阅读说明：本技术 用于产生高产物强度溶液的电氯化系统配置 (Electro-chlorination system configuration for producing high product strength solutions ) 是由 约书亚·格里菲斯 西蒙·P·杜克斯 保罗·贝多斯 彼得·G·罗杰斯 于 2019-02-22 设计创作，主要内容包括：一种电氯化系统包括进料流体的源、产物流体出口和流体地连接在进料流体的源和产物流体出口之间的多于一个电化学电池。该系统被配置成以第一电流密度或第一流量中的一种操作多于一个电化学电池中的至少一个电化学电池,并且以不同于相应的第一电流密度或第一流量的第二电流密度或第二流量操作多于一个电化学电池中的另一个电化学电池。(An electro-chlorination system includes a source of a feed fluid, a product fluid outlet, and more than one electrochemical cell fluidly connected between the source of the feed fluid and the product fluid outlet. The system is configured to operate at least one of the more than one electrochemical cells at one of a first current density or a first flow rate, and to operate another of the more than one electrochemical cells at a second current density or a second flow rate different from the respective first current density or first flow rate.)

1. An electro-chlorination system, comprising:

a source of feed fluid;

a product fluid outlet; and

more than one electrochemical cell fluidly connected between the source of feed fluid and the product fluid outlet,

the system is configured to operate at least one of the more than one electrochemical cells at one of a first current density or a first flow rate, and to operate another of the more than one electrochemical cells at a second current density or a second flow rate different from the respective first current density or first flow rate.

2. The system of claim 1, wherein the more than one electrochemical cell is a series electrochemical cell fluidly connected in series.

3. The system of claim 1, wherein the more than one electrochemical cell are parallel electrochemical cells fluidly connected in parallel.

4. The system of claim 1, wherein the more than one electrochemical cell comprises one or more series electrochemical cells fluidly connected in series and one or more parallel electrochemical cells fluidly connected in parallel.

5. The system of any of claims 2-4, wherein the more than one electrochemical cells are electrically connected in series.

6. The system of any of claims 2-4, wherein the more than one electrochemical cell are electrically connected in parallel.

7. The system of any of claims 2-4, wherein the more than one electrochemical cell comprises one or more electrochemical cells electrically connected in series and one or more electrochemical cells electrically connected in parallel.

8. The system of any of claims 2-4, wherein the more than one electrochemical cell comprises one or more electrochemical cells that are electrically independent of other electrochemical cells of the more than one electrochemical cell.

9. The system of claim 1, further comprising a controller configured to operate a first electrochemical cell fluidly disposed upstream of a second electrochemical cell at the first current density and to operate the second electrochemical cell at the second current density, the first current density being higher than the second current density.

10. The system of claim 9, further comprising a third electrochemical cell fluidly disposed between the first electrochemical cell and the second electrochemical cell.

11. The system of claim 10, wherein the controller is further configured to operate the third electrochemical cell at a third current density that is lower than the first current density and higher than the second current density.

12. The system of claim 11, further comprising a fourth electrochemical cell disposed fluidly downstream of the second electrochemical cell, the controller further configured to operate the fourth electrochemical cell at the second current density.

13. The system of claim 12, further comprising a pump, wherein the controller is further configured to cause the pump to flow fluid from the source of feed fluid through each of the first electrochemical cell, the second electrochemical cell, the third electrochemical cell, and the fourth electrochemical cell at the first flow rate.

14. The system of claim 1, wherein the more than one electrochemical cell comprises a first set of parallel electrochemical cells fluidly connected in parallel between the source of feed fluid and more than one series electrochemical cells fluidly connected in series.

15. The system of claim 14, further comprising a controller configured to operate each electrochemical cell of the set of parallel electrochemical cells at the first flow rate and each electrochemical cell of the more than one series electrochemical cells at the second flow rate, the first flow rate being less than the second flow rate.

16. The system of claim 15, wherein the fluid outlet conduit from each electrochemical cell in the set of parallel electrochemical cells is combined into a single fluid input conduit for the more than one series electrochemical cells.

17. The system of claim 15, wherein the controller is further configured to operate each electrochemical cell of the set of parallel electrochemical cells and each electrochemical cell of the more than one series electrochemical cells at the first current density.

18. The system of claim 15, wherein the controller is further configured to operate each electrochemical cell of the set of parallel electrochemical cells at the first current density and each electrochemical cell of the more than one series electrochemical cells at the second current density.

19. The system of claim 18, wherein the first current density is greater than the second current density.

20. The system of claim 1, further comprising a product tank fluidly connected to the fluid outlets of the more than one electrochemical cell.

21. The system of claim 20, further comprising a parallel electrochemical cell having a fluid inlet connected to the fluid outlet of the product tank and a fluid outlet connected to the fluid inlet of the product tank.

22. The system of claim 20, further comprising a controller configured to operate the parallel electrochemical cells at a third current density different from the first and second current densities.

23. The system of claim 20, further comprising a controller configured to operate the parallel electrochemical cells at a third flow rate different from the first and second flow rates.

24. The system of claim 20, further comprising a controller configured to operate the parallel electrochemical cells at one of the first current density or the second current density.

25. The system of claim 20, further comprising a controller configured to operate the parallel electrochemical cells at one of the first flow rate or the second flow rate.

26. An electro-chlorination system, comprising:

a source of feed fluid;

a product fluid outlet;

a pair of parallel electrochemical cells fluidly connected in parallel to a fluid outlet of the source of feed fluid;

a series electrochemical cell fluidly connected in series between the pair of parallel electrochemical cells and the product fluid outlet; and

a controller configured to operate the pair of parallel electrochemical cells at one of a first current density or a first flow rate, and to operate the series electrochemical cells at a second current density or a second flow rate different from the first current density or the first flow rate.

27. The system of claim 26, wherein the controller is configured to operate each electrochemical cell of the pair of parallel electrochemical cells and the series electrochemical cell at a same current density.

28. A method of operating an electro-chlorination system, the method comprising:

flowing a feed fluid through a first electrochemical cell and a second electrochemical cell of the system, the second electrochemical cell being operated at one of a different current density or a different flow rate than a corresponding current density or flow rate of the first cell.

29. The method of claim 28, comprising flowing the feed fluid through the first electrochemical cell and the second electrochemical cell in series.

30. The method of claim 28, comprising flowing the feed fluid through the first electrochemical cell and the second electrochemical cell in parallel.

31. The method of claim 30, further comprising flowing the feed fluid through a third electrochemical cell in series with the first electrochemical cell and the second electrochemical cell.

32. The method of claim 31, further comprising one of:

flowing the feed fluid from both the first electrochemical cell and the second electrochemical cell into the third electrochemical cell, or

Flowing the feed fluid from the third electrochemical cell into both the first electrochemical cell and the second electrochemical cell.

33. The method of claim 32, wherein the flow rate of the feed fluid through the third electrochemical cell is the sum of the flow rates of the feed fluids through the first electrochemical cell and the second electrochemical cell.

34. The method of claim 33, wherein each of the first electrochemical cell, the second electrochemical cell, and the third electrochemical cell is operated at the same current density.

35. The method of claim 29, comprising flowing the feed fluid through the first electrochemical cell and the second electrochemical cell at the same flow rate.

36. The method of claim 35, further comprising operating the first electrochemical cell at a higher current density than the second electrochemical cell.

37. The method of claim 29, comprising flowing the feed fluid through the second electrochemical cell at a higher flow rate than a flow rate of the feed fluid through the first electrochemical cell.

38. The method of claim 37, further comprising recirculating feed fluid from an outlet of the second electrochemical cell to an inlet of the second electrochemical cell.

39. The method of claim 38, further comprising operating the first electrochemical cell at a higher current density than the second electrochemical cell.

40. The method of claim 29, further comprising recirculating feed fluid from an outlet of the second electrochemical cell to an inlet of the first electrochemical cell.

41. The method of claim 40, further comprising operating said first electrochemical cell at a higher current density than said second electrochemical cell.

42. The method of claim 29, further comprising flowing the feed fluid from a product tank into the first electrochemical cell, from the first electrochemical cell through the second electrochemical cell, and from the second electrochemical cell back into the product tank.

43. The method of claim 42, further comprising operating said first electrochemical cell at a higher current density than said second electrochemical cell.

44. The method of claim 28, further comprising flowing the feed fluid from the first electrochemical cell into a product tank.

45. The method of claim 44, further comprising recirculating feed fluid from the product tank through the second electrochemical cell and then back into the product tank.

46. The method of claim 45, further comprising operating said first electrochemical cell at a higher current density than said second electrochemical cell.

47. A method of operating an electro-chlorination system, the method comprising:

flowing a feed fluid through an electrolysis cell at a first flow rate to produce a product solution, the electrolysis cell comprising one or more electrochemical cells;

flowing the product solution from the electrolysis cell operating at the first flow rate into a product tank;

recirculating the product solution from the product tank through the electrolytic cell and back into the product tank at a second flow rate higher than the first flow rate; and

flowing the product solution from the product tank through an outlet of the electro-chlorination system to a point of use at a third flow rate that is higher than the second flow rate.

48. The method of any one of claims 28-47, comprising electrochemically generating a product solution from the feed fluid having a NaOCl concentration of at least 3000 ppm.

49. The method of claim 48, comprising electrochemically generating a product solution from the feed fluid having a NaOCl concentration of at least 6000 ppm.

1. Field of the invention

Aspects and embodiments disclosed herein relate generally to electrochemical devices, and more particularly, to an electro-chlorination cell and an electro-chlorination device, and systems and methods utilizing the same.

2. Discussion of the related Art

Electrochemical devices for producing product solutions from feed streams by chemical reactions at electrodes are widely used in industrial and municipal implementations. Examples of reactions include:

A. electro-chlorination, in which sodium hypochlorite is produced from sodium chloride and water.

Reaction at the anode: 2Cl^-→C1₂+2e^-

Reaction at the cathode: 2Na⁺+2H₂O+2e^-→2NaOH+H₂

In solution: c1₂+2OH^-→ClO^-+Cl^-+H₂O

And (3) total reaction: NaCl + H₂O→NaOCl+H₂

E⁰ _{Oxidation by oxygen}1.36V (chlorine generation)

E⁰ _{Reduction of}not-0.83V (hydrogen generation)

E⁰ _{Battery with a battery cell}＝-2.19V

B. Generating sodium hydroxide and chlorine gas from sodium chloride and water, wherein a cation exchange membrane separates the anode and cathode:

reaction at the anode: 2Cl^-→C1₂+2e^-

Reaction at the cathode: 2H₂O+2e^-→2OH^-+H₂

And (3) total reaction: 2NaC1+2H₂O→2NaOH+C1₂+H₂

C. Vanadium redox cell for energy storage, wherein a proton permeable membrane separates the electrodes:

during charging:

reaction at electrode 1: v³⁺+e^-→V²⁺

Reaction at electrode 2: v⁴⁺→V⁵⁺+e^-

During the discharge period:

reaction at electrode 1: v²⁺→V³⁺+e^-

Reaction at electrode 2: v⁵⁺+e^-→V⁴⁺

In some embodiments, an electro-chlorination device may be used to produce sodium hypochlorite from sodium chloride present in seawater. The concentration of different dissolved solids in seawater may vary depending on location, however, one example of seawater may include the following components:

table 1: typical seawater composition and concentration

Background

SUMMARY

According to an aspect of the present invention, an electrochemical cell is provided. The electrochemical cell includes a housing having an inlet, an outlet, and a central axis, and an anode-cathode pair disposed substantially concentrically within the housing about the central axis and defining an active area (active area) between an anode and a cathode of the anode-cathode pair, the active area of at least one of the anode and the cathode having a surface area greater than a surface area of an inner surface of the housing, the anode-cathode pair being configured and arranged to direct all fluid passing through the electrochemical cell axially through the active area.

In some embodiments, the electrochemical cell has at least about 2mm^-1Total electrode fill density.

In some embodiments, the electrochemical cell further comprises a central core element disposed within the electrochemical cell and configured to inhibit fluid flow through a portion of the electrochemical cell along the central axis, the central core element not connected to at least one electrode of the anode-cathode pair.

In some embodiments, the anode-cathode pair is spirally wound around a central shaft.

In some embodiments, the electrochemical cell further comprises one or more spirally wound bipolar electrodes. In some embodiments, the anode is laterally displaced (laterally displaced) from the cathode along the length of the electrochemical cell.

In some embodiments, at least one of the anode and the cathode is a rigid electrode. The anode and the cathode may each comprise a titanium plate, and the surface of the anode may be coated with an oxidation-resistant coating selected from the group consisting of: platinum and mixed metal oxides. The anode and cathode may each comprise one or more of titanium, nickel and aluminum. The surface of the anode may be coated with an oxidation resistant coating selected from the group consisting of: platinum, mixed metal oxides, magnetite, ferrite, cobalt spinel, tantalum, palladium, iridium, gold, and silver. At least one of the anode and cathode may be fluid permeable and/or may comprise a perforated titanium plate.

In some embodiments, the electrochemical cell further comprises a separator (separator) configured to maintain a gap distance between the anode and the cathode, the separator being open to allow the electrolyte solution to flow through the active area. The separator may include a hub (hub) having spokes (spokes) with slots engaging an edge of at least one of the anode and cathode. The hub may further include an electrical connector configured to electrically connect one of the anode and the cathode to a power source.

In some embodiments, the electrochemical cell further comprises a hub comprising spokes in electrical contact with one of the anode and the cathode. The spokes may include slots that engage an edge of one of the anode and cathode and maintain a gap between turns (turn) of the spirally wound anode-cathode pair.

In some embodiments, the central core element comprises a non-conductive core disposed within the innermost winding of the anode-cathode pair.

In some embodiments, the anode-cathode pair includes more than one concentric electrode tube and a gap defined between adjacent electrode tubes. The more than one concentric electrode tube may include one of more than one anode electrode tube and more than one cathode electrode tube. One of the more than one anode electrode tube and the more than one cathode electrode tube may be a rigid electrode.

In some embodiments, the more than one concentric tube electrode comprises more than one anode electrode tube and more than one cathode electrode tube.

In some embodiments, the electrochemical cell is configured to be capable of flowing an electric current (DC and/or AC) from the anode electrode tube through the electrolyte solution to the cathode electrode tube in a single pass.

In some embodiments, the electrochemical cell further comprises a bipolar electrode tube disposed between the anode electrode tube and the cathode electrode tube.

In some embodiments, the anode electrode tube is laterally displaced along the length of the electrochemical cell from a cathode electrode tube having the same diameter as the anode electrode tube. An electrochemical cell may include an electrode tube including an anode half (anodic half) and a cathode half (cathodic half).

In some embodiments, the electrochemical cell further comprises more than one bipolar electrode tube disposed between each concentrically arranged pair of adjacent anode and cathode electrode tubes.

In some embodiments, at least one of the more than one anode electrode tube and the more than one cathode electrode tube is perforated and/or fluid permeable.

In some embodiments, the electrochemical cell further comprises at least one separator positioned between adjacent electrode tubes, the at least one separator configured to define and maintain a gap between adjacent electrode tubes. The separators may be open to allow the electrolyte solution to flow through gaps defined between the adjacent electrode tubes.

In some embodiments, the electrochemical cell further comprises a metal hub comprising spokes electrically coupled to the rim of the more than one concentric electrode tube. Each spoke may include a slot that engages an edge of the more than one concentric electrode tube, maintaining a gap between adjacent ones of the more than one concentric electrode tubes.

In some embodiments, the central core element comprises an end cap (end cap) disposed within an end of an innermost concentric tube electrode of the electrochemical cell.

In some embodiments, the electrochemical cell has an oblong cross-section.

In some embodiments, the electrochemical cell further comprises an electrical connector in electrical communication with one of the anode and the cathode, the electrical connector comprising at least two materials having different degrees of resistance to chemical attack by the electrolyte solution. The at least two materials may include a first material and a second material, and the electrical connector may include a fluid permeable body formed from the first material. The fluid permeable body may comprise more than one aperture.

In some embodiments, an electrochemical cell includes a plate or body of a second material coupled to a fluid permeable body formed of a first material with one or more mechanical fasteners.

In some embodiments, an electrochemical cell includes a plate or body of a second material coupled to a fluid permeable body formed of a first material with a compression fit.

In some embodiments, an electrochemical cell includes a plate or body of a second material coupled to a fluid permeable body formed of a first material with threads formed in an edge of the fluid permeable body formed of the first material.

In some embodiments, an electrochemical cell includes a body formed of a second material coupled to a fluid permeable body formed of a first material with threads formed in a cylindrical portion of the body formed of the second material.

In some embodiments, an electrochemical cell includes a body formed of a second material that is welded to a body formed of a first material.

In accordance with another aspect, a system is provided that includes an electrochemical cell. The electrochemical cell includes a housing having an inlet, an outlet, and a central axis, and an anode-cathode pair disposed substantially concentrically within the housing about the central axis and defining an effective area between an anode and a cathode of the anode-cathode pair, the effective surface area of at least one of the anode and the cathode having a surface area greater than a surface area of an inner surface of the housing, the anode-cathode pair being configured and arranged to direct all fluid passing through the electrochemical cell axially through the effective area. The system also includes an electrolyte source in fluid communication with the electrochemical cell. The electrochemical cell is configured to produce one or more reaction products from an electrolyte source and output the one or more reaction products. The system also includes a point of use for one or more reaction products output by the electrochemical cell. The one or more reaction products may include a disinfectant. The disinfectant may comprise or consist essentially of sodium hypochlorite.

In some embodiments, the electrolyte source comprises one of saline water and seawater.

In some embodiments, the system is included in one of a vessel and an oil platform.

In some embodiments, the point of use comprises one of a cooling water system and a ballast tank (ballast tank).

In some embodiments, the system is included in a land-based oil drilling system, wherein the point of use is the bottom hole of the oil drilling system.

In accordance with another aspect, an electrochemical cell is provided. The electrochemical cell includes a cathode and an anode disposed in the housing and defining a gap therebetween, each of the cathode and the anode including an arcuate portion, an effective surface area of the anode being greater than a surface area of an inner surface of the housing and an effective surface area of the cathode being greater than a surface area of the inner surface of the housing, the cathode and the anode being configured and arranged to direct all fluid passing through the electrochemical cell axially through the gap.

In some embodiments, the anode comprises more than one plate extending from an arcuate base and the cathode comprises more than one plate extending from the arcuate base, the more than one plate of the anode interleaved with the more than one plate of the cathode.

In accordance with another aspect, an electrochemical cell is provided. The electrochemical cell includes a cathode and an anode disposed in the housing and defining a gap therebetween, each of the cathode and the anode including a portion conforming to a respective portion of the inner surface of the housing, an effective surface area of the anode being greater than a surface area of the inner surface of the housing, and an effective surface area of the cathode being greater than a surface area of the inner surface of the housing, the cathode and the anode being configured and arranged to direct all fluid passing through the electrochemical cell axially through the gap. At least one of the anode and the cathode may include a corrugated portion.

In one embodiment, by varying the flow rate through a Concentric Tube Electrode (CTE) cell and the current density applied to the electrodes of the CTE cell in a system of CTE cells, factors that lead to scale formation may be reduced and thus a novel system with higher product strength (product strength) may be constructed.

According to one aspect, an electro-chlorination system is provided. The system includes a source of feed fluid, a product fluid outlet, and more than one electrochemical cell fluidly connected between the source of feed fluid and the product fluid outlet. The system is configured to operate at least one of the more than one electrochemical cells at one of a first current density or a first flow rate, and to operate another of the more than one electrochemical cells at a second current density or a second flow rate different from the respective first current density or first flow rate.

In some embodiments, the more than one electrochemical cell is a series electrochemical cell fluidly connected in series.

In some embodiments, the more than one electrochemical cell is parallel electrochemical cells fluidly connected in parallel.

In some embodiments, the more than one electrochemical cell includes one or more series electrochemical cells fluidly connected in series and one or more parallel electrochemical cells fluidly connected in parallel.

In some embodiments, more than one electrochemical cell is electrically connected in series.

In some embodiments, more than one electrochemical cell is electrically connected in parallel.

In some embodiments, the more than one electrochemical cell includes one or more electrochemical cells electrically connected in series and one or more electrochemical cells electrically connected in parallel.

In some embodiments, the more than one electrochemical cell includes one or more electrochemical cells that are electrically independent (electrically independent) of other electrochemical cells of the more than one electrochemical cell.

In some embodiments, the system further comprises a controller configured to operate the first electrochemical cell fluidly disposed upstream of the second electrochemical cell at a first current density and operate the second electrochemical cell at a second current density, the first current density being higher than the second current density.

In some embodiments, the system further comprises a third electrochemical cell fluidly disposed between the first electrochemical cell and the second electrochemical cell.

In some embodiments, the controller is further configured to operate the third electrochemical cell at a third current density, the third current density being lower than the first current density and higher than the second current density.

In some embodiments, the system further comprises a fourth electrochemical cell disposed fluidly downstream of the second electrochemical cell, the controller further configured to operate the fourth electrochemical cell at the second current density.

In some embodiments, the system further comprises a pump, wherein the controller is further configured to cause the pump to flow fluid from the source of feed fluid through each of the first electrochemical cell, the second electrochemical cell, the third electrochemical cell, and the fourth electrochemical cell at a first flow rate.

In some embodiments, the more than one electrochemical cell comprises a first set of parallel electrochemical cells fluidly connected in parallel between the source of feed fluid and the more than one series electrochemical cells fluidly connected in series.

In some embodiments, the system further comprises a controller configured to operate each electrochemical cell of the set of parallel electrochemical cells at a first flow rate and each electrochemical cell of the more than one series electrochemical cells at a second flow rate, the first flow rate being less than the second flow rate.

In some embodiments, the fluid outlet conduit from each electrochemical cell in the set of parallel electrochemical cells is combined in a single fluid input conduit of more than one series electrochemical cell.

In some embodiments, the controller is further configured to operate each electrochemical cell of the set of parallel electrochemical cells and each electrochemical cell of the more than one series electrochemical cells at the first current density.

In some embodiments, the controller is further configured to operate each electrochemical cell of the set of parallel electrochemical cells at a first current density and each electrochemical cell of the more than one series electrochemical cells at a second current density.

In some embodiments, the first current density is greater than the second current density.

In some embodiments, the system further comprises a product tank fluidly connected to the fluid outlet of the more than one electrochemical cell.

In some embodiments, the system further comprises a parallel electrochemical cell having a fluid inlet connected to the fluid outlet of the product tank and a fluid outlet connected to the fluid inlet of the product tank.

In some embodiments, the system further comprises a controller configured to operate the parallel electrochemical cells at a third current density different from the first and second current densities.

In some embodiments, the system further comprises a controller configured to operate the parallel electrochemical cells at a third flow rate different from the first flow rate and the second flow rate.

In some embodiments, the system further comprises a controller configured to operate the parallel electrochemical cells at one of the first current density or the second current density.

In some embodiments, the system further comprises a controller configured to operate the parallel electrochemical cells at one of the first flow rate or the second flow rate.

According to another aspect, an electro-chlorination system is provided. The system comprises: a source of feed fluid; a product fluid outlet; a pair of parallel electrochemical cells fluidly connected in parallel to a fluid outlet of a source of feed fluid; a series electrochemical cell fluidly connected in series between a pair of parallel electrochemical cells and a product fluid outlet; and a controller configured to operate the pair of parallel electrochemical cells at one of a first current density or a first flow rate, and to operate the series electrochemical cells at a second current density or a second flow rate different from the first current density or the first flow rate.

In some embodiments, the controller is configured to operate each electrochemical cell of the pair of parallel electrochemical cells and the series electrochemical cell at the same current density.

In accordance with another aspect, a method of operating an electro-chlorination system is provided. The method includes flowing a feed fluid through a first electrochemical cell and a second electrochemical cell of the system, the second electrochemical cell being operated at one of a different current density or a different flow rate than a corresponding current density or flow rate of the first cell.

In some embodiments, the method includes flowing a feed fluid through a first electrochemical cell and a second electrochemical cell in series.

In some embodiments, the method includes flowing a feed fluid through a first electrochemical cell and a second electrochemical cell in parallel.

In some embodiments, the method further comprises flowing the feed fluid through a third electrochemical cell in series with the first electrochemical cell and the second electrochemical cell.

In some embodiments, the method further comprises flowing the feed fluid from both the first electrochemical cell and the second electrochemical cell into a third electrochemical cell, or flowing the feed fluid from the third electrochemical cell into both the first electrochemical cell and the second electrochemical cell.

In some embodiments, the flow rate of the feed fluid through the third electrochemical cell is the sum of the flow rates of the feed fluids through the first electrochemical cell and the second electrochemical cell.

In some embodiments, each of the first electrochemical cell, the second electrochemical cell, and the third electrochemical cell is operated at the same current density.

In some embodiments, the method includes flowing a feed fluid through the first electrochemical cell and the second electrochemical cell at the same flow rate.

In some embodiments, the method further comprises operating the first electrochemical cell at a higher current density than the second electrochemical cell.

In some embodiments, the method includes flowing the feed fluid through the second electrochemical cell at a higher flow rate than the flow rate of the feed fluid through the first electrochemical cell.

In some embodiments, the method further comprises recirculating the feed fluid from the outlet of the second electrochemical cell to the inlet of the second electrochemical cell.

In some embodiments, the method further comprises operating the first electrochemical cell at a higher current density than the second electrochemical cell.

In some embodiments, the method further comprises recirculating the feed fluid from the outlet of the second electrochemical cell to the inlet of the first electrochemical cell.

In some embodiments, the method further comprises operating the first electrochemical cell at a higher current density than the second electrochemical cell.

In some embodiments, the method further comprises flowing a feed fluid from the product tank into the first electrochemical cell, from the first electrochemical cell through the second electrochemical cell, and from the second electrochemical cell back into the product tank.

In some embodiments, the method further comprises operating the first electrochemical cell at a higher current density than the second electrochemical cell.

In some embodiments, the method further comprises flowing a feed fluid from the first electrochemical cell into the product tank.

In some embodiments, the method further comprises recirculating the feed fluid from the product tank through the second electrochemical cell and then back into the product tank.

In some embodiments, the method further comprises operating the first electrochemical cell at a higher current density than the second electrochemical cell.

In accordance with another aspect, a method of operating an electro-chlorination system is provided. The method comprises the following steps: flowing a feed fluid through an electrolysis cell at a first flow rate to produce a product solution, the electrolysis cell comprising one or more electrochemical cells; flowing the product solution from the electrolysis cell operating at a first flow rate into a product tank; recirculating the product solution from the product tank through the electrolytic cell and back into the product tank at a second flow rate higher than the first flow rate; and flowing the product solution from the product tank through an outlet of the electro-chlorination system to a point of use at a third flow rate that is higher than the second flow rate.

Embodiments of the methods disclosed herein may include electrochemically generating a product solution from a feed fluid having a concentration of NaOCl of at least 3000 ppm.

Embodiments of the methods disclosed herein may include electrochemically generating a product solution from a feed fluid having a NaOCl concentration of at least 6000 ppm.

Brief Description of Drawings

The figures are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:

FIG. 1A is a perspective view of an embodiment of a concentric tube electrolyzer cell;

FIG. 1B is a side view of the concentric tube electrolyzer cell of FIG. 1A;

FIG. 1C is a cross-sectional view of the concentric tube electrolyzer cell of FIG. 1A;

FIG. 2A is a perspective view of an embodiment of a multi-tube concentric tube electrolyzer cell;

FIG. 2B is a side view of the concentric tube electrolyzer cell of FIG. 2A;

FIG. 2C is a cross-sectional view of the concentric tube electrolyzer cell of FIG. 2A;

FIG. 3 includes a table listing various design parameters for a 20-cell electrolyzer system (20-cell electrolyzer system);

FIG. 4 illustrates examples of different arrangements of fluid connections between cells in an electrolyzer system;

FIG. 5 illustrates examples of different arrangements of electrical connections between cells in an electrolyzer system;

FIG. 6 illustrates examples of different arrangements of recirculation lines between cells in an electrolyzer system;

figure 7 illustrates the recirculation of fluid from the product tank through the electrochemical cells in the electrolyzer system.

FIG. 8 depicts an example of a once-through electrolyzer system;

FIG. 9 depicts an example of a feed-and-bleed electrolyzer system;

FIG. 10 depicts an example of a flow-through electrolyzer system comprising more than one CTE cell in series;

FIG. 11 depicts another example of a flow-through electrolyzer system comprising more than one CTE cell in series;

figure 12 depicts an example of a flow-through electrolyzer system comprising a first more than one CTE cell operated in parallel and a second more than one CTE cell operated in series;

figure 13 depicts another example of a flow-through electrolyzer system comprising more than one CTE cell in series;

figure 14 depicts an example of an electrolyzer system comprising a first more than one CTE cell operated in series and parallel CTE cells disposed in feed-and-vent lines from a product tank;

FIG. 15A depicts another example of a feed-and-bleed electrolyzer system;

FIG. 15B is a table of operating parameters of the system of FIG. 15A;

fig. 16 illustrates a control system for embodiments of the electrochemical cells and systems disclosed herein; and

FIG. 17 illustrates a memory system for the control system of FIG. 16.

Detailed description of the invention

The aspects and embodiments disclosed herein are not limited to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The aspects and embodiments disclosed herein are capable of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, "comprising," "including," "having," "containing," "involving," and variations thereof, is intended to encompass the items listed thereafter and equivalents thereof as well as additional items.

The present disclosure describes various embodiments of systems including an electro-chlorination cell and an electro-chlorination device, however, the present disclosure is not limited to systems including an electro-chlorination cell or an electro-chlorination device, and the aspects and embodiments disclosed herein may be applied to systems including an electrolysis cell and an electrochemical cell that are used for any of a variety of purposes.

Currently commercially available electro-chlorination cells are typically based on one of two electrode arrangements, Concentric Tubes (CTE) and Parallel Plates (PPE).

Aspects and embodiments disclosed herein relate generally to systems including electrochemical devices that produce disinfectants, such as sodium hypochlorite. The terms "electrochemical device" and "electrochemical cell" and grammatical variations thereof are understood to encompass "electro-chlorination device" and "electro-chlorination cell" and grammatical variations thereof. Aspects and embodiments of the electrochemical cells disclosed herein are described as including one or more electrodes.

Embodiments of electrochemical cells included in the systems disclosed herein may include metal electrodes, such as one or more anodes, one or more cathodes, and/or one or more bipolar electrodes. The term "metal electrode" or grammatical variations thereof as used herein is understood to encompass an electrode formed of, including, or consisting of: one or more metals such as titanium, aluminum or nickel, although the term "metal electrode" does not exclude electrodes comprising or consisting of other metals or alloys. In some embodiments, a "metal electrode" may include multiple layers of different metals. The metal electrodes used in any one or more of the embodiments disclosed herein may include a core of a highly conductive metal, such as copper or aluminum, coated with a layer of a metal or metal oxide, such as titanium, platinum, Mixed Metal Oxide (MMO), magnetite, ferrite, cobalt spinel, tantalum, palladium, iridium, silver, gold, or other coating material, having a high resistance to chemical attack by the electrolyte solution. The "metal electrode" may be coated with an oxidation resistant coating such as, but not limited to, platinum, Mixed Metal Oxides (MMO), magnetite, ferrite, cobalt spinel, tantalum, palladium, iridium, silver, gold, or other coating materials. Mixed metal oxides used in embodiments disclosed herein may include one or more oxides (an oxide or oxides) of one or more of the following: ruthenium, rhodium, tantalum (optionally alloyed with antimony and/or manganese), titanium, iridium, zinc, tin, antimony, titanium-nickel alloys, titanium-copper alloys, titanium-iron alloys, titanium-cobalt alloys, or other suitable metals or alloys. The anode used in embodiments disclosed herein may be coated with platinum, and/or one or more oxides of one or more of iridium, ruthenium, tin, rhodium, or tantalum (optionally alloyed with antimony and/or manganese). The cathode used in embodiments disclosed herein may be coated with platinum, and/or one or more oxides of one or more of iridium, ruthenium, and titanium. Electrodes used in embodiments disclosed herein may include a substrate that includes one or more of the following: titanium, tantalum, zirconium, niobium, tungsten and/or silicon. The electrodes used in any electrochemical cell in any system disclosed herein can be formed as or from plates, sheets, foils, extrudates and/or sintered.

Some aspects and embodiments of electrochemical cells included in the systems disclosed herein are described as including rigid electrodes. As the term is used herein, a "rigid" object is an object that retains its shape in the absence of forces at normal operating temperatures and/or at elevated temperatures. A "rigid electrode," as that term is used herein, is considered to have sufficient mechanical rigidity such that it retains its shape and spacing between adjacent electrodes or electrode windings without the need for spacers in the various embodiments of electrochemical cells and devices disclosed herein. For example, a flexible film comprising a metal coating is not considered a "rigid electrode" as that term is used herein.

The term "tube" as used herein includes cylindrical conduits, however, conduits having other cross-sectional geometries are not excluded, for example conduits having square, rectangular, elliptical or oblong geometries or cross-sectional geometries shaped as any regular or irregular polygon.

The term "concentric tubes" or "concentric spirals" as used herein includes tubes or interleaved spirals that share a common central axis, but does not exclude tubes or interleaved spirals that surround a common axis that is not necessarily central to each of the concentric tubes or interleaved spirals in a set of concentric tubes or interleaved spirals.

In some embodiments, a line passing from a central axis of the electro-chlorination cell towards a periphery of the electro-chlorination cell in a plane defined orthogonal to the central axis passes through more than one (multiple) electrode plate. The more than one electrode plate may comprise more than one anode and/or more than one cathode and/or more than one bipolar electrode. The central axis may be parallel to the average flow direction of the fluid through the electrochemical cell.

In embodiments of the electrochemical cells included in the systems disclosed herein that include more than one anode tube electrode or cathode tube electrode, the more than one anode tube electrode may be collectively referred to as an anode or anode tube and the more than one cathode tube electrode may be collectively referred to as a cathode or cathode tube. In embodiments of electrochemical cells included in systems including more than one anode tube electrode and/or more than one cathode tube electrode, the more than one anode tube electrode and/or more than one cathode tube electrode may be collectively referred to herein as an anode-cathode pair.

In some aspects and embodiments of the electrochemical cells included in the systems disclosed herein comprising concentric tube electrodes, e.g., one or more anodes and/or cathodes as disclosed herein, the electrodes are configured and arranged to direct a fluid through one or more gaps between the electrodes in a direction parallel to a central axis of the electrochemical cell. In some aspects and embodiments of electrochemical cells comprising concentric tube electrodes, e.g., one or more anodes and/or cathodes as disclosed herein, the electrodes are configured and arranged to direct all fluid introduced into the electrochemical cell through one or more gaps between the electrodes in a direction parallel to a central axis of the electrochemical cell.

Electro-chlorination cells are used in marine applications, offshore applications, municipal applications, industrial applications, and commercial applications. Design parameters of an electro-chlorination cell including more than one concentric electrode tube, such as inter-electrode spacing, thickness and coating density of the electrodes, electrode area, method of electrical connection, and the like, may be selected for different embodiments. Aspects and embodiments disclosed herein are not limited to the number of electrodes, the spacing between electrodes, the electrode material or spacer material, the number of channels within an electrochemical cell, or the electrode coating material.

PCT application PCT/US2016/018210 is incorporated herein by reference in its entirety for all purposes.

One of the major considerations with respect to CTE cells is cathode fouling, which limits the overall strength of hypochlorite that can be produced. When the local pH at the cathode approaches 10.7-11, magnesium in the solution will precipitate to form magnesium hydroxide and plug the electrode surface. Without being bound by a particular theory, it is believed that the following reaction may occur at the cathode of the CTE cell to produce fouling:

CaCl₂+2HCO₃+2NaOH→CaCO₃+2H₂O^-+2NaCl

2NaOH+MgCl₂→2NaCl+Mg(OH)₂

the potential for fouling may also increase due to the presence of excess hydrogen (reduced volume) and high temperatures (faster kinetics). If scale deposits are allowed to continue to form, they can plug the CTE electrode gap, leading to system failure.

Two measures for preventing fouling are:

turbulence: velocities in excess of 2m/s are believed to clean fouling

Current density: 3000A/m²Is a nominal value (nominal), but can be reduced to about 1500A/m²。

Aspects and embodiments disclosed herein provide for operation of a system including more than one CTE cell to produce a product having a higher concentration of NaOCl than previously available without accumulation of scale in the CTE cells of the system. Aspects and embodiments may achieve these advantages by selecting an appropriate configuration of CTE cells with appropriate flow rates and current densities. Other parameters that may be selected or adjusted to achieve high product concentrations without cell fouling include feed water composition (e.g., TDS, pH, etc.) and/or kinetics (e.g., temperature, flow rate, etc.).

Another aspect of cell design is volumetric footprint (volumetric focus) because a larger footprint has higher relative operating expense (OPEX) costs. Prior art level CTE cells, e.g., as illustrated in FIGS. 1A-1C, are at about 0.02m³Comprises about 0.138m in volume²The anode surface area of (a). However, the current technology includes more than one alternating concentric anode and cathodeSurgical level CTE cells, e.g., as illustrated in fig. 2A-2C, containing about 0.85m within the same volume²The anode surface area of (a). This represents an increase of about 6x for the same volume footprint.

In some examples, state of the art CTE cells operating in areas with high temperatures (40 ℃ -45 ℃) and employing seawater with higher than average dissolved solids (TDS) are limited in the concentration of sodium hypochlorite product that can be produced and the flow rate that should be maintained to avoid scaling. In one example of installing state-of-the-art CTE cells located in the Middle East (Middle East), these cells can produce a product solution with 1000ppm NaOCl, but at 8m³Flow rate of 3000A/m and/or/hr²And still build up scale that is removed in cleaning operations performed every two to three months. Under similar conditions, state-of-the-art CTE cells can produce product solutions with 1000ppm NaOCl, and at 7.5m³Flow rate per hour and no cleaning due to fouling build up is required after 8 months of operation. In another example, a state-of-the-art CTE cell as described in PCT application number PCT/US2018/027564, incorporated herein by reference, can be operated with the same high temperature/high TDS seawater while at a flow rate of 2m/s-3m/s and 3000A/m/s²Operate to produce a product solution having 2500ppm to 3000ppm NaOCl and is self-cleaning and does not produce fouling.

Different electrochemical cell configurations disclosed herein may operate according to different design parameters. Fig. 3 includes a table listing design parameters from four different system examples, each system including 20 electrochemical cells operating in series. Example 1 is a system comprising a dual-tube electrochemical cell having a diameter of about 50mm and a length of about 1 m. Example 2 is a system comprising a three-tube electrochemical cell having a diameter of about 50mm and a length of about 1.2 m. Example 3 is a system comprising a three-tube electrochemical cell having a diameter of about 100mm and a length of about 1.2 m. Example 4 is a system comprising five tubes of electrochemical cells having a diameter of about 100mm and a length of about 1.2 m. Provided across each electrochemical cellElectrode 3000A/m²Current density, NaOCl yield (productivity (prod. rate), cell output parameters in fig. 3) was calculated for each exemplary system. Each instance has a recommended maximum flow rate, which may be set based on the associated pressure drop across the electrochemical cells and their mechanical strength, and a recommended minimum flow rate, which may be set to a flow rate that avoids scale build-up in the electrochemical cells. The system may operate in the case of fail-safe (failsafe): the failsafe shuts off flow to the electrochemical cell if flow through the cell drops below a minimum value (limit trip (LIMIT TRIP) parameter in fig. 3).

As illustrated in fig. 3, an embodiment of an electrolyzer system can include, for example, 20 electrochemical cells arranged in series, where all cells operate at the same flow rate and current density. 3000A/m²Is an example. Other systems may be at 1500A/m²-3000A/m²、3000A/m²-6000A/m²、500A/m²-1500A/m²Or 0A/m²-500A/m²Current density operation of. In some examples, the flow rate of the liquid through the electrochemical cell may be 2m/s to 3m/s, but in other examples may be 0.5m/s to 2m/s, 3m/s to 6m/s, or 10m/s to 15 m/s. The designation of different embodiments in fig. 3 is not intended to indicate that the embodiments differ. For example, an electrolyzer system comprising electrochemical cells operating at current densities of one or more of embodiments 1-4 can be operated at cell speeds of any of embodiments 5-9.

Embodiments of the electrolyzer system can include more than one electrochemical cell, which can be fluidly and/or electrically connected in series and/or in parallel. Figure 4 illustrates four different examples of arrangements of fluid connections between electrochemical cells in an electrolyzer system. For all the examples in fig. 4, cell 1, cell 2 and cell 3 may have the same or different flow rates depending on their respective flow areas and the same or different current densities depending on their respective electrode areas. It should be understood that the example illustrated in fig. 4 only shows the connections between adjacent cells. The example illustrated in fig. 4 may be extended to encompass electrolyzer systems having a greater number, e.g., 20 or more electrochemical cells, where adjacent electrochemical cells are fluidly connected according to one or more of the examples illustrated in fig. 4.

Different arrangements of power connections of adjacent electrochemical cells of the electrolyzer system are illustrated in the example shown in fig. 5. As shown, adjacent electrochemical cells may be electrically connected in series, in parallel, a combination of series and parallel, or may each be powered by a separate dedicated power source. For all examples in fig. 5, cell 1, cell 2 and cell 3 may have the same or different current densities depending on their respective electrode areas. The example illustrated in fig. 5 can be extended to encompass electrolyzer systems having a greater number, e.g., 20 or more electrochemical cells, where adjacent electrochemical cells are electrically connected according to one or more of the examples illustrated in fig. 5.

In some embodiments of the electrolyzer system disclosed herein, the fluid can be recirculated between the output of a downstream electrochemical cell to the inlet of an upstream electrochemical cell. Figure 6 illustrates three examples of fluid recirculation through the electrochemical cells in an electrolyzer system. In example 1, the upstream cell may include a recirculation line that recirculates at least some fluid from the outlet to the inlet of the upstream cell, while the downstream cell is not coupled to the recirculation line. In example 2, the downstream cell may include a recycle line that recycles at least some fluid from the outlet to the inlet of the downstream cell, while the upstream cell is not coupled to the recycle line. In example 3, the downstream cell may include a recycle line that recycles at least some fluid from the outlet of the downstream cell to the inlet of the upstream cell. For each example illustrated in fig. 6, recirculation may occur for one or more cells having the same or different flow rates depending on their respective flow areas and the same or different current densities depending on their respective electrode areas. It should be understood that recirculation may be performed by more than one electrochemical cell, not just the limited number illustrated in fig. 6. For example, cell 1 or cell 2 in fig. 6 may be replaced with more than one electrochemical cell fluidly connected in series and/or parallel.

Embodiments of the electrolyzer system disclosed herein can include a product tank that receives treated fluid from one or more electrochemical cells. As illustrated in the example of fig. 7, the product tank may be fed by one or more cells, where the one or more cells are recycled out of the product tank. The one or more cells may have the same or different flow rates depending on their respective flow areas and may have the same or different current densities depending on their respective electrode areas. It should be understood that the recirculation may be performed by more than one electrochemical cell, not just the one illustrated in fig. 7. For example, cell 1 or cell 2 in fig. 7 may be replaced with more than one electrochemical cell fluidly connected in series and/or parallel.

Figure 8 depicts a flow-through cell system comprising three state-of-the-art CTE cells 305 in series. Pump 310 is configured and arranged to pump a feed liquid, such as seawater, brine, or brackish water, from a source 315 of the feed liquid through cell 305. The pump 310, or any of the pumps in the various embodiments disclosed herein, may include one or more sensors, such as a flow meter or other sensor for one or more quality indicators, such as a sensor for measuring pH, temperature, oxidation-reduction potential (ORP), conductivity, or dissolved oxygen in the fluid passing through the pump. The pump 310 and any included sensors may be in communication with a control system, for example, as illustrated in fig. 16, for monitoring and controlling operation of the system. In other embodiments, the electrolyzer system does not use a controller, but rather sets and operates the flow rate of the cells and the current density of the cells through the system at constant values.

Chlorinated liquid (chlorinated liquid) produced in the cell may be stored in the product tank 320 until used as a product. The chlorinated liquid produced in the cell may haveFor example, a NaOCl concentration of about 3000 ppm. In such a configuration, the nominal flow rate will likely be 2m/s-3m/s, such as 2m/s, or 2m/s or greater, and the nominal current density will likely be 3000A/m²And the nominal electrode area will correspond to about 18 state of the art cells. The product tank 320, or any of the various embodiments disclosed herein, may include one or more sensors S, such as a flow meter or other sensor for one or more quality indicators, such as a sensor for measuring pH, temperature, Oxidation Reduction Potential (ORP), conductivity, or dissolved oxygen of a fluid entering the product tank 320 or present in the product tank 320. Any sensors included in the product tank 320 may be in communication with the control system, for example as illustrated in fig. 16, for monitoring and controlling operation of the system. It should be understood that additional tanks, valves, or pumps may be included in appropriate locations in the system illustrated in fig. 8 or in any other system disclosed herein, as will be understood by one of ordinary skill in the art.

Fig. 9 depicts a feed-and-drain electrolyzer system in which chlorinated liquid produced in cell 305 can be returned upstream through recirculation line 425 to mix with feed liquid entering pump 310. The recirculation line 425 may include one or more pumps and/or valves (not shown). Again, the nominal flow rate will likely be 2m/s-3m/s, such as 2m/s, or 2m/s or greater, and the nominal current density will likely be 3000A/m². In such a configuration, the overall strength of hypochlorite in the produced product fluid may be increased, for example, up to about 6000ppm NaOCl or more, however, as detailed above, cathode fouling should be considered as a function of increasing solution strength and pH.

In conclusion, and the temperature/H is controlled₂To produce, alternative system orientations can be envisaged to compensate for the increased pH and thereby achieve higher product intensity. These systems will still have a smaller total footprint relative to the state of the art.

FIG. 10 depicts a flow-through cell system comprising more than one, e.g., six or more, or up to 20 or more, of the current technology in seriesThe CTE cell 305 is at the surgical level, although it should be understood that such a system may also have less than six cells 305 in series, for example, four or five cells 305. Applying a lower current density across the electrodes of the cells at the end of the system than at the beginning of the system closer to the feed inlet, e.g. 1500A/m²、1000A/m²Or 500A/m²To compensate for the increased pH. The applied current density may decrease from a maximum value, such as 2500A/m at the most upstream cell 305²And may be dropped to, for example, 2000A/m in the second and third cells 305 connected in series²And 1500A/m². The applied current density may continue to decrease for cells further downstream, or may reach a constant value, e.g., 1500A/m, for adjacent downstream cells 305²、1000A/m²Or 500A/m². The fluid flow rate may be the same for each cell 305 in the system, such as 2m/s-3m/s, 2m/s, or 2m/s or greater.

In another embodiment, a system similar to that depicted in fig. 10 may be provided, but the current density of all cells 305 may be reduced below the nominal current density of the cells in the systems of fig. 8 and 9, e.g., to 1500A/m²As illustrated in fig. 11. The fluid flow rate may be the same for each cell 305 in the system, such as 2m/s-3m/s, 2m/s, or 2m/s or greater.

In some embodiments, the flow rate of fluid through one or more cells in a system of CTE cells may be adjusted to a level that reduces or prevents fouling. In a system that includes more than one CTE cell in series, a cell that is to be expected to process a fluid having a higher pH, such as a cell in a downstream portion of the system, may be operated with the flow rate of fluid through the cell set at a higher level than the flow rate of fluid through a cell that is to be expected to process a fluid having a lower pH (such as a cell in an upstream portion of the system). In some embodiments, this may be achieved by operating an upstream CTE cell in parallel and a downstream CTE cell in series. For example, as illustrated in fig. 12, there are four upstream batteries 305U and two or more downstream cells 305D. The fluid inlet of the set of downstream cells is in fluid communication with the combined fluid outlet of the upstream cells. The upstream cells of the first group or first parallel pair are in fluid communication upstream of the upstream cells of the second group or second parallel pair. The fluid streams from the outlets of the upstream cells of the second parallel pair are combined and enter the inlet of the first one of the downstream cells of the stack. The fluid velocity of the fluid entering the first of the set of downstream cells is the sum of the fluid velocities of the fluids exiting the outlets of the second parallel pair of upstream cells. At least a second additional downstream cell, and in some embodiments, more than two additional downstream cells are connected in series downstream of the first of the set of downstream cells. The fluid flow rate through each upstream cell may be 2m/s to 3m/s, for example 2m/s, or 2m/s or more. The fluid flow rate through each downstream cell may be 4m/s to 6m/s, for example 4m/s, or 4m/s or more. The current density applied to each upstream cell and each downstream cell may be equal, for example 3000A/m². In other embodiments, the current density applied across the electrodes of the upstream cell may be higher or lower than the current density applied across the electrodes of the downstream cell. It should be understood that a system similar to that illustrated in fig. 12 may include more than two parallel cells in the upstream cell of each group, and/or may include more than two groups of parallel cells. In some embodiments, the current density and/or flow in different CTE cells or in different CTE cells arranged in series in the set of parallel CTE cells is different.

The velocity of fluid flow through CTE cells arranged in series, for example, as illustrated in fig. 10 and 11, may also be increased on the nominal fluid flow through the cells in a system, such as the system illustrated in fig. 13 or 14. The higher fluid flow rate through the cells may allow each cell to operate at a higher current density than the cells in the system of fig. 10 or 11 while still exhibiting little or no fouling. As illustrated in FIG. 13, the higher flow rate may be 4m/s to 6m/s, such as 4m/s, or 4m/s or greater. Is applied to a higher fluid flow as illustrated in fig. 12The applied current density of the operating series cells may be, for example, 3000A/m². The applied current density may be the same for each series-arranged cell operating at a higher fluid flow rate as illustrated in fig. 13, but in other embodiments may be different for different cells, e.g., lower for cells further downstream in the system than other cells and higher for cells upstream of other cells in the system.

In another embodiment, the CTE battery may be disposed in the feed-and-drain fluid lines. The feed-and-drain fluid lines may remove and return fluid to a product tank, such as the system illustrated in fig. 8, that includes more than one, such as two, three, or more CTE cells in series that provide treated fluid to the product tank. A configuration of an embodiment in which parallel CTE cells process and recycle fluid from the product tank is illustrated in fig. 14. The treatment and recirculation of fluid from product tank 320 through parallel CTE cells 905, pump 910, and feed-and-drain fluid line 915 increases the concentration of NaOCl in product tank 320 without increasing the risk of fouling in the series CTE cells 305. The series CTE cell 305 can be at a nominal fluid flow rate of 2m/s-3m/s, such as 2m/s, or 2m/s or more and 3000A/m²The nominal current density of (a). Parallel CTE cells 905 can flow at fluid of X m/s and Y A/m²Current density operation of. The values of X and Y may be selected based on, for example, the desired concentration of NaOCl in product tank 320. In some embodiments, the fluid flow through the parallel CTE cells 905 may be 2m/s-3m/s, such as 2m/s, or 2m/s or greater, or may be 4m/s-6m/s, such as 4m/s, or 4m/s or greater. The current density applied across the electrodes of parallel CTE cells may be, for example, 1500A/m²、2000A/m²、2500A/m²Or 3000A/m²Less than 1500A/m²Or more than 3000A/m²Any one of the above. By recirculating the product tank liquid through the parallel CTE cell 905, the concentration of NaOCl in the liquid in the product tank 320 can be set or maintained at, for example, 3000ppm or higher, for exampleSuch as up to 6000ppm or more. The system may be operated at steady state conditions at the same rate of fluid flow through the series CTE cell 305, e.g., 2m/s-3m/s, 2m/s, or 2m/s or higher, with the treated fluid being withdrawn from the product tank. The system can operate at a lower rate than the fluid flow through the series CTE cell 305 to accumulate a concentration of NaOCl in the product tank from which the treated fluid is withdrawn, or can operate at a higher rate than the fluid flow through the series CTE cell 305 from which the treated fluid is withdrawn, optionally with flow through the parallel CTE cell 905 suspended, to reduce the concentration of NaOCl in the product tank.

Another embodiment of a feed-and-bleed electrochemical cell system is illustrated in fig. 15A. In this configuration, valve CV1 and valve CV2 are opened while valve CV3 and valve CV4 are closed. The electrolyzer, which may include one or more CTE cells fluidly and/or electrically coupled in series and/or parallel, and may include a set of CTE cells arranged according to any of the previously described embodiments, is operated via pump a to draw feed fluid from an inlet of the system until the product tank is filled. During tank filling or replenishing operations, pump a may be at, for example, 12m³Operation/hr, or flowing the fluid through the cell at 2m/s to 3 m/s. The nominal concentration of NaOCl in the product tank will be between about 1500ppm and 1800 ppm. Once the product tank is full, valve CV1 is closed and valve CV3 is opened. The cell is operated again via pump a and the fluid solution in the product tank is recirculated back through the cell and back into the product tank. Operation during recycle operation will be at higher flow rates to enhance self-cleaning of the CTE cells of the electrolyzer. In some cases, during recirculation operation, the fluid flow rate through the electrolyzer will be 4m/s to 5m/s (pump A at, for example, 24 m/s)³/hr operation), and in other cases it will be higher. The maximum fluid flow rate may depend on the CTE cell pressure rating of the electrolyzer. The system will operate continuously to achieve higher product strengths. In some cases, the NaOCl product strength will reach 3,000 ppm. In other cases, can obtainHigher NaOCl concentration. The peak concentration of NaOCl in the product tank may depend on the balance between Mg and Ca precipitation and maximum self-cleaning speed. To dose the product to the point of use, valve CV1 and valve CV2 are closed while valve CV3 and valve CV4 are opened. Then, using bulk product tank solutions, pump a and pump B were used for external shock dosing (external shock dose) to the point of use. The table in fig. 15B shows exemplary flow and valve and cell conditions during make-up, recirculation, and bump dosing operations.

In some embodiments, for example, as illustrated in fig. 15A, one or more product tanks of any of the systems disclosed herein can include a lower end having a sloped (e.g., conical) sidewall 325 and a sediment outlet 330, the sediment outlet 330 can be opened or closed with, for example, a valve CV 5. Calcium and magnesium deposits have higher specific gravities than sodium hypochlorite or seawater and may tend to settle out in the product tank. Settled sediment may be flushed from the product tank at desired intervals or after an unacceptable level is reached, for example by a fluid, such as seawater, pumped into the product tank via pump a. During flushing of the product tank, valve CV5 may be opened to allow outward flow of sediment.

The systems disclosed herein can pull feed, process liquid, or electrolyte (which in some embodiments is seawater, brine, or brackish water) to the system from an external source and/or an internal source. For example, if the system is a sea-based system, the external source may be the sea, and the internal source may be, for example, a ballast tank in a ship. In land based systems, the external source may be the ocean and the internal source may be brackish wastewater from an industrial process carried out in the system. The electro-chlorination system disclosed herein can produce chlorinated water and/or a solution comprising sodium hypochlorite from water from a feed source, and can dispense it to a point of use. The point of use may be a source of cooling water for the system, a source of disinfectant for a ballast tank of a ship, downhole of an oil drilling system, or any other system in which chlorinated water may be useful. Various pumps, such as pump 310 and pump 910, may control the flow of fluid through the system. One or more sensors may monitor one or more parameters of the fluid flowing through the system, such as ion concentration, chlorine concentration, temperature, or any other parameter of interest. The pump and sensors may be in communication with a control system or controller that communicates with the sensors and the pump and controls operation of the pump and other elements of the system to achieve desired operating parameters.

The controller used to monitor and control the operation of the various elements of the system may comprise a computer control system. Aspects of the controller may be implemented as specialized software executing in a general-purpose computer system 1000 such as that shown in fig. 16. The computer system 1000 may include a processor 1002, the processor 1002 being connected to one or more memory devices 1004, such as a disk drive, solid state memory, or other device for storing data. The memory 1004 is typically used for storing programs and data during operation of the computer system 1000. The components of computer system 1000 may be coupled by an interconnection mechanism 1006, which interconnection mechanism 1006 may include one or more buses (e.g., between components integrated within the same machine) and/or networks (e.g., between components residing on separate, discrete machines). The interconnection mechanism 1006 enables communications (e.g., data, instructions) to be exchanged between system components of the system 1000. The computer system 1000 also includes one or more input devices 1008, such as a keyboard, a mouse, a trackball, a microphone, a touch screen, and one or more output devices 1010, such as a printing apparatus, a display screen, or a speaker.

The output 1010 may also include a valve, pump, or switch that may be used to introduce product water (e.g., brackish or sea water) from a feed source into an electro-chlorination system or point of use as disclosed herein and/or to control the speed of the pump. One or more sensors 1014 may also provide input to the computer system 1000. These sensors may include, for example, pressure sensors, chemical concentration sensors, temperature sensors, fluid flow sensors, or sensors for any other parameter of interest to an operator of the electro-chlorination system. These sensors may be located in any part of the system in which they would be useful, such as upstream of the point of use and/or the electro-chlorination system, or in fluid communication with the feed source. Further, the computer system 1000 may include one or more interfaces (not shown) that additionally connect the computer system 1000 to a communication network or, alternatively, to the interconnection mechanism 1006.

The storage system 1012, shown in more detail in fig. 17, generally includes a computer-readable and writable nonvolatile recording medium 1102 in which signals defining a program executed by the processor 1002 or information processed by the program are stored. The medium may comprise, for example, disk memory or flash memory. Generally, in operation, the processor causes data to be read from the non-volatile recording medium 1102 into another memory 1104 that allows the information to be accessed more quickly than if the medium 1102 were processed by the processor. This memory 1104 is typically a volatile random access memory such as a Dynamic Random Access Memory (DRAM) or static memory (SRAM). It may be located in the storage system 1012 as shown, or in the memory system 1004. The processor 1002 typically manipulates the data within the integrated circuit memory 1104 and then copies the data to the medium 1102 after processing is completed. Various mechanisms are known for managing data movement between the medium 1102 and the integrated circuit memory element 1104, and the aspects and embodiments disclosed herein are not limited thereto. The aspects and embodiments disclosed herein are not limited to a particular memory system 1004 or storage system 1012.

The computer system may include specially-programmed, special-purpose hardware, such as an application-specific integrated circuit (ASIC). The aspects and embodiments disclosed herein may be implemented in software, hardware, or firmware, or any combination thereof. Additionally, such methods, acts, systems, system elements and components thereof may be implemented as part of the computer systems described above or as a stand-alone component.

While computer system 1000 is shown by way of example as one type of computer system upon which the various aspects and embodiments disclosed herein may be practiced, it should be understood that the aspects and embodiments disclosed herein are not limited to being implemented on a computer system as shown in fig. 16. The aspects and embodiments disclosed herein may be practiced on one or more computers having different configurations or components than those shown in fig. 16.

Computer system 1000 may be a general-purpose computer system programmable using a high-level computer programming language. Computer system 1700 may also be implemented using specially programmed, special-purpose hardware. In computer system 1000, processor 1002 is typically a commercially available processor, such as the well-known Pentium (Pentium) available from Intel Corporation^TMOr Core (Kurui)^TMA class processor. Many other processors are available, including programmable logic controllers. Such processors typically execute an operating system, which may be, for example, the Windows 7, Windows 8, or Windows 10 operating systems available from Microsoft Corporation, the MAC OS System X available from Apple Computer, the Solaris operating system available from Sun Microsystems, or UNIX available from a variety of sources. Many other operating systems may be used.

The processor and operating system together define a computer platform on which application programs in a high-level programming language are written. It should be understood that the present invention is not limited to a particular computer system platform, processor, operating system, or network. In addition, it should be apparent to those skilled in the art that the aspects and embodiments disclosed herein are not limited to a particular programming language or computer system. In addition, it should be understood that other suitable programming languages and other suitable computer systems may also be used.

One or more portions of the computer system may be distributed across one or more computer systems (not shown) coupled to the communication network. These computer systems may also be general purpose computer systems. For example, aspects of the invention may be distributed among one or more computer systems configured to provide services (e.g., servers) to one or more client computers, or to perform an overall task as part of a distributed system. For example, various aspects and embodiments disclosed herein may be performed on a client-server system that includes components distributed among one or more server systems that perform various functions in accordance with various aspects and embodiments disclosed herein. These components may be executable code, intermediate code (e.g., IL), or interpreted code (e.g., Java) that communicates over a communication network (e.g., the internet) using a communication protocol (e.g., TCP/IP). In some embodiments, one or more components of computer system 200 may communicate with one or more other components over a wireless network, including, for example, a cellular telephone network.

It should be understood that aspects and embodiments disclosed herein are not limited to execution on any particular system or group of systems. Additionally, it should be understood that the aspects and embodiments disclosed herein are not limited to any particular distribution architecture, network, or communication protocol. The various aspects and embodiments disclosed herein may be programmed using an object-oriented programming language such as SmallTalk, Java, C + +, Ada, or C # (C-Sharp). Other object-oriented programming languages may also be used. Alternatively, a functional, scripting, and/or logic programming language, such as ladder logic, may be used. The various aspects and embodiments disclosed herein may be implemented in a non-programming environment (e.g., a file created in HTML, XML, or other format that renders aspects of a graphical-user interface (GUI) or performs other functions when viewed in a window of a browser program). The various aspects and embodiments disclosed herein may be implemented as programmed or non-programmed elements, or any combination thereof.

Examples

As a proof of concept of parallel feed and discharge (e.g., as illustrated in fig. 14), at 2000A/m, respectively²And 3000A/m²With 3.5% synthetic seawater, the product tank was recirculated across a single CTE cell. The product strength was then allowed to increase over time, with NaOCl concentrations of about 800ppm, 1300ppm, 2200ppm, 3500ppm, and 6100ppm being reached without precipitate formation.

The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term "more than one" refers to two or more items or components. The terms "comprising", "including", "carrying", "having", "containing" and "involving" are open-ended terms, i.e. meaning "including but not limited to", whether in the written description or in the claims and the like. Thus, use of such terms is intended to encompass the items listed thereafter and equivalents thereof, as well as additional items. In reference to the claims, the transitional phrases "consisting of" and "consisting essentially of," are each a closed or semi-closed transitional phrase. The use of ordinal terms such as "first," "second," "third," and the like in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.

Having thus described several aspects of at least one embodiment, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Any feature described in any embodiment may be included in or substituted for any feature of any other embodiment. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.