WO2024100678A1

WO2024100678A1 - Membraneless flow-by electrolytic reactor

Info

Publication number: WO2024100678A1
Application number: PCT/IN2023/051025
Authority: WO
Inventors: Rochan SINHA; Prasanta Sarkar
Original assignee: Newtrace Private Limited
Priority date: 2022-11-08
Filing date: 2023-11-06
Publication date: 2024-05-16

Abstract

The present disclosure discloses a reactor body (100) and method for producing products such as gases by using a membraneless flow-by electrolytic reactor (100). The reactor body (100) has a pair of electrodes (40) – anode (42) and cathode (44) and a separator (7). The rector body (100) is designed to produce laminar flow. It also provides a system having multiple such rector bodies. Further, it provides a reactor body having two horizontal channels.

Description

MEMBRANELESS FLOW-BY ELECTROLYTIC REACTOR

FIELD OF THE DISCLOSURE

[0001] The present disclosure relates to a reactor body for producing products involving electrochemical reactions for use in variety of industrial applications. The disclosure also provides a method for the production of products using the same.

BACKGROUND OF THE DISCLOSURE

[0002] Electrolysis is a crucial industrial process used to produce a variety of vital chemical building blocks. The process of electrolysis is performed in a device called electrolyzer which generally consists of a stack where the generation of products such as gases occurs.

[0003] Currently, the type of electrolyzers available are - Alkaline water electrolyzers (AWE), Proton exchange membrane electrolyzers (PEM), Anion Exchange Membrane electrolyzers (AEM) and solid oxide electrolyzers (SOE). The essential (or main) components of commercially available electrolyzer stacks are- an anode where oxidation occurs; a cathode where reduction occurs; and a membrane, which allows specific ions to pass.

[0004] For most of the electrolysis processes, the economics are dominated by the high cost of electrolyzers. The capital cost of existing electrolyzer technologies is much higher compared to solar cells or batteries. This high cost is because of the high cost of anode, cathode, membrane and a number of other components built in the electrolyzer stack to support the three essential (or, main) components thereby making the existing designs complex and resulting in increased manufacturing costs. Additionally, the membrane in particular is expensive and only a few suppliers exist to manufacture them. This has a direct impact on the high cost of electrolyzers.

[0005] Further, the membranes used in current commercial electrolyzer systems are very sensitive to variations in input power, water quality in case of aqueous system, impurities in the electrolyte and operating conditions under which the electrolyzer system is operated. They can be easily damaged or broken due to extreme operating conditions or fouling due to impurities in the electrolyte. This results in high cost of components such as power supply and water filtration. Thus, use of membranes indirectly drives up the cost of the electrolyzers as well.

[0006] Also, membranes are selective in nature thereby only allowing specific ions to pass through. Consequently, if a membrane only allows protons (H+) to pass through the electrolyzer, it will only work in acidic conditions. Similarly, if a membrane only allows hydroxyl ions (OH-) to pass through, then the electrolyzer will only work in alkaline conditions thus restricting the possible areas of application.

[0007] Various attempts have been made to solve the problems associated with the membranes. One is by using a cheaper, more easily available material for the membrane. However, these materials have other issues such as durability, lower performance etc. Also, this does not solve the issue of high indirect costs. Another approach that exists to solve the issue with membranes is to use a membraneless electrolyzer where the membrane is removed altogether and the product or gas separation is done by other means. In specific cases, membraneless electrolyzers concentrate the separation of gases by using the flow of electrolyte or buoyancy of gases or physical separation of the products generated. In the existing designs that use the approach of flow by electrolyte for separation of products, the flow is only done in 2 dimensions (X &Y). However, these designs are not scalable due to several practical implications including but not limited to the amount of production, fluid maldistribution in thousands of channels, setup costs, and fabrication deviations. In flow-through systems, mesh electrodes are positioned in a face-to-face configuration and as water is forced into the electrode gap, the flow separates, carrying the products into distinct channels. This system faces the issue of turbulent flow which causes mixing of the products. Another approach is using the buoyancy of product to separate the products like gases. This method is very sensitive to operating conditions and any slight disturbance to the system can cause mixing of products/gases. Yet another approach that existing membraneless electrolyzer use is by physical separation of gases produced. In such case one product such as hydrogen is produced in a separate chamber and another product such as oxygen in another chamber. This technology is very difficult and expensive to scale up.

[0008] In view of the aforesaid, it is evidently necessary to develop a simple, scalable, cost - efficient, easy to assemble electrolytic reactor body that is suitable for a variety of electrochemical processes. Further, it is desired to develop an electrolytic reactor body with improved yield, energy efficiency, economics, and yet does not have hazardous impact on the environment.

SUMMARY OF THE DISCLOSURE

[0009] Accordingly, in an aspect, the present disclosure provides a reactor body for the production and separation of products by electrolysis of an electrolytic solution. The reactor body comprises: - an inlet chamber; - at least two outlets; - a channel in communication with the inlet chamber at a first end and the at least two outlets at a second end, said channel being capable of containing and directing flow of electrolytic solution, wherein said electrolytic solution includes at least one reactant; - a pair of first and second electrodes present in the channel at a predetermined distance from the inlet chamber, each of said first and second electrodes having a first side and a second side, the first sides of the first and second electrodes arranged to face each other to define an electrode gap within the channel; - a separator fixed proximal to the pair of electrodes in the channel, in fluid communication with the at least two outlets; and capable of separating the products from each other; - the at least two outlets comprises a first outlet capable of receiving a first product from the first electrode and a second outlet capable of receiving a second product from the second electrode; wherein : - the first electrode and the second electrode are separated by an electrode gap ranging between lmm<d<10mm - a height of one or more of the first and second electrodes is in the range of 0.1 mm to 500 mm, and a width of one or more of the first and second electrodes is in the range of 0.5mm to 50mm.; and - inlet chamber tapers toward the channel containing the electrodes.

[0010] In another aspect, the present disclosure provides a method for production and separation of products, by electrolysis of an electrolytic solution using the reactor body as described herein. The method comprising: - supplying a stream of electrolytic solution through an inlet chamber of a reactor body to a channel in communication with the inlet chamber on one side and having a pair of first and second electrodes, - diverging the electrolytic solution within an electrode gap between the pair of first and second electrodes;- providing a potential difference over the pair of first and second electrodes so that electrolysis of the electrolytic solution ensues, and so that a first product forms on the first electrode, and a second product forms on the second electrode; and -removing at least a portion of the first and second product from the first and second electrodes into at least two outlets by a separator configured in the channel after the pair of electrodes.

[0011] In another aspect, the present disclosure provides a flow by cell system having at least two reactor bodies for the production of hydrogen gas by electrolysis of an electrolytic solution. One of the reactor body comprising: an inlet chamber bifurcating into a plurality of inlet channels; at least two outlets, each of the at least two outlets are formed by the joining of plurality of outlet channels; at least two horizontal channels in communication with the plurality of inlet channels at a first end and to plurality of outlet channels at a second end, said channels being capable of containing and directing flow of electrolytic solution, wherein said electrolytic solution includes at least one reactant; and a pair of first and second electrodes as detailed above.

[0012] One application of the electrolyzer according to the disclosure, is for the production of hydrogen via water electrolysis without any greenhouse gas (GHG) emissions. The zero-emission hydrogen is called ‘green hydrogen’, which is useful in variety of industries.

[0013] The membraneless flow-by electrolytic reactor body only uses three components- the anode, cathode and separator for electrolyte flow. Thus, the electrolyzer reduces device complexity, cost involved in procuring the materials and manufacturing costs.

[0014] The flow-by electrolytic reactor body according to the disclosure does not use a membrane and thus, is not as sensitive to impurities or operating conditions and are therefore, by design, durable devices with possibly long operating lifetimes and greater resilience to extreme operating conditions or impurities in electrolyte.

[0015] Since, the flow-by electrolytic reactor body according to the disclosure does not use a membrane, it is electrolyte agnostic and finds application with acidic, alkaline and even neutral pH electrolytes. It is also possible to use the reactor body for areas of application beyond water electrolysis, such as CO2 electroreduction, chlor-alkali process and other electrochemical applications. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0016] While the specification concludes with claims that particularly point out and distinctly claim the disclosure, it is believed that the advantages and features of the present disclosure will become better understood with reference to the following more detailed description of expressly disclosed exemplary embodiments taken in conjunction with the accompanying drawings. The drawings and detailed description which follow are intended to limit the scope of the present disclosure as set forth in the appended claims. In the drawings:

[0017] Figure 1 is an isometric view of the reactor body in accordance with the present disclosure,

[0018] Figure 2 is top view of the reactor body in accordance with the present disclosure,

[0019] Figure 3 is a sectional side view of the reactor body in accordance with the present disclosure,

[0020] Figure 4 is enlarged view of second end of the channel of the reactor body in accordance with the present disclosure

[0021] Figure 5 is back view of the reactor body in accordance with the present disclosure,

[0022] Figure 6 is an enlarged view of the placement of the electrodes and the separator in channel of the reactor body in accordance with the present disclosure,

[0023] Figure 7 is a pictorial image of a 3D printed reactor body in accordance with the present disclosure,

[0024] Figure 8 are the side view and top view of a system having two reactor bodies in accordance with the present disclosure, [0025] Figure 9 is a graphical representation of the impact of electrode gap of 2mm on the efficiency and purity of the reactor body in accordance with the present disclosure.

[0026] Figures 10 is a graphical representation of the impact of electrode gap of 4mm on the efficiency and purity of the reactor body in accordance with the present disclosure;

[0027] Figures 11 is a graphical representation of the impact of electrode gap of 8mm on the efficiency and purity of the reactor body in accordance with the present disclosure;

[0028] Figure 12 is a graphical representation of the change in height and width of the electrode and its impact on efficiency and purity of the system having reactor body in accordance with the present disclosure;

[0029] Figure 13 is a graphical representation of the gas sample extracted from the reactor body in accordance with the present disclosure;

[0030] Figure 14 is a graphical representation of efficiency and purity of the system having multiple reactor bodies in accordance with the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

CALL OUT LIST

100 reactor body

10 inlet chamber

20 outlets

20a first outlet

20b second outlet

30 channel

30a first end

30b second end

40 electrodes

42 first electrode

42a first side

42b second side

44 second electrode 44a first side

44b second side

46 electrode gap

7 separator

[0031 ] The embodiments described herein detail for illustrative purposes are subject to many variations in structure, design and layout. It should be emphasized, however, that the present disclosure is not limited to a particular structure, design and layout as shown and described. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the present disclosure.

[0032] EFFICIENCY is defined as the amount of charge passed through the electrodes that is used for producing the reactants. Higher efficiency means lower energy is required for a certain amount of product formation.

[0033] PRODUCT CROSSOVER RATE/ GAS PURITY- Some amount of products from electrochemical reactor cross the membrane and moves to the other electrode, leading to the loss of system efficiency and increase in gas impurity. This is crossover. The rate at which this happens is the product crossover rate. In a preferred embodiment, it would be the amount of oxygen (/hydrogen) present in the hydrogen (/oxygen) stream to the total oxygen (/hydrogen) generated. Lower product crossover rate means higher purity of the products being generated. The product crossover rate is inversely proportional to the gas purity which is defined by the % of oxygen (/hydrogen) in the hydrogen (/oxygen) stream. Higher the crossover rate, lower the gas purity

[0034] The present disclosure discloses a membraneless flow-by electrolytic reactor body. Referring to Figures 1,2, 4, 5, 6, 7 and 8, the membraneless flow-by electrolytic reactor body (100) has a channel (30) having a pair of electrodes (40) and a separator (7).

[0035] The reactor body (100) is designed in such a way that an electrolytic solution flows into the reactor body (100_ at the inlet (10) and crosses the anode and cathode with a uniform flow rate and profile, known as laminar flow. [0036] In an embodiment, the reactor body (100) walls are of different thickness. In an embodiment, the outer shape and dimensions of the reactor body (100) is varied along with the designs of the electrodes.

[0037] Referring to Figures 1, 2 and 4, the channel (30) is a hollow container having oblique wall portions and flat side wall portions. The flat sidewall portions are at 90 degrees to each other. The channel (30) has a first end (30a) and a second end (30b). The first end (30a) is in communication with an inlet chamber (10) and the second end (30b) of the channel is in communication with at least two outlets (20a, 20b). A pair of electrodes (40) and the separator (7) are disposed in the channel (30). The channel (30) may surround the pair of electrodes (40), so that the electrodes are immersed in electrolytic solution during operation when a stream of electrolytic solution flows by the electrodes (40), before diverging into the at least two outlets (20a, 20b). From the standpoint of strength, it is preferred that the channel (30) is made of non- conductive polymeric material, typically such as Acrylonitrile butadiene styrene(ABS) or Polypropylene (PP) or Polytetrafluoroethylene (PTFE) or Chlorinated Polyvinyl Chloride (CPVC) or Nylon or the like. In some embodiments, the channel (30) may be of any size and shape suitable to convey electrolytic solution to the pair of electrodes (40). In preferred embodiments, the channel (30) may be polyhedral or any other functional shape to facilitate flow of electrolytic solution to electrodes (40). For instance, in some embodiments, the channel (30) may be hexagonally shaped. In some instances at least a portion of the reactor body (100) may be substantially transparent, allowing flow through the reactor body (100) to be viewed and/or imaged from outside the reactor body (100).

[0038] In an embodiment, the length of the channel (30) inside the reactor body (100) may be about 1mm to 300mm. In some embodiments, the length of the channel may be about 5mm to about 150mm, or about 1mm to about 50mm. It is observed that as the length of the channel (30) increases, product crossover rate decreases.

[0039] In an embodiment, the pair of electrodes (40) is made of a first electrode (42) called an anode and a second electrode (44) called a cathode, respectively. In an embodiment, the pair of first and second electrodes (42, 44) are disposed in the channel (30) and are capable to perform redox reaction. In some embodiments, at least one of the electrodes is a cathode. In some embodiments, at least one of the electrodes is an anode. The oxidation occurs at the anode and the reduction occurs at the cathode. In some embodiments, multiple pairs of electrodes may be used and may impact the higher efficiency evolution of product. Presence of multiple pairs of electrodes increases the contact area between the electrolytic solution and a pair of first and second electrodes thereby resulting in corresponding increases in product evolution and output. Thus, membraneless electrochemical flow-by reactor body (100) is advantageously scalable by simply increasing the total area of the electrodes. In some embodiments, electrodes are stacked to enable inducing higher current densities through the electrodes. In some embodiments, at least one electrode includes electrodeposited platinum on titanium or nickel on stainless steel.

[0040] In an embodiment, the height and width of the electrodes (42, 44) (anode and cathode) may be about 0.1 mm to about 500 mm and about 0.5mm to about 50mm, respectively. Preferably, the height may be about 10 mm to about 400 mm and width may be about 1mm to about 35mm. More preferably, the width may be about 1mm to about 30mm. It is observed that as the height increases, there is a negligible variation in product crossover rate. Further, as the width increases, product crossover rate should increase. However, in some embodiments, due to change in laminar flow conditions as a result of large channel dimensions the product crossover rate for increased height and width of electrode can reduce.

[0041] In some embodiments, each of the electrodes (40) i.e. first electrode (42) and second electrode (44) have a first side (42a, 44a) and a second side (42b, 44b). The first sides (42a, 44a) of the first and second electrodes are arranged to face each other to define an electrode gap (46) within the channel (30). In some embodiments, electrodes (40) are disposed relative to each other within the channel (30). In a preferred embodiments the electrodes are arranged parallel to each other. By changing the channel width the distance between them i.e. electrode gap (46) decreases, and as a result the uncompensated solution resistance decreases.

[0042] In some embodiments, the first electrode and the second electrode are separated by an electrode gap (46) ranging between about 1mm >d> 10mm. In a preferred embodiment, the distance between the cathode and anode of the reactor body i.e. the electrode gap (46) is equal to width of channel (30). It is preferably about 1mm to about 10mm; more preferably, it is about 2mm to about 8mm. It is observed that as distance between cathode and anode is increased, efficiency decreases because uncompensated solution resistance increases. The product crossover rate also decreases as the electrode gap increases. [0043] In an embodiment, the distance from start of the channel (30) to electrode position may be about 10mm to about 200mm. In some embodiments it may be about 20mm to about 120mm. It is observed that further the distance between the start of channel (30) and the position of the electrodes (40), the lower the product crossover rate. However, the pumping power required also increases which results in lowering of the efficiency of the system.

[0044] In an embodiment, referring to figure 6, a separator (7) is disposed in the channel (30) so as to facilitate separation of products formed. In some embodiments, the separator (7) is disposed downstream of the at least one anode and the at least one cathode. In some embodiments, the separator (7) fixed proximal to the pair of electrodes in the channel (30) which is in fluid communication with the at least two outlets (20). In some embodiments, the separator (7) may be of any suitable shape to facilitate separation of products formed at the cathode or anode while limiting crossover between the product streams. This design of the reactor body (100) keeps the generated products separated without the need for a membrane in between the anode and cathode.

[0045] In an embodiment, the thickness of separator (7) at outlet of channel may be about 0.1 mm to about 3 mm. In some embodiments, it may be about 0.5 to about 1mm. It is to be noted that higher thickness of the separator (7) may result in turbulent flow thereby causing increase in product crossover rate.

[0046] As used herein, electrolytic solution for use in reactor body (100) includes any electrolyte suitable to facilitate a desired electrochemical reaction. In a preferred embodiment, the electrolyte comprises water with a salt. In some instances, the salt may be selected from, but not limited to, alkali hydroxides such as potassium hydroxide (KOH) which increases conductivity. In some embodiments, the electrolyte is a reactant. The reactant is a composition of matter that includes a product. In some embodiments, the product is obtained as a liquid. In some embodiments, the product is obtained as a gas. In some embodiments, the product is obtained as a solid.

[0047] In some embodiments, electrolytic solution stream enters the membraneless electrochemical flow-by reactor body (100) and flows along the channel (30). The electrolytic solution (which in an embodiment may be the reactant) and the products generated at anode and cathode exit through the at least two outlets (20a, 20b). In this way membraneless separation of products takes place inside the reactor body (100).

[0048] In some embodiments, electrolytic solution stream flows through a pair of first and second electrodes. When a voltage is applied across a pair of first and second electrodes, an electrolytic solution stream flows by the electrodes thereby, a redox reaction occurs resulting in the generation of products. In some embodiments, the applied voltage can be substantially constant. In some embodiments, the applied voltage can be pulsed. In some embodiments, the voltage can be applied by a power source.

[0049] Referring to Figures 1, 2 and 3, reactor body (100) includes at least one inlet in communication with the inlet chamber (10) for receiving electrolytic solution. The electrolytic solution passing through the at least one inlet comprises matter to be reacted in membraneless electrochemical flow-by reactor body (100). In some instances the communication of the electrolytic solution from the inlet chamber (10) tapers toward the channel (30) containing the electrodes (40).

[0050] In an embodiment, the inlet is circular in shape. The circular inlet may have a diameter of about 5 mm to about 300 mm. Further, the length of the circular inlet may be about 5 mm to about 100 mm. Furthermore, the distance between the circular inlet and the channel (30) may be about 10 mm to 500 mm. There is a non-linear relationship between inlet diameter and distance between inlet and channel to the product crossover rate. Larger inlet and higher distance between inlet and channel (30) may result in more laminar flow which may result in lower product crossover. In a preferred embodiment, the inlet chamber (10) tapers toward the channel containing the electrodes. In more preferred embodiment the taper can be straight. In more preferred embodiment the taper can be concave. In most preferred embodiment the taper can be convex.

[0051] In a preferred embodiment, the circular inlet has a diameter in the range of 10 mm to 50 mm. Further, the length of the circular inlet is in the range of 10 mm to 30 mm. Furthermore, the distance between circular inlet and channel (30) may be about 10 mm to 200 mm. [0052] In an embodiment, reactor body (100) is capable of keeping the generated products separate by only using fluid flow controlled by the design parameters and without the need for any sort of membrane. The membraneless flow-by electrolytic reactor body (100) separates the products by a 3D design, controlling a number of design parameters thereby increasing the production throughput and separation efficiency of the different products as compared to the existing knowledge.

[0053] Referring to sectional side view of the reactor body in Figure 3 and the enlarged view of Figure 4, the electrolytic solution enters the reactor body through an inlet of diameter (4a) and flows through an inlet chamber (4b). The electrolytic solution moves from the inlet chamber to the channel (30). The channel has three sections. The first section is the inlet connection section (4f) and the walls of the inlet connection section are at an obtuse angle (4d) to the walls of the inlet chamber. The electrolytic solution from the inlet connection section (4f) moves to the main rectangular channel section having flat sidewall portions at an angle (4e) from the walls of the inlet connection section (4f). The electrodes are disposed in the main rectangular channel section at a distance (6) from the start of the main section. The electrodes have a thickness (3a) as shown. The formed products at the electrodes are moved out from the main rectangular channel section to the outlet connection section (5d). The walls of the outlet connection section (5d) narrows down to communicate with the outlets (5b). The products formed at the electrodes move through the separator (7) to the outlets (5b). This communication has been shown in the enlarged view B in Figure 4. Figure 4 shows the flow changes from a broader channel to the pair of outlets through the separator (7).

[0054] Referring to Figure 5, the at least two outlets (20a, 20b) are in communication with channel (30). The at least two outlets (20a, 20b) are present at the second end (30b) of the channel (30). The at least two outlets (20) comprises a first outlet (20a) capable of receiving a first product from the first electrode and a second outlet (20b) capable of receiving a second product from the second electrode.

[0055] In an embodiment of the circular outlets (20), the outlet diameter may be about 5 mm to about 300 mm. Further, the length of the circular outlets (20) may be about 5 mm to about 100 mm. Furthermore, the distance between the circular outlet and the channel (30) may be about 5mm to about 300 mm. It is observed that small outlet (20) diameter and lower distance between the outlet (20) and channel (30) may result in recirculation leading to higher product crossover.

[0056] In some embodiments, at least two reactor bodies are incorporated into a system. In some embodiments, the at least two reactor body (100) are placed in series. In some embodiments, the at least two reactor body (100) are placed in parallel.

[0057] In a preferred embodiment, the flow by cell system has a plurality of reactors. Referring to Figure 8, in a more preferred embodiment, the side view and top view of the system of flow by cells is provided. The system comprises at least four flow by reactor bodies. The channel (30) of the rector body has two parts (31 ,32) formed by symmetrical horizontal division. The top symmetrical part of the channel is named as cell top half (31) and lower symmetrical half of the channel is named as cell bottom half (32). This designing of the channel eases the manufacturing of the reactor bodies without causing any imbalances in the flow of the electrolyte. The inlet chamber in communication with the channel is further bifurcated into a plurality of inlet channels. The plurality of inlet channels are designed to maintain equal flow and pressure of electrolytes in the plurality of channels. In this preferred embodiment as shown there are four inlet channels. Accordingly, the outlet chamber combines the plurality of outlets into a single outlet. Each for hydrogen and oxygen separately. The plurality of outlet channels are designed to maintain equal flow and pressure of electrolytes in the plurality of channels. In a preferred embodiment, the electrode height is 150mm

[0058] In an embodiment, an electrolyzer system having the reactor body (100) includes a recycle stream for recycling electrolytic solution from the membraneless electrochemical flow-by reactor body to an electrolyte reservoir. In some embodiments, the electrolyzer system includes a plurality of pumps to move electrolytic solution streams throughout the system. In some embodiments, a valve may be provided to control the flow of the electrolytic solution to at least one inlet. In some embodiments, the electrolyzer system may include a controller. In some embodiments, the controller controls at least one of electrolytic solution flow rate, electrolyte/reactant concentration, pulse time, sensors, and the like.

[0059] In another aspect, the present disclosure discloses a method for production and separation of products, by electrolysis of an electrolytic solution using the reactor body (100) as described herein. The method comprising: - supplying a stream of electrolytic solution through an inlet chamber (100) of the reactor body (100) to a channel (30) in communication with the inlet chamber (100) on one side and having a pair of first and second electrodes (40), - diverging the electrolytic solution within an electrode gap (46) between the pair of first and second electrodes (42,44) providing a potential difference over the pair of first and second electrodes (42,44) so that electrolysis of the electrolytic solution ensues, thereby forming a first product on the first electrode, and a second product on the second electrode; and -removing at least a portion of the first and second product from the first and second electrodes into at least two outlets (20a, 20b) by a separator (7) disposed in the channel (30).

[0060] In a preferred embodiment, the reactor body (100) performs electrolysis of water. The anode oxidizes the water into oxygen gas and the cathode reduces the water to hydrogen gas. The design of the reactor body (100) keeps the generated products of oxygen and hydrogen gases separate without the need for a membrane in between the anode and cathode. The mixture of electrolyte and hydrogen gas exists at the first outlet (20a) and the mixture of electrolyte and oxygen gas exists at the second outlet (20b). In this way membraneless separation of gaseous product takes place inside the flow-by electrolytic reactor body.

[0061] The design parameters which are essential (or main) for the functioning of the disclosure are: (1) the distance between the cathode and anode (which is equal to width of channel or the electrode gap), (2) length of the channel inside the reactor, (3) height and width of the electrodes (anode and cathode), (4) design of circular inlet to rectangular channel and the concomitant dimensions, (5) channel to circular outlets and concomitant dimensions, (6) distance from first end of channel to electrode position, (7) thickness of separator at outlet of channel.

[0062] The design parameters 1 , 2, 3, 6, 7 of the reactor body (100) are calculated using a process which involves the use of different formulas which are based on parameters such as: (a) the density, conductivity and viscosity of the electrolyte; (b) the velocity of the electrolyte at the inlet; and (c) the water splitting activity (Tafel slope and exchange current density) of the electrode materials. [0063] The design parameters 4, 5 are based on CFD (Computational Fluid Dynamics) simulations of the designed reactor body (100) or the like. The listed design parameters are calculated based on the formulas and the CFD simulations. These control the following outputs: efficiency of the reaction, which in this preferred embodiment is the water splitting process (related to capex of electrolyzer); the current density achievable (related to hydrogen production rate); the dimensions, scalability (related to capex of electrolyzer); and the purity of the reactants, which in the preferred embodiment are the hydrogen and oxygen streams (related to product quality and safety). The inventors after rigorous effort arrived at parameters to find the most suitable dimensions of the reactor body (100) to get the highest efficiency and product/H2 production rate at the highest possible purity.

[0064] In an embodiment, the design parameters as stated above have different values based on different height, width and length of the reactor body (100).

EXAMPLES:

[0065] The examples below illustrate the various embodiments of the present disclosure in a non-limiting fashion while establishing the enhanced technical effect achieved due to the various design parameters. For all the examples 6M KOH in water as electrolyte at room temperature (25°C) and flow rate of 1.7 LPM was used.

[0066] The below experimental work was performed to demonstrate the effectiveness based on the claimed electrode gap ranging between 2mm >d> 8mm between the first electrode and the second electrode.

[0067] Example 1 : The reactor body with the following conditions was run.

Experiment details

Scan rate 10 mV/s [0068] The electrode height is 30mm and electrode width is 10mm in all versions. Referring to figure 9, it is noted that the reactor has electrode gap of 2mm. This resulted in an efficiency of 62% LHV (Lower heating value (LHV) of H2). Further, the purity of gas is 98.247%.

[0069] Example 2: The reactor body with the following conditions was run.

Experiment details

[0070] The electrode height is 30mm and electrode width is 10mm in all versions. Referring to figure 10, it is noted that the reactor has electrode gap of 4mm. It was observed that the efficiency of the reactor is 55.65% LHV. Further, the purity of H2 gas is 98.343%.

[0071] Example 3: The reactor body with the following conditions was run.

Experiment details

> Scan rate 10 mV/s [0072] The electrode height is 30mm and electrode width is 10mm in all versions. Referring to figure 11 , it is noted that the reactor has electrode gap of 8mm. It was observed that the efficiency is 52.2% LHV. Further, the purity of H2 gas is 99.492%.

[0073] It is noted from the above experimental work in Example 1 -3 that efficiency improves when electrode gap is reduced and reduces when electrode gap is increased. This is due to lower solution resistance as electrode gap reduces. The H2 purity decreases and hence the product crossover rate is higher with reduction in electrode gap. The H2 purity is better and the crossover rate is lower with increased electrode gap.

[0074] Example-4: Demonstrates the effectiveness based on the claimed height and width of one or more of the first and second electrodes. The following conditions were maintained:

Experiment details

Scan rate 10 mV/s

Referring to figure 12, the electrode height was changed to 150mm. The electrode width was changed to 20mm. The electrode gap is 3.9mm. This resulted in efficiency of 59.2% LHV. The H2 purity is 98.7%.

[0075] It is observed that both efficiency and H2 purity has improved compared to 30mm height and 10mm width electrode (electrode gap for both is 4mm as in Example 2). This is due to the improvement in laminar flow conditions as a result of larger channel due to increased hydraulic diameter of the channel.

[0076] Example 5: Hydrogen production: A test setup was prepared and used to study the purity of the hydrogen obtained from the reactor body (100) of the present electrolyzer. The test setup included as major components apart from the reactor body, an electrolyte reservoir, a pump, a flowmeter, a reactor, a power supply, a hydrogen/electrolyte separator, and an oxygen/electrolyte separator. The gas produced was collected in a gas sampling bag. The collected gas sample was extracted via a syringe and fed into a gas chromatograph. The results are given in the report given in Figure 13.

[0077] Results: Hydrogen and Nitrogen peaks were detected in the gas chromatograph. The detected hydrogen peak was from the hydrogen gas generated during electrolysis and carried via tubing to the hydrogen/electrolyte separator where it was collected at the top of the vessel from which it was extracted as explained before.

[0078] The nitrogen peak was due to the use of nitrogen as an inert collection gas. In short, the separator vessel has a non-return valve attached to its outlet in order to prevent any contamination from atmosphere. Since the experiment is run at atmospheric pressure, in order to collect the hydrogen in the gas sampling bag, we needed to flow nitrogen into the separator vessel. This was collected along with the hydrogen in the gas sampling bag.

[0079] Notably no oxygen peaks were detected in the measurement. Based on the sensitivity levels of the gas chromatograph, it is observed that hydrogen purity would be at 99.99%.

[0080] Example-6: Demonstrates the effectiveness of multireactor cell system. Referring to figure 14, there are four reactors in the system. Each reactor has a height of 150mm, width of 20mm and an electrode gap of 3.9mm. The remaining conditions were as above. The system having multiple reactor bodies was tested for its efficiency and it gave an efficiency of 56.5% LHV (Lower heating value (LHV) of H2). Further, the purity of gas is 99.94%.

Claims

We Claim:

1. A reactor body (100) for the production and separation of products by electrolysis of an electrolytic solution, the reactor body comprising:

- an inlet chamber (10);

- at least two outlets (20);

- a channel (30) in communication with the inlet chamber (10) at a first end (30a) and the at least two outlets (20) at a second end (30b), said channel (30) being capable of containing and directing flow of electrolytic solution, wherein said electrolytic solution includes at least one reactant;

- a pair of first and second electrodes (40) present in the channel (30) at a predetermined distance from the inlet chamber (10), each of said first and second electrodes having a first side (42a, 44a) and a second side (42b, 44b), the first sides of the first and second electrodes arranged to face each other to define an electrode gap (46) within the channel (30);

- a separator (7) fixed proximal to the pair of electrodes (40) in the channel (30), in fluid communication with the at least two outlets (20); and capable of separating the products from each other;

- the at least two outlets (20) comprises a first outlet (20a) capable of receiving a first product from the first electrode (42) and a second outlet (20b) capable of receiving a second product from the second electrode (44); wherein :

- the first electrode (42) and the second electrode (44) are separated by an electrode gap (46) ranging between 1mm to 10mm ;

- a height of one or more of the first and second electrodes is in the range of 0.1 mm to 500 mm, and a width of one or more of the first and second electrodes is in the range of 0.5mm to 50mm; and

- inlet chamber (10) tapers toward the channel (30) containing the pair of first and second electrodes (40).

2. The reactor body (100) as claimed in claim 1, wherein the length of the channel (30) inside the reactor body (100) is in the range of 1mm to 300mm.

3. The reactor body (100) as claimed in claim 1, wherein the length of the channel (30) to the outlets (20) is in the range of 5mm to 300 mm.

4. The reactor body (100) as claimed in claim 1, wherein the distance from start of channel (30a) to electrode position is in the range of 10mm to 200mm.

5. The reactor body (100) as claimed in claim 1, wherein the thickness of separator (7) in the channel is in the range 0.1 mm to 3 mm.

6. The reactor body (100) as claimed in claim 1, wherein the electrode gap (46) is equal to the width of the channel (30).

7. The reactor body (100) as claimed in claim 1, wherein the inlet is circular with a diameter in the range of 5 mm to 300 mm.

8. The reactor body (100) as claimed in claim 1, wherein the flow of electrolytic solution to the narrow channel (30) containing the electrodes (40) is laminar.

9. The reactor body (100) as claimed in claims 1 and 2, is based on parameters: (a) the density, conductivity and viscosity of the electrolytic solution; (b) the velocity of the electrolyte at the inlet; and (c) the water splitting activity (Tafel slope and exchange current density).

10. The reactor body (100) as claimed in claim 1, wherein the products are gases.

11. The reactor body (100) as claimed in claim 1, wherein the inlet chamber (10) tapering is straight, or concave, or convex shaped.

12. A method for production and separation of products, by electrolysis of an electrolytic solution using the reactor body (100) as claimed in claim 1, the method comprising the steps of:

- supplying a stream of electrolytic solution through an inlet chamber (10) of the reactor body (100) to the channel (30) in communication with the inlet chamber (10) on one side and having a pair of first and second electrodes (40),

- diverging the electrolytic solution within the electrode gap (46) between the pair of first and second electrodes (40); - providing a potential difference over the pair of first and second electrodes (40) so that electrolysis of the electrolytic solution ensues, and so that a first product forms on the first electrode, and a second product forms on the second electrode; and

-removing at least a portion of the first and second product from the first and second electrodes into at least two outlets by a separator (7) disposed in the channel (30).

13. The method as claimed in claim 12, comprising the further step of collecting and storing the separated first and second products.

14. A system comprising the reactor body (100) as claimed in claim 1.

15. A flow by cell system having at least two reactor bodies for the production of hydrogen gas by electrolysis of an electrolytic solution, one of the reactor body (100) comprising:

- an inlet chamber (10) bifurcating into a plurality of inlet channels;

- at least two outlets (20), each of the at least two outlets are formed by the joining of plurality of outlet channels;

- at least two horizontal channels in communication with the plurality of inlet channels at a first end (30a) and to plurality of outlet channels at a second end (30b), said channels (30) being capable of containing and directing flow of electrolytic solution, wherein said electrolytic solution includes at least one reactant;

- a pair of first and second electrodes (40) present in the channel (30) at a predetermined distance from the inlet chamber (10), each of said first and second electrodes having a first side (42a, 44a) and a second side(42b,44b), the first sides of the first and second electrodes arranged to face each other to define an electrode gap (46) within the channel (30);

- a separator (7) fixed proximal to the pair of electrodes (40) in the channel (30) , in fluid communication with the at least two outlets (20); and capable of separating the hydrogen gas from the electrolytic solution;

- the at least two outlets (20) comprises a first outlet (20a) capable of receiving hydrogen from the first electrode (42) and a second outlet (20b) capable of receiving oxygen from the second electrode (44); wherein :

- the first electrode and the second electrode are separated by an electrode gap (46) ranging between 1mm to 10mm - a height of one or more of the first and second electrodes is in the range of 0.1 mm to 500 mm, and a width of one or more of the first and second electrodes is in the range of 0.5mm to 50mm; and

- inlet chamber (10) tapers toward the channel (30) containing the electrodes (40).

16. The system as claimed in claim 14 or 15, wherein the plurality of inlet channels are at least two.

17. The system as claimed in claim 14 or 15, wherein the plurality of outlet channels are at least two.

18. The reactor body or system as claimed in claims 1-14 is capable of an efficiency of 55% -65% (Lower heating value (LHV) of H2) and H2 gas of purity 98%-99.99%.