explosion of hydrogen and oxygen in the filtration chamber 16 and very quickly reseals enabling the system 10 to resume operation without any operator interference.
  • the flash back valve 20 also includes a clear housing between the end cap 24 and the screw thread 22 so that operation of components of the flash back valve 20 can be visually inspected. It can be seen that the clear housing also includes vent holes 32 for venting the gaseous fuel and or pressure way to atmosphere.
  • FIG. 3 shows the electrolyser output treatment system 11 , particularly the filtration chamber 16, in more detail.
  • the filtration chamber 16 is a bubbler configured to filter the gaseous fuel produced by the electrolyser 12.
  • the flash back valve 20 is attached to the filtration chamber 16 via the screw thread 22 at the second end of the filtration chamber 16 via a cap 34.
  • the cap 34 also houses the output passage 19 so that the gaseous fuel can be outputted to the combustion engine.
  • At the first end of the filtration chamber 16 there is another cap 36 housing the input 38 from the gaseous passage 14.
  • the bubbler containing the liquid 18 In between the two end caps 34 36 is the bubbler containing the liquid 18 which also has a clear housing 40 so that operation of the filtration chamber 16 is visible to the user.
  • the bubbler is backlit for two reasons: (1 ) to provide visible proof to the operator that hydrogen is being produced; (2) to display any changes in the colour in the bubbler liquid which would indicate a migration of electrolyte into the bubbler fluid.
  • the fluid 18 is indicator fluid which configured to change colour when contaminated by electrolytes in the filtration chamber 16.
  • the liquid 18 has a purple to light red colour when safe and working which changes to yellow to green when it is contaminated with electrolytes and needs to be changed and replaced with fresh liquid to adequately filter the gaseous fuel. The operator is therefore confident that harmful electrolytes have not been produced and entered the combustion engine.
  • the fluid 18 is configured to neutralise the pH of the fluid 18 resulting from contamination by electrolytes in the filtration chamber 16 whilst working properly and then to change colour when the pH is too high and the fluid 18 can no longer neutralise the pH.
  • the electrolyser output treatment system 11 further includes a PH sensor probe 41 embedded into a lower part of the bubbler filtration chamber 16, where the probe 41 is in continuous contact with the bubbler fluid.
  • the PH sensor probe 41 is calibrated so that, if fluid in the Bubbler filtration chamber 16 exceeds a PH of 9 (e.g. Baking Soda), the probe 41 triggers an electrical switch that simultaneously sounds a buzzer 42, and stops the system 10 from making gaseous fuel; thus acting as a safety switch to prevent harmful Potassium Hydroxide from entering the vehicle engine and alerting a technician to inspect and correct the operation of the system 10 prior to continuing.
  • a PH of 9 e.g. Baking Soda
  • electrolyser of this type will generate small or large amounts of foaming bubbles, depending on a number of variables (e.g. heat, amperage/voltage flow rate, etc.), to the point that it may overtake the capacity of the system 10 to negate and diminish this foam before it migrates to the bubbler fluid.
  • the present system 10 solves this problem with an internal Recycle Tank that pumps excess foam back into the main Circulation KOH Tank.
  • Figure 4 displays a flow chart of an example of operation of the system 10, including this Recycle Tank.
  • the horizontal part of the Recycle Tank captures the precipitate vapour coming from the top of the Circulation KOH Tank.
  • a float switch triggers a small pump when the precipitate reaches a certain level in the Recycle Tank.
  • the vertical part of the Recycle Tank acts as the second filter stage in the system 10.
  • Stage 1 Upper half of the Circulation Tank
  • Stage 2 Vertical tower of the Recycle Tank; and Stage 3: The entire Bubbler Tank.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Automation & Control Theory (AREA)
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Abstract

An electrolyser output treatment system, the system including: a filtration chamber having a first end and a second end, the filtration chamber being connected to an electrolyser at the first end and is configured to filter gaseous fuel produced by the electrolyser and to output the gaseous fuel at the second end; and a flash back valve connected to the filtration chamber and is configured to open when the gaseous fuel in the filtration chamber exceeds a designated pressure and at least partially vent the gaseous fuel to atmosphere to reduce pressure in the filtration chamber.

Description

An electrolyser output treatment system
Technical Field
[0001] The present invention relates to an electrolyser output treatment system including a filtration chamber connected to an electrolyser and a flash back valve connected to the filtration chamber configured to open when the gaseous fuel in the filtration chamber exceeds a designated pressure. In particular, but not exclusively, the present invention involves the filtration chamber filtering electrolytes produced from an aqueous solution that is used by the electrolyser to produce hydrogen and oxygen and the flash back valve venting gasses to atmosphere if pressure in the filtration chamber exceeds a designated pressure.
Background of Invention
[0002] Hydrogen and oxygen gas can be produced by the electrolysis of water by an electrolyser, such as a wet cell electrolytic generator or a dry cell electrolytic generator. Water, however, is a relatively poor conductor of electric current.
Accordingly, a chemical like potassium hydroxide, sulfuric acid, or sodium hydroxide is typically added to the water to form an aqueous solution with electrolytes that optimises the production of hydrogen and oxygen gas by the electrolyser. Chemicals like potassium and sodium hydroxide, however, make the water highly corrosive and potentially harmful to people and to devices that ultimately use the produced hydrogen and oxygen gas such as combustion engines.
[0003] As mentioned, one existing type of electrolyser for producing hydrogen and oxygen gas is a wet cell electrolytic generator. Here, plates forming an anode and a cathode are submerged into a tank containing an aqueous solution with an electrolyte such as sodium hydroxide in water. These wet cell generators may typically require 1 to 2 litres of electrolyte per tank and most designs of this type require 6 to 12 two-litre tanks, meaning that the total electrolyte may be in 10 to 20 litres of aqueous solution. The wet cell electrolytic generators work under pressure to produce the hydrogen and oxygen gas which can result in safety issues. For example, the resultant hydrogen and oxygen gas may pool at the top of the tank which could conceivably be ignited by a static electrical charge. The tanks also continually generate hydrogen and oxygen gas long after the generator is turned off. [0004] Another existing type of electrolyser for producing hydrogen and oxygen gas is a dry cell electrolytic generator. Here, the generator may have a series of flat conductive plates between which circulates a pumped aqueous solution of electrolyte such as sodium hydroxide in water. These plates are sandwiched between insulating gaskets and their electric connections are located on the outside of the plates thus eliminating the possibility of a spark igniting the gas produced within the tanks. The resultant gas, however, is passed to a central gas tank and may pool in components of the electrolyser which can still result in safety issues.
[0005] Both types of existing electrolysers use an aqueous ionic solution for producing hydrogen and oxygen gas which may contain say ten to twenty five percent of an electrolytic solution such as sodium hydroxide, potassium hydroxide or similar chemical. Sodium hydroxide solution is very caustic and corrosive, and the electrolysis may produce caustic gasses in the resultant hydrogen and oxygen gas. These caustic gasses are deleterious to devices that ultimately use the hydrogen and oxygen gas such as combustion engines.
[0006] The above discussion of background art is included to explain the context of the present invention. It is not to be taken as an admission that any of the documents or other material referred to was published, known or part of the common general knowledge at the priority date of any one of the claims of this specification.
Summary of Invention
[0007] According to one aspect of the present invention, there is provided an electrolyser output treatment system, the system including: a filtration chamber having a first end and a second end, the filtration chamber being connected to an electrolyser at the first end and is configured to filter gaseous fuel produced by the electrolyser and to output the gaseous fuel at the second end; and a flash back valve connected to the filtration chamber and is configured to open when the gaseous fuel in the filtration chamber exceeds a designated pressure and at least partially vent the gaseous fuel to atmosphere to reduce pressure in the filtration chamber.
[0008] Preferably, the gaseous fuel includes hydrogen and oxygen. The hydrogen and oxygen gas may be used in a combustion engine in a continuous injection process at a certain volume to enhance engine fuel efficiency, or in short service cycles of 30 minutes to 90 minutes at higher delivery rates to dislodge and burn off built up layers of carbon that plague internal combustion engines. Both application methods bring significant benefits to engines. Alternatively, the gaseous fuel could be just hydrogen. During operation, if the gaseous fuel in the filtration chamber or attached delivery hoses is ignited by say the combustion engine backfiring or other unintended spark event, the flash back valve vents the gaseous fuel and the explosive gasses to atmosphere to prevent an explosion.
[0009] In an embodiment, the flash back valve includes a sealing means connected to a stabilising rod and a biasing means, whereby the sealing means is biased to a closed position by the biasing means and the sealing means moves to an open position when the gaseous fuel in the filtration chamber exceeds the designated pressure. For example, the sealing means is a ball valve and the biasing means is a spring. The flash back valve thus prevents excess gaseous fuel, such as hydrogen and oxygen, from pooling in the filtration chamber. Further, if the gaseous fuel did ignite in the filtration chamber, the flash back valve would vent the high pressure wave away from the filtration chamber to prevent a potentially fiery explosion, and then the spring would reseal the ball valve. The flash back valve further includes a plurality of vent holes for venting the gaseous fuel and or pressure wave to atmosphere.
[0010] In an embodiment, the flash back valve includes a clear housing so operation of the flash back valve can be visually inspected.
[0011] In an embodiment, the filtration chamber contains fluid, and the fluid is configured to filter the gaseous fuel and to prevent ingress of a spark, flame or pressure wave following operation of the flash back valve. As mentioned, electrolysers use an aqueous solution for producing hydrogen and oxygen gas which may contain an electrolytic solution such as sodium hydroxide. The fluid in the filtration chamber is thus configured to filter electrolytes from an aqueous solution used by the electrolyser to produce the gaseous fuel that made their way into the filtration chamber. That is, the fluid filters caustic gasses produced by the electrolyser from the addition of the electrolytic solution to water. In an example, the fluid is configured to neutralise its pH resulting from contamination by electrolytes in the filtration chamber. In another example, the fluid is configured to change colour when contaminated by the electrolytes in the filtration chamber beyond its operating capability.
[0012] In an embodiment, the fluid in the filtration chamber is indicator fluid and the filtration chamber is configured to provide a visible indicator of production of the gaseous fuel. The gaseous fuel here forms bubbles in the indicator fluid indicative of a rate of production of the gaseous fuel. For example, the electrolyser may be configured to produce between 5 and 20 litres per minute of gaseous fuel and, at 20 litres per minute, four times the bubbles in the indicator fluid are formed than at 5 litres per minute.
[0013] In an embodiment, the filtration chamber includes a pH sensor and the system is configured to prevent the gaseous fuel from being outputted at the second end following sensed pH in the filtration chamber exceeding a threshold value. For example, the threshold value is 7 to 14.
[0014] Preferably, the fluid includes naturally occurring plant dyes or synthetically manufactured chemicals that change colour when exposed to chemicals or gases of a specific acidic or basic nature. A typical example is a swimming pool chlorine test kit used to keep swimming pools in a pH range that discourages algae growth.
Brief Description of Drawings
[0015] Embodiments of the invention will now be described with reference to the accompanying drawings. It is to be understood that the embodiments are given by way of illustration only and the invention is not limited by this illustration. In the drawings:
[0016] Figure 1 is a representation of an electrolyser system including an electrolyser output treatment system according to an embodiment of the present invention;
[0017] Figure 2 is a representation of a flash back valve of an electrolyser output treatment system according to an embodiment of the present invention; [0018] Figure 3 is a representation of an electrolyser output treatment system according to another embodiment of the present invention; and
[0019] Figure 4 is a flow chart of operation of an electrolyser output treatment system according to another embodiment of the present invention.
Detailed Description
[0020] An example of at least part of an electrolyser system 10 is shown in Figure 1 including an electrolyser output treatment system 11 which is shown in more detail in Figure 3. The electrolyser system 10 here includes an electrolyser 12 configured to be controlled by a controller 13 to produce gaseous fuel. In the example, the electrolyser 12 produces hydrogen and oxygen gaseous fuel which is outputted to be used by devices such as a combustion engine (not shown) via a gaseous passage 14 and subsequent hoses (not shown). For example, the hydrogen may be used by the combustion engine as fuel and in doing so may clean various components of the combustion engine.
[0021] In the example, the electrolyser 12 is a dry cell type electrolyser which uses an aqueous solution for producing the hydrogen and oxygen gas which contains an electrolytic solution, such as sodium or potassium hydroxide, to aid in the electrolysis of water. During operation, the dry cell type electrolyser 12 reaches maximum output within 3 minutes regardless of ambient temperature and stops generating gas within 3 seconds of being turned off. Also, the electrolyser 12 requires one or more power supplies with built in safety features such as circuit and power regulation logic, and has a control panel for controlling the controller 13. The control panel enables the operator to select different modes of operation of the electrolyser 12 such as 4 different rates of production of the gaseous fuel.
[0022] In another example, the electrolyser 12 is a wet cell type electrolyser which also uses the same aqueous solution. The aqueous solution is stored in a tank (not shown) of the dry cell type electrolyser 12 that is made from a non-metal composite material so that it cannot rust, leak, or corrode. Further, the tank is configured to exceed heat and chemical resistance criteria for operation within the electrolyser 12. The tank in this example is a 300ml barrel. The tank also has sensors and one or more electrolyte pumps to automatically keep the electrolyte balance in the aqueous solution at an optimal level, circulates the solution to dislodge gas bubbles forming at the electrolyser plates and to dissipate heat, and can shut down the system 10 if the solution level falls below and prescribed level. The aqueous solution in the tank can also be pumped through radiator cooling fins to dissipate heat.
[0023] The system 10 includes the electrolyser output treatment system 11 to treat the hydrogen and oxygen produced by the electrolyser 12 to prevent any electrolyte from being outputted with the gaseous fuel and to prevent any gasses produced from the electrolytes in the aqueous solution being electrolysed from being outputted and, for example, entering a combustion engine. To do so, the electrolyser output treatment system 11 includes filtering stages include a filtration chamber 16 that is configured to filter the gaseous fuel. The filtration chamber 16 is elongate is shape and has a first end connected to the gaseous passage 14 of the electrolyser 12 and a second, opposed end connected to an output passage 19. As mentioned, the output passage 19 is, in this example, connected to a combustion engine for burning the produced hydrogen.
[0024] The filtration chamber 16 filters electrolytes in the resultant gaseous fuel outputted from the electrolyser 12 from being outputted to the combustion engine via the passage 19. In the embodiment, the filtration chamber 16 is a bubbler barrel containing fluid 18. The fluid is configured to filter the gaseous fuel so as to output a higher purity of hydrogen and oxygen. As mentioned, the aqueous solution includes an electrolytic solution such as sodium hydroxide, and the fluid filters electrolytes from being outputted with the hydrogen and oxygen gas produced by the electrolyser 12. The fluid 18 is configured to neutralise its pH resulting from contamination by electrolytes in the filtration chamber 16.
[0025] The electrolyser output treatment system 11 further includes a flash back valve 20 connected to the filtration chamber 16 that is configured to open when the hydrogen and oxygen produced from the electrolyser 12 in the filtration chamber 16 exceeds a designated pressure for the filtration chamber 16. Further, it is configured to open if the hydrogen in the filtration chamber 16 or the attached delivery hoses is ignited by, for example an engine backfire or other unintended spark event. That is, when the pressure in the filtration chamber 16 exceeds the designated pressure, such as if an explosion event occurs, the flash back valve 20 vents the pressure wave in the filtration chamber 16 to atmosphere to reduce pressure in the filtration chamber 16. The fluid 18 would then prevent ingress of a spark, flame or pressure wave into the filtration chamber 16 following operation of the flash back valve 20.
[0026] The electrolyser output treatment system 11 further includes a pH sensor 43 in the filtration chamber 16. The pH sensor 43 is used as a preventative measure to avoid any KOH leaching out of the system 1 1 into the unit it is connected to via the passage 19. In use, the pH sensor 43 will indicate KOH leaching by changing its value towards the basic region, e.g., 7 to 14. As KOH is corrosive, the controller 13, upon receipt of the signal from the pH sensor 43 that KOH has been detected, can prevent the resultant gaseous fuel from being outputted via the passage 19 via activation of a valve (not shown). This will avoid any leaching by having a real-time value of pH for the gas output of the system 1 1 .
[0027] There is a safe range of pH level up to where it is not dangerous for any system and the KOH is getting filtered already by passing through the water in different stages. Having the pH sensor 43 at the last stage indicates that the gas output to be outputted in passage 19 is free of KOH or within the safe operation limit.
[0028] Figure 2 shows the flash back valve 20 in more detail. Here, it can be seen that the flash back valve 20 includes a screw thread 22 for attachment to the filtration chamber 16 at one end of an elongate shaped flash back valve 20. The screw thread 22 provides for ease of removal, inspection and maintenance. At the opposed end of the flash back valve 20 is an end cap 24 configured to retain a biasing means 26 in the form of a spring. The spring 26 biases a sealing means 28 in the form of a ball valve in the closed position within a seat 25. The flash back valve 20 also includes washers and rubber seals assembled in such a way that the flash back valve 20 does not jam during operation or leak.
[0029] The ball valve 28 is connected to a stabilising rod 30 so that the ball valve 28 moves to an open position when the gaseous fuel in the filtration chamber exceeds the designated pressure. The flash back valve 20 thus prevents excess hydrogen and oxygen from pooling in the filtration chamber 16 and acts as a low pressure relief valve in case, for example, the operator accidentally starts the system before plugging the delivery hose into the output port 19. Further, as mentioned, if the hydrogen and oxygen in the filtration chamber 16 did ignite then the flash back valve 20 would vent the high pressure wave away from the filtration chamber 16 via vent holes 32 for venting the gaseous fuel and or pressure way to atmosphere, and then the spring 26 would reseal the ball valve 28. That is the flash back valve 20 reacts very quickly to dissipate a supersonic pressure wave generated by the explosion of hydrogen and oxygen in the filtration chamber 16 and very quickly reseals enabling the system 10 to resume operation without any operator interference.
[0030] The flash back valve 20 also includes a clear housing between the end cap 24 and the screw thread 22 so that operation of components of the flash back valve 20 can be visually inspected. It can be seen that the clear housing also includes vent holes 32 for venting the gaseous fuel and or pressure way to atmosphere.
[0031] Figure 3 shows the electrolyser output treatment system 11 , particularly the filtration chamber 16, in more detail. As mentioned, the filtration chamber 16 is a bubbler configured to filter the gaseous fuel produced by the electrolyser 12. The flash back valve 20 is attached to the filtration chamber 16 via the screw thread 22 at the second end of the filtration chamber 16 via a cap 34. The cap 34 also houses the output passage 19 so that the gaseous fuel can be outputted to the combustion engine. At the first end of the filtration chamber 16, there is another cap 36 housing the input 38 from the gaseous passage 14. In between the two end caps 34 36 is the bubbler containing the liquid 18 which also has a clear housing 40 so that operation of the filtration chamber 16 is visible to the user. To further increase visibility, the bubbler is backlit for two reasons: (1 ) to provide visible proof to the operator that hydrogen is being produced; (2) to display any changes in the colour in the bubbler liquid which would indicate a migration of electrolyte into the bubbler fluid.
[0032] As mentioned, during operation of the electrolyser 12, hydrogen and oxygen gas is produced which bubbles through the liquid 18 to the output 19. Thus, the rate of production of the hydrogen and oxygen gas is visible based on the rate of bubble formation in the fluid 18. Also, the fluid 18 is indicator fluid which configured to change colour when contaminated by electrolytes in the filtration chamber 16. For example, the liquid 18 has a purple to light red colour when safe and working which changes to yellow to green when it is contaminated with electrolytes and needs to be changed and replaced with fresh liquid to adequately filter the gaseous fuel. The operator is therefore confident that harmful electrolytes have not been produced and entered the combustion engine. Further, the fluid 18 is configured to neutralise the pH of the fluid 18 resulting from contamination by electrolytes in the filtration chamber 16 whilst working properly and then to change colour when the pH is too high and the fluid 18 can no longer neutralise the pH.
[0033] The electrolyser output treatment system 11 further includes a PH sensor probe 41 embedded into a lower part of the bubbler filtration chamber 16, where the probe 41 is in continuous contact with the bubbler fluid. The PH sensor probe 41 is calibrated so that, if fluid in the Bubbler filtration chamber 16 exceeds a PH of 9 (e.g. Baking Soda), the probe 41 triggers an electrical switch that simultaneously sounds a buzzer 42, and stops the system 10 from making gaseous fuel; thus acting as a safety switch to prevent harmful Potassium Hydroxide from entering the vehicle engine and alerting a technician to inspect and correct the operation of the system 10 prior to continuing.
[0034] Another problem with any electrolyser of this type is that the electrolyte will generate small or large amounts of foaming bubbles, depending on a number of variables (e.g. heat, amperage/voltage flow rate, etc.), to the point that it may overtake the capacity of the system 10 to negate and diminish this foam before it migrates to the bubbler fluid. The present system 10 solves this problem with an internal Recycle Tank that pumps excess foam back into the main Circulation KOH Tank.
[0035] Figure 4 displays a flow chart of an example of operation of the system 10, including this Recycle Tank. The horizontal part of the Recycle Tank captures the precipitate vapour coming from the top of the Circulation KOH Tank. A float switch triggers a small pump when the precipitate reaches a certain level in the Recycle Tank. The vertical part of the Recycle Tank acts as the second filter stage in the system 10.
[0036] Therefore, the three filter stages of the system 10 are as follows:
Stage 1 : Upper half of the Circulation Tank;
Stage 2: Vertical tower of the Recycle Tank; and Stage 3: The entire Bubbler Tank. [0037] Those skilled in the art will also appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the invention includes all such variations and modifications.

Claims

The claims defining the invention are as follows
1 . An electrolyser output treatment system, the system including: a filtration chamber having a first end and a second end, the filtration chamber being connected to an electrolyser at the first end and is configured to filter gaseous fuel produced by the electrolyser and to output the gaseous fuel at the second end; and a flash back valve connected to the filtration chamber and is configured to open when the gaseous fuel in the filtration chamber exceeds a designated pressure and at least partially vent the gaseous fuel to atmosphere to reduce pressure in the filtration chamber.
2. An electrolyser output treatment system of claim 1 , wherein the flash back valve includes a sealing means connected to a stabilising rod and a biasing means, whereby the sealing means is biased to a closed position by the biasing means and the sealing means moves to an open position when the gaseous fuel in the filtration chamber exceeds the designated pressure.
3. An electrolyser output treatment system of claim 2, wherein the sealing means is a ball valve and the biasing means is a spring.
4. An electrolyser output treatment system of claim 2 or 3, wherein the flash back valve includes a plurality of vent holes for venting the gaseous fuel to atmosphere.
5. An electrolyser output treatment system of any one of claims 2 to 4, wherein the flash back valve includes a clear housing so operation of the flash back valve can be visually inspected.
6. An electrolyser output treatment system of any one of claims 1 to 5, wherein the filtration chamber contains fluid, and the fluid is configured to filter the gaseous fuel and to prevent ingress of a spark, flame or pressure wave following operation of the flash back valve.
7. An electrolyser output treatment system of claim 6, wherein the fluid in the filtration chamber is indicator fluid and the filtration chamber is configured to provide a visible indicator of production of the gaseous fuel.
8. An electrolyser output treatment system of claim 7, wherein the gaseous fuel forms bubbles in the indicator fluid indicative of a rate of production of the gaseous fuel.
9. An electrolyser output treatment system of claims 6 to 8, wherein the fluid is configured to filter electrolytes from an aqueous solution used by the electrolyser to produce the gaseous fuel.
10. An electrolyser output treatment system of claim 9, wherein the fluid is configured to neutralise its pH resulting from contamination by the electrolytes in the filtration chamber.
11. An electrolyser output treatment system of claim 10, wherein the fluid is configured to change colour when contaminated by the electrolytes in the filtration chamber.
12. An electrolyser output treatment system of claims 1 to 11 , wherein the gaseous fuel includes hydrogen and oxygen.
13. An electrolyser output treatment system of any one of claims 1 to 2, wherein the filtration chamber includes a pH sensor and the system is configured to prevent the gaseous fuel from being outputted at the second end following sensed pH in the filtration chamber exceeding a threshold value.
PCT/AU2023/050832 2022-08-29 2023-08-29 An electrolyser output treatment system WO2024044812A1 (en)

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AU2022902479A AU2022902479A0 (en) 2022-08-29 An electrolyser output treatment system

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4081656A (en) * 1973-07-20 1978-03-28 Yull Brown Arc-assisted oxy/hydrogen welding
EP2034053A1 (en) * 2006-05-16 2009-03-11 Diewersol, S.L. Equipment and method for obtaining gases by means of the electrolysis of water
EP2145982A1 (en) * 2008-07-14 2010-01-20 Boo-Sung Hwang System for producing a mixture of hydrogen and oxygen gases
KR20200074499A (en) * 2018-12-17 2020-06-25 김철진 Manufacturing of mixed fuel by dissolving gas produced by electrolysis of water in the form of a microbubble in liquid fuel

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4081656A (en) * 1973-07-20 1978-03-28 Yull Brown Arc-assisted oxy/hydrogen welding
EP2034053A1 (en) * 2006-05-16 2009-03-11 Diewersol, S.L. Equipment and method for obtaining gases by means of the electrolysis of water
EP2145982A1 (en) * 2008-07-14 2010-01-20 Boo-Sung Hwang System for producing a mixture of hydrogen and oxygen gases
KR20200074499A (en) * 2018-12-17 2020-06-25 김철진 Manufacturing of mixed fuel by dissolving gas produced by electrolysis of water in the form of a microbubble in liquid fuel

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