CAT HODE OPT IMIZING SOL UT ION OPT I MI ZE YOUR CHL OR - AL K AL I ME MBRANE CE L L By Dino DiF ra nc o CONF IDE NT IAL
About Me • B.S./ M.S. in Che mic a l E ng ine e ring fro m CWRU with a spe c ia lty in E le c tro c he mistry • Ma ste r’ s T he sis in E le c tro pla ting • Spe nt 12 ye a rs wo rking in e le c tro pla ting a va rie ty o f ma te ria ls fo r a F o rtune 100 e le c tro nic s c o mpa ny (Cathode F oc use d) Co ppe r • Autho r o n 30+ Pa te nts Nic ke l • Winne r o f a n R&D 100 Awa rd Go ld Silve r T in L e a d-tin so lde r Bra ss Chro mium Pla tinum Zinc Zinc -nic ke l e tc . CONF I DE NT I AL
About Me : (Continue d) Jo ine d E L T E CH Syste ms / De No ra fo r 20 ye a rs ( Anode F oc use d ) T he se c o mpa nie s c o mme rc ia lize d He nri Be e r’ s histo ric 1968 Ano de inve ntio n whic h is a the rma lly a pplie d mixe d me ta l o xide o n tita nium. He nri Be e r’ s inve ntio n o f using me ta l o xide s a s a n a no de in a n o xidizing e nviro nme nt de live rs e xc e ptio na l pe rfo rma nc e a nd c a n de live r 25+ ye a rs o f se rvic e witho ut a ppre c ia b le vo lta g e e sc a la tio n. While it c a n a lso func tio n a s a c a tho de , this te c hno lo g y is no t o ptimum fo r c a tho de s whic h a re in a re duc ing e nviro nme nt. L imita tio ns inc lude : Cr ac ks and Por e s in a • Vo lta g e e sc a la tio n • Re q uire Po la riza tio n T he r mally Applie d • Po o r a dhe sio n • Po o r sub stra te pro te c tio n Coating • Hig h we a r ra te • Hig h c o st • L imite d life time • So me a re a s no t a c tiva te d I be lie ve the r e is r oom to impr ove c hlor - alkali c athode s and this is one of the r e asons I star te d E le c tr ode Solutions. CONF I DE NT I AL
IN- SIT U CAT HODE ACT IVAT ION BE NE F IT S • No Ca tho de Re c o a ting No c e ll dis-a sse mb ly No shipping o f c a tho de s No spa re c a tho de re q uire me nts (I dle c a pita l) No c a tho de disto rtio n o r thinning fro m re c o a ting No c a tho de wa rra nty c o nstra ints / c o nc e rns OE M Cathode No la rg e c a pita l e xpe nse fo r re c o a ting War r anty • Ope ra te a t the L OWE ST E NE RGY CONSUMPT ION Voltage Ac tiva te a ll a re a s c a pa b le o f hydro g e n e vo lutio n No vo lta g e e sc a la tio n (c o nsiste nt c e ll ro o m pe rfo rma nc e ) I mme dia te re c o ve ry fro m upse ts T ime On- L ine • MUCH L E SS e xpe nsive a nd BE T T E R tha n OE M supplie d c a tho de c o a ting s • Po ssib le impro ve me nt fo r the me mb ra ne E q uilib ra te the c urre nt de nsity a c ro ss the me mb ra ne surfa c e L e ss he a ting a t the me mb ra ne surfa c e = Highe r E ffic ie nc y L e ss hydro g e n o n the me mb ra ne = L owe r H 2 in Cl 2 CONF I DE NT I AL
IN- SIT U CAT HODE ACT IVAT ION – Histor y So me OE M’ s ha ve pro mo te d in-situ a c tiva tio n in the pa st (CE C, E L T E CH, e tc ). I pro mo te d a pro duc t c a lle d VRS (Vo lta g e Re duc tio n So lutio n) fo r E L T E CH in the e a rly 2000’ s. Ma ny c usto me rs use d it in the ir c e ll ro o ms Vo lta g e re duc tio n wa s o b se rve d using VRS (T e c hnic a l suc c e ss) E c o no mic s o f using VRS we re no t sa tisfa c to ry (E c o no mic fa ilure ) VRS wa s to o e xpe nsive b ut it de mo nstra te d the pro mise o f a b e tte r c a tho de via in-situ a c tiva tio n. CONF I DE NT I AL
IN- SIT U CAT HODE ACT IVAT ION – T ODAY ION (COS) wa s de ve lo pe d to de live r o ptimize d CAT HODE OPT IMIZING SOL UT c a tho de pe rfo rma nc e a t a n e c o no mic pric e . COS is a dde d in-situ to the c a tho lyte a nd imme dia te ly a c tiva te s a ll surfa c e s c a pa b le o f hydro g e n e vo lutio n. Surfa c e s pre vio usly a c tiva te d a re re ne we d COS is e c o no mic a l e no ug h tha t it is c o ntinuo usly a dde d to ma inta in the lo we st e ne rg y c o nsumptio n a nd a c hie ve a sta b le c a tho de pe rfo rma nc e . Unlike the rma lly a pplie d c o a ting s pro vide d b y OE M’ s, COS will se a l o ff the unde rlying nic ke l a nd pro te c t the nic ke l sub stra te during po we r o uta g e s. Non-Catalyst, Binder, Filler Catalyst Catalyst Cracks Voids NICKEL METAL SUBSTRATE NICKEL METAL SUBSTRATE Oxide Coating COS Coating CONF I DE NT I AL
T o a vo id vo lta g e e sc a la tio n, the c o a ting must pro te c t the unde rlying nic ke l a nd b e a dhe re nt. T his is e spe c ia lly impo rta nt during o uta g e s. COS is a dhe re nt to the nic ke l sub stra te a nd pro te c ts it. CONF I DE NT I AL
Po ro us OE M Ca tho de Co a ting a llo ws c o rro sio n a nd c o rro sio n pro duc ts (g re e nish c o lo r) to mig ra te to the surfa c e . CONF I DE NT I AL
FIXED GAP CHLOR-ALKALI MEMBRANE CELL MEMBRANE E ARL Y CHL OR-AL K AL I ME MBRANE CE L L S ANODE (ACTIVATED) WE RE DE SI GNE D WI T H A F I XE D GAP COARSE MESH BE T WE E N T HE CAT HODE AND T HE (ACTIVATED) ME MBRANE T O PRE VE NT ME MBRANE DAMAGE . T HE SE CE L L S ARE RE F E RRE D T O AS “F I XE D GAP” CE L L S. C A A N T O H L O Y L T Y E T E CHLORINE GAS HYDROGEN GAS CONF I DE NT I AL
FIXED GAP CHLOR-ALKALI MEMBRANE CELL MEMBRANE ANODE I N A F I XE D GAP CE L L , T HE HYDROGE N GAS (ACTIVATED) I S E VOL VE D ON T HE ACT I VAT E D COARSE COARSE MESH (ACTIVATED) ME SH AS SHOWN HE RE . C A A N T O H L O Y L T Y E T E CHLORINE GAS HYDROGEN GAS CONF I DE NT I AL
ZERO GAP CHLOR-ALKALI MEMBRANE CELL FINE MESH MEMBRANE NE WE R CE L L DE SI GNS AND/ OR RE T ROF I T S (ACTIVATED) ANODE COMPRESSIBLE LAYER OF OL DE R CE L L S I NCORPORAT E A ZE RO (ACTIVATED) (NOT ACTIVATED) GAP DE SI GN WHE RE I N A COMPRE SSI BL E COARSE MESH (NOT ACTIVATED) L AYE R I S PL ACE D BE T WE E N T HE COARSE ME SH AND A F I NE SCRE E N. C A A N T O H L O Y L T Y E T E CHLORINE GAS HYDROGEN GAS CONF I DE NT I AL
ZERO GAP CHLOR-ALKALI MEMBRANE CELL FINE MESH MEMBRANE (ACTIVATED) ANODE COMPRESSIBLE LAYER (ACTIVATED) (NOT ACTIVATED) COARSE MESH (NOT ACTIVATED) C I N A ZE RO GAP CE L L , T HE F I NE ME SH I S A A N T ACT I VAT E D AND T HE HYDROGE N GAS I S O H L E VOL VE D ON T HE F I NE ME SH ONL Y. O Y L T Y E T E CHLORINE GAS HYDROGEN GAS CONF I DE NT I AL
ZERO GAP CHLOR-ALKALI MEMBRANE CELL FINE MESH MEMBRANE (ACTIVATED) ANODE ds OF COMPRESSIBLE LAYER HAN 2/ 3 r T HE AVAI L ABL E (ACTIVATED) MORE T (NOT ACTIVATED) CAT HODE SURF ACE ARE A I S NOT COARSE MESH (NOT ACTIVATED) D I N PRE SE NT DAY ZE RO GAP ACT IVAT E CE L L S. C A A N T O H L O Y L T Y E T E CHLORINE GAS HYDROGEN GAS CONF I DE NT I AL
ZERO GAP CHLOR-ALKALI MEMBRANE CELL BY ELECTRODE SOLUTIONS FINE MESH MEMBRANE (ACTIVATED) AF T E R T HE ADDI T I ON OF ANODE COMPRESSIBLE LAYER (ACTIVATED) (ACTIVATED) CAT HODE OPT IMIZING SOL UT ION COARSE MESH F ROM E L E CT RODE SOL UT I ONS, AL L (ACTIVATED) SURF ACE S I N T HE CAT HOL YT E ARE ACT I VAT E D AND E VOL VI NG HYDROGE N GAS, AND T HE CE L L VOL T AGE I S RE DUCE D! C A A N T O H L O Y L T Y E T E CHLORINE GAS HYDROGEN GAS CONF I DE NT I AL
ZERO GAP CHLOR-ALKALI MEMBRANE CELL BY ELECTRODE SOLUTIONS CAT HODE OPT IMIZING SOL UT ION FINE MESH MEMBRANE (ACTIVATED) ANODE OPT I MI ZE S T HE CAT HODE OPE RAT I ON. COMPRESSIBLE LAYER (ACTIVATED) (ACTIVATED) PRE VI OUSL Y UNACT I VAT E D SURF ACE S ARE COARSE MESH ACT I VAT E D AND PRE VI OUSL Y ACT I VAT E D (ACTIVATED) SURF ACE S ARE RE NE WE D. T HE CAT HODE CURRE NT DE NSI T Y I S L OWE RE D. C Cathode Voltage vs Current Density A A N 1.25 T O H CATHODE VOLTAGE 1.2 L O Y L 1.15 T Y E T 1.1 E 1.05 1 0 1 2 3 4 5 6 7 8 9 10 kA/m2 CHLORINE GAS HYDROGEN GAS CONF I DE NT I AL
COS F IE L D DAT A Imme diate r e sults with COS.e CONF I DE NT I AL
OT HE R BE NE F IT S OF A CAT AL YZE D CUSHION L AYE R OE M supplie d c a ta lyze d fine me sh la ye rs inc re a se the te mpe ra ture o f the me mb ra ne b y a t le a st 5 o C a c c o rding to AGC c he mic a ls whic h lo we rs the Curre nt E ffic ie nc y b y 0.5-1%. Ca ta lyzing the c ushio n la ye r c o unte rs the se ne g a tive e ffe c ts a nd impro ve s the o pe ra tio n. AGC da ta pre se nte d a t Clo ro sur T e c hnic a l Se mina r CONF I DE NT I AL
OT HE R BE NE F IT S OF A CAT AL YZE D CUSHION L AYE R OE M supplie d c a ta lyze d fine me sh la ye rs inc re a se the hydro g e n in c hlo rine . Ca ta lyzing the c ushio n la ye r with COS c o unte rs this ne g a tive e ffe c t a nd impro ve s the o pe ra tio n. AGC da ta pre se nte d a t Clo ro sur T e c hnic a l Se mina r CONF I DE NT I AL
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