阅读说明：本技术 电解槽用垫片组合物及电解槽用垫片、以及电解槽及使用有它们的电解方法 (Gasket composition for electrolytic cell, gasket for electrolytic cell, and electrolysis method using same ) 是由 田宫克弘 大高丰史 于 2020-09-28 设计创作，主要内容包括：本发明的技术问题在于提供一种用于得到垫片的垫片组合物,所述垫片用于离子交换膜法电解槽,且具有良好的耐压缩永久变形性能,并具有良好的耐化学药品性。所述电解槽用垫片组合物通过以特定比例在乙丙橡胶中混合作为第二成分的溴化丁基橡胶,提高耐化学药品性。(The technical problem of the present invention is to provide a gasket composition for obtaining a gasket which is used for an ion exchange membrane method electrolytic cell, has good compression set resistance, and has good chemical resistance. The gasket composition for an electrolytic cell has improved chemical resistance by mixing a brominated butyl rubber as a second component with an ethylene propylene rubber at a specific ratio.)

1. A gasket composition for an electrolytic cell, which is used for an ion exchange membrane method electrolytic cell containing ethylene-propylene rubber and bromobutyl rubber, characterized in that the blending proportion of the ethylene-propylene rubber and the bromobutyl rubber is 5 to 40 parts by mass relative to 100 parts by mass of the ethylene-propylene rubber.

2. The gasket composition for electrolytic cells according to claim 1, wherein the ethylene-propylene rubber is an ethylene-propylene-diene copolymer rubber.

3. A rubber material obtained by crosslinking the gasket composition for electrolytic cells according to claim 1 or 2.

4. A gasket for electrolytic cells, which is made of the rubber material according to claim 3.

5. An ion exchange membrane process electrolytic cell comprising the gasket for electrolytic cell according to claim 4.

6. A process for producing caustic soda, chlorine and/or hydrogen, comprising: a step of supplying a salt solution to the electrolytic cell according to claim 5 and electrolyzing the salt solution by supplying electricity.

Technical Field

The present invention relates to a gasket composition for an electrolytic cell and a gasket for an electrolytic cell having excellent chemical resistance, and an electrolytic cell and an electrolysis method using the same.

Background

As an apparatus for industrially producing chlorine gas, hydrogen gas and alkali hydroxide by an electrolytic method, an electrolytic cell having an ion exchange membrane selectively permeable to specific ions is used. The electrolytic cell has two types, a monopolar type and a bipolar type, depending on the power supply method, and has a structure having an electrode chamber in which an anode and a cathode of an ion exchange membrane are sandwiched. Further, the anode and the cathode are classified into a normal pitch type, a narrow pitch type, a finite (fine) pitch type, and a zero pitch type according to the relationship between the pitches, but the anode and the cathode having the ion exchange membrane interposed therebetween are the same in all of the configurations. The electrolyte filled in the anode chamber and the cathode chamber differs depending on the production target product, but a solution of an alkaline salt or an alkaline hydroxide is generally used.

In order to prevent leakage from the electrode compartment, the electrolytic cell has an anode gasket and a cathode gasket sandwiching an ion exchange membrane, and the gaskets are required to have chemical resistance to water, alkaline salts, alkaline hydroxides, hypochlorous acid compounds, chloric acid compounds, and the like. In addition, in order to efficiently perform the electrolytic reaction, a heating operation may be performed, and therefore, heat resistance is also required. As a soft material satisfying the above conditions, ethylene propylene rubber and the like are widely used for gaskets (see patent documents 1 and 2).

In recent years, there has been a demand for an increase in the lifetime of an ion exchange membrane, and accordingly, an increase in the lifetime of peripheral parts, and an increase in chemical resistance and heat resistance of gaskets.

Documents of the prior art

Patent document

Patent document 1: japanese laid-open patent publication No. 5-9772

Patent document 2: japanese patent laid-open publication No. 2000-178780

Disclosure of Invention

Technical problem to be solved by the invention

The present invention has been made in view of the above-mentioned needs, and an object of the present invention is to provide a gasket composition for obtaining a gasket which is used for an ion exchange membrane method electrolytic cell, has good compression set resistance, and has good chemical resistance.

Means for solving the problems

The present inventors have conducted extensive studies and as a result, have found that the chemical resistance can be improved by mixing a brominated butyl rubber as a second component with an ethylene-propylene rubber at a specific ratio, and have completed the present invention.

The gasket composition for an electrolytic cell for use in an ion exchange membrane method electrolytic cell containing ethylene-propylene rubber and bromobutyl rubber, characterized in that the blending ratio of the ethylene-propylene rubber to the bromobutyl rubber is 5 to 40 parts by mass relative to 100 parts by mass of the ethylene-propylene rubber.

Item 2. the gasket composition for electrolytic cells according to item 1, wherein the ethylene-propylene rubber is an ethylene-propylene-diene copolymer rubber.

Item 3. a rubber material crosslinked by the gasket composition for electrolytic cells described in the above item 1 or 2.

Item 4. a gasket for electrolytic cells, which is composed of the rubber material described in item 3.

An ion exchange membrane process electrolytic cell according to item 5, which is provided with the gasket for electrolytic cells according to item 4.

Item 6. a process for producing caustic soda, chlorine and/or hydrogen, having: a step of supplying a saline solution to the electrolytic cell of claim 5 and electrolyzing the saline solution by supplying electricity.

Effects of the invention

The gasket for an electrolytic cell obtained from the gasket composition for an electrolytic cell of the present invention has excellent compression set resistance and excellent chemical resistance, and therefore, the gasket can reduce the frequency of maintenance of an electrolytic cell using an ion exchange membrane method provided with the gasket.

Drawings

FIG. 1 is a schematic cross-sectional view of a monopolar electrolytic cell.

FIG. 2 is a schematic cross-sectional view of a bipolar cell.

Description of the reference numerals

101: an anode chamber frame (anode chamber); 102: an anode; 103: an anode flange face; 104: an anode gasket; 105: an ion exchange membrane; 106: a cathode chamber frame (cathode chamber); 107: a cathode; 108: a cathode flange face; 109: a cathode pad; 201: an anode chamber in the multipole chamber frame; 202: an anode; 203: an anode chamber frame flange face; 204: a cathode pad; 205: an ion exchange membrane; 206: a cathode chamber in the multipole chamber frame; 207: a cathode; 208: a cathode flange face; 209: an anode gasket; 210: a partition wall.

Detailed Description

The gasket composition for an electrolytic cell of the present invention is a gasket composition for an ion exchange membrane method electrolytic cell, which contains ethylene propylene rubber and bromobutyl rubber, and contains 5 to 40 parts by mass of the bromobutyl rubber relative to 100 parts by mass of the ethylene propylene rubber.

In the gasket composition for electrolytic cells used in the present invention, ethylene-propylene rubber that can be used as a soft material can be suitably used in consideration of moldability required for the gasket composition and mechanical properties, heat resistance, chemical resistance and the like required for a gasket for electrolytic cells as a molded article thereof. In addition, in order to improve the compression set, it is preferable to use an ethylene-propylene rubber further copolymerized with a diene component.

In order to improve the compression set, the respective blending ratios of ethylene, propylene and diene may be arbitrarily adjusted. The diene component is not particularly limited, and examples thereof include chain nonconjugated dienes such as 1, 4-hexadiene, 1, 6-octadiene, 2-methyl-1, 5-hexadiene, 6-methyl-1, 5-heptadiene, and 7-methyl-1, 6-octadiene; cyclic nonconjugated dienes such as cyclohexadiene, dicyclopentadiene, methyltetrahydroindene, 5-vinylnorbornene, 5-ethylidene-2-norbornene, 5-methylene-2-norbornene, 5-isopropylidene-2-norbornene and 6-chloromethyl-5-isopropenyl-2-norbornene; trienes such as 2, 3-diisopropylidene-5-norbornene, 2-ethylidene-3-isopropylidene-5-norbornene, 2-propenyl-2, 2-norbornadiene, 1,3, 7-octatriene and 1,4, 9-decatriene, etc., among which 1, 4-hexadiene, dicyclopentadiene and 5-ethylidene-2-norbornene are preferred, and 5-ethylidene-2-norbornene is particularly preferred.

The propylene component of the ethylene-propylene rubber is not particularly limited as long as the effect of the present invention is not impaired, but is preferably 5 to 58%.

The ethylene component of the ethylene-propylene rubber is not particularly limited as long as the effects of the present invention are not impaired, but is preferably 40 to 80%.

The diene component of the ethylene-propylene rubber is not particularly limited as long as the effect of the present invention is not impaired, but is preferably 2 to 15%.

The brominated butyl rubber used as the second component is obtained by brominating a butyl rubber obtained by copolymerizing isobutylene and isoprene, and conventionally known brominated butyl rubbers can be suitably used in consideration of moldability required for gasket materials, mechanical properties, heat resistance, chemical resistance and the like required for gaskets for electrolytic cells as molded articles thereof. The bromine content is not particularly limited, and may be arbitrarily adjusted.

The unsaturation degree of the brominated butyl rubber is not particularly limited as long as the effect of the present invention is not impaired, but is preferably 0.5 to 3.0 mol%.

The bromine content of the brominated butyl rubber is not particularly limited as long as the effect of the present invention is not impaired, but is preferably 0.1 to 5.0% by mass, more preferably 0.5 to 4.0% by mass. The bromine content can be measured by solution NMR.

The bromobutyl rubber is preferably 5 to 40 parts by mass, more preferably 10 to 30 parts by mass, and even more preferably 15 to 30 parts by mass, relative to 100 parts by mass of the ethylene propylene rubber.

As the gasket composition for electrolytic cells, additives such as reinforcing agents, fillers, softeners, anti-aging agents, lubricants, crosslinking agents, crosslinking aids, and crosslinking activators, which are generally used, can be added.

The type of the reinforcing agent or filler is not particularly limited, and examples thereof include carbon fillers such as carbon black and carbon fiber, inorganic fillers such as white carbon, clay, talc and calcium carbonate glass fiber, and polymer resins such as fluorine resins (polytetrafluoroethylene, ETFE and the like). May be used alone or in combination, and among them, carbon black is preferably mainly used. The carbon black is not limited as long as it is a carbon black that is generally used, and specific examples thereof include furnace black, acetylene black, thermal black, channel black, graphite, and the like. One or more kinds of carbon black may be used. The amount of the reinforcing agent or filler used is preferably 30 to 200 parts by mass, more preferably 30 to 150 parts by mass, and still more preferably 30 to 100 parts by mass, based on 100 parts by mass of the ethylene-propylene rubber. When the rubber composition is used together with another reinforcing agent or filler which is different from the carbon black system, the amount of the other reinforcing agent or filler is preferably 0 to 7 parts by mass, more preferably 0 to 5 parts by mass, per 100 parts by mass of the ethylene propylene rubber.

The type of the softener is not particularly limited as long as it is a commonly used softener, and specific examples thereof include phthalate softeners such as di-2-ethylhexyl phthalate, dibutyl phthalate, diheptyl phthalate, and diisodecyl phthalate; fatty acid ester softeners such as di-2-ethylhexyl adipate, diisobutyl adipate, and dibutyl adipate; epoxy ester softeners such as epoxidized soybean oil; polyester softeners such as adipate esters and adipate polyesters; trimellitate softeners such as tri-2-ethylhexyl trimellitate and triisononyl benzenetricarboxylate; phosphoric acid ester softeners such as trimethyl phosphate and triethyl phosphate; processing oil such as mineral oil. One or two or more of the softening agents may be used. The amount of the softener used is preferably 0 to 200 parts by mass, more preferably 0 to 100 parts by mass, and still more preferably 0 to 50 parts by mass, per 100 parts by mass of the ethylene-propylene rubber.

The kind of the antioxidant is not particularly limited, and examples thereof include thioether compounds, phosphoric acid compounds, hindered phenol compounds, phenol Monoacrylate compounds, nitroxide compounds, and the like. One or more of the age resistors may be used. The amount of the antioxidant to be used is preferably 0 to 10 parts by mass, more preferably 0 to 5 parts by mass, and still more preferably 0 to 3 parts by mass, based on 100 parts by mass of the ethylene-propylene rubber.

The type of the lubricant is not particularly limited, and for example, fatty acids such as stearic acid and palmitic acid; fatty acid metal salts such as calcium stearate, zinc stearate, magnesium stearate, potassium palmitate, and sodium palmitate; waxes such as polyethylene wax, polypropylene wax, montanic acid wax, and the like; low molecular weight polyolefins such as low molecular weight polyethylene or low molecular weight polypropylene; a polyorganosiloxane such as dimethylpolysiloxane, an amide lubricant such as octadecylamine, an alkyl phosphate, a fatty acid ester, or ethylene bis stearamide; fluororesin powder such as tetrafluoroethylene resin, molybdenum disulfide powder, silicone resin powder, silicone rubber powder, silicon dioxide, and the like. These lubricants can be used singly or in combination of two or more. The amount of the lubricant used is preferably 0.1 to 10 parts by mass, more preferably 0.1 to 5 parts by mass, and still more preferably 0.3 to 3 parts by mass, based on 100 parts by mass of the ethylene-propylene rubber.

The kind of the crosslinking agent is not particularly limited, and a general one for crosslinking rubber, for example, sulfur, peroxide, resin crosslinking agent, etc. can be used, but a peroxide having excellent heat resistance is preferable because heat resistance and compression set resistance are particularly required in the use environment of the gasket.

Specific examples of the organic peroxide include 1, 1-di (t-hexylperoxy) -3, 5, 5-trimethylcyclohexane, 2, 5-dimethylhexane-2, 5-dimethylhydroxyperoxide, di-t-butylperoxide, t-butylcumylperoxide, dicumylperoxide, α' -di (t-butylperoxy) -p-diisopropylbenzene, 2, 5-dimethyl-2, 5-di (t-butylperoxy) -hexane, 2, 5-dimethyl-2, 5-di (t-butylperoxy) -3-hexane, benzoyl peroxide, t-butylperoxybenzene (Tert-butylperoxy) hexane, 2, 5-dimethyl-2, 5-bis (benzoylperoxy) hexane, t-butylperoxymaleic acid, T-butyl peroxy isopropyl monocarbonate, and the like. Among them, diisopropylbenzene peroxide is exemplified. One or two or more of the organic peroxides may be used. The amount of the crosslinking agent used is preferably 0.1 to 20 parts by mass, more preferably 0.2 to 10 parts by mass, and still more preferably 0.5 to 5 parts by mass, based on 100 parts by mass of the ethylene-propylene rubber.

The kind of the crosslinking assistant is not particularly limited, and examples thereof include triallyl cyanurate, triallyl isocyanurate, 1,3, 5-triacryloylhexahydro-1, 3, 5-triazine, triallyl trimellitate, dipropargyl terephthalate, diallyl phthalate, tetraallylterephthalamide, triallyl phosphate, and the like, and among them, triallyl isocyanurate is preferable. The amount of the crosslinking aid used is preferably 0.1 to 6.0 parts by mass, more preferably 0.3 to 5.0 parts by mass, and still more preferably 0.4 to 3.0 parts by mass, based on 100 parts by mass of the ethylene-propylene rubber.

The kind of the crosslinking activator is not particularly limited, and examples thereof include metal oxides such as zinc oxide. The amount of the crosslinking activator used is preferably 0 to 15 parts by mass, more preferably 0.5 to 10 parts by mass, per 100 parts by mass of the ethylene-propylene rubber.

Other blending agents commonly used in the rubber processing field can be blended. Examples of such additives include light stabilizers, adhesives, flame retardants, mildewcides, antistatic agents, colorants, silane coupling agents, and crosslinking retarders. The blending amount of these blending agents is not particularly limited as long as it does not impair the object and effect of the present invention, and an amount suitable for the purpose of blending may be appropriately blended.

The method for producing the gasket composition for electrolytic cells of the present invention can use a common mixer. Examples of the mixer include a Banbury mixer, a kneader, an INTERMIX, an internal mixer, and a roll mixer.

The gasket for an ion exchange membrane method electrolytic cell of the present invention is produced using the gasket composition for an electrolytic cell of the present invention. In an ion exchange membrane process, for example, in an electrolytic cell for electrolyzing an alkaline chloride solution using a cation exchange membrane, the gasket of the present invention is used at a connection site (joint) of an appliance through which an internal fluid such as a raw material solution and a generated gas passes. In particular, the gasket of the present invention is used at the above-mentioned portion in an electrolytic cell for electrolyzing an aqueous solution of sodium chloride to produce chlorine gas and caustic soda. As the life of the ion exchange membrane or the like is extended, it is required to improve chemical resistance and heat resistance of the gasket for an electrolytic cell against caustic soda, chlorine gas, sodium hypochlorite, or the like.

Further, durability of the gasket itself is required not only for chemical resistance and heat resistance but also for preventing leakage of an electrolyte and a gas generated by electrolysis of common salt, and the durability can be measured by the compression set property according to JIS K6262: 2013 for evaluation. As the performance required for the gasket for electrolytic cells according to the present invention, it is preferable that the compression set is 20% or less (measurement conditions: compression ratio 25%, temperature 125 ℃ C., 72 hours). If the compression set exceeds 20%, the gasket has poor durability and sufficient liquid-tightness and air-tightness cannot be ensured.

Specifically, the gasket for an ion exchange membrane method electrolytic tank of the invention can be produced by crosslinking and molding the gasket composition for an ion exchange membrane method electrolytic tank of the invention. The crosslinking is carried out by heating at 150 to 220 ℃ for about 1 to 30 minutes. If necessary, the secondary crosslinking may be performed at about 100 to 200 ℃ for about 0.5 to 15 hours.

As the molding machine, an injection molding machine, a Press molding machine (Press molding machine), a transfer molding machine, a compression molding machine, or the like can be used.

Further, after the sheet-shaped gasket is formed by a calender molding machine or a drum molding machine, the gasket shape may be cut, and pressed.

Among these molding machines, a press molding machine is preferably used in order to reduce variations in uniform thickness, hardness, and the like.

The gasket for electrolytic cell (also referred to as "gasket") composed of the gasket composition for electrolytic cell of the present invention is disposed on the flange surface of the electrode chamber frame to prevent leakage of the electrolyte or gas. Therefore, the gasket is formed with an opening having a size approximately equal to the area of the electrode so that ions generated in the electrode chamber by the electrochemical reaction can permeate through the ion exchange membrane. In general, the electrolytic cell is rectangular in plan view, and therefore the gasket is also preferably rectangular with a rectangular opening.

The gasket for an electrolytic cell of the present invention can be used for a gasket provided in an anode chamber frame and a cathode chamber frame described later, and the gasket provided in the anode chamber frame and the gasket provided in the cathode chamber frame may be the same or different. By making the gasket provided in the anode chamber frame the same as the gasket provided in the cathode chamber frame, the production cost and the inventory management cost can be reduced. Further, when the anode-side member and the cathode-side member are different from each other in assembling the electrolytic cell, careful assembly is required, but the assembly work of the electrolytic cell can be managed easily and without error by making the anode-side member and the cathode-side member the same, that is, by sharing the members of the anode side and the cathode side. The term "the spacers are made to be the same" means that they are molded so as to have the same size, and specifically, are preferably molded by molds having the same size. In this case, it is more preferable to use a mold having the same material and perform molding under the same conditions.

Electrode chamber frame

The electrode chamber frame of the present invention is provided with the gasket for electrolytic cells of the present invention on the flange surface of the electrode chamber frame. The electrode chamber frame may be referred to as an anode chamber frame, and the electrode chamber frame provided with the anode may be referred to as a cathode chamber frame. The electrode chamber frame of the present invention refers to a portion which becomes an electrode chamber after the electrolytic cell is manufactured.

Preferably, an adhesive layer/adhesive layer is provided between the cathode chamber frame, the anode chamber frame, and the gasket for electrolytic cell. As the adhesive used for the adhesive layer or the adhesive used for the adhesive layer, any of an adhesive/adhesive containing an organic solvent such as a dry-curing chloroprene-based adhesive and an adhesive/adhesive containing no organic solvent can be used, and an adhesive/adhesive containing no organic solvent is preferable in that no change in physical properties is caused.

The adhesive containing no organic solvent is preferably a reactive adhesive, and examples thereof include epoxy resin adhesives (one-pack/two-pack type mixed adhesives), cyanoacrylate adhesives, urethane adhesives, acrylic resin adhesives, other reactive adhesives, modified silicone adhesives such as epoxy-modified silicones and acrylic-modified silicones, and silylated urethane adhesives. Examples of the adhesive containing no organic solvent include an acrylic adhesive, a urethane adhesive, and a silicone adhesive.

Electrolytic cell

The electrolytic cell of the present invention includes an electrode chamber constituted by the electrode chamber frame of the present invention. Preferably, the ion exchange membrane comprises an electrode chamber formed by the electrode chamber frame of the present invention and an ion exchange membrane.

The anode provided in the anode chamber frame of the present invention has a conductive substrate provided with an opening and a catalytic layer provided on the conductive substrate.

As the conductive substrate, a titanium expanded metal (expanded metal), a titanium woven mesh, or a titanium punched metal (expanded metal) having corrosion resistance is preferable, and a titanium expanded metal is particularly preferable from the viewpoint of uniform conductivity and economy. In order to achieve both mechanical strength and liquid permeability, the opening ratio of the conductive substrate is preferably 25 to 75%.

As the catalyst layer of the anode, that is, the electrode active material covering the surface of the conductive substrate, a mixed oxide of an oxide of a platinum group metal such as iridium, ruthenium, platinum, or palladium and an oxide of 1 or more metals selected from the group consisting of valve metals such as titanium, tantalum, niobium, tungsten, and zirconium, and tin is preferable. As one example, iridium-ruthenium-titanium mixed oxide, iridium-ruthenium-platinum-titanium mixed oxide, platinum, and iridium oxide may be cited. In addition, when electrolysis is performed using a solution of an alkaline hydroxide as an anolyte, a compound containing nickel can be used as an electrode active material.

As the surface treatment to be performed on the conductive substrate, mechanical surface treatment and chemical surface treatment can be cited. As the mechanical surface treatment method, there is a blast (blast) treatment method in which the surface of a base material is finely roughened using a fine abrasive, and as the chemical surface treatment method, there is a method in which a chemical etching treatment is performed in a bath of oxalic acid, nitric acid, sulfuric acid, hydrochloric acid, hydrofluoric acid, or the like.

The chemical surface treatment may be performed alone or the mechanical surface treatment may be performed alone, or both of the methods may be combined. In order to ensure liquid permeability and protect the ion exchange membrane, the maximum value of the difference in height between the irregularities formed on the surface of the anode is preferably 3 to 50 μm, and more preferably 5 to 40 μm.

The cathode provided in the cathode chamber frame of the present invention has a conductive substrate having an opening and a catalytic layer provided on the conductive substrate.

In addition, iron, copper, stainless steel, nickel, or the like can be used as the conductive base of the cathode, and nickel is preferably used particularly from the viewpoint of corrosion resistance or the like. As for the shape of the conductive substrate, it is desirable that liquid permeability is ensured and uniform conductivity is maintained, and specifically, it may be an expanded metal mesh plate, a punched metal mesh plate, a fine mesh (fine-mesh), a plain mesh, for example, a fine mesh made of nickel or a plain mesh made of nickel is preferable. The aperture ratio of the conductive substrate of the cathode is preferably 25-75%.

As the catalytic layer of the cathode, that is, the electrode active material coated on the surface of the conductive substrate, it is preferable to use a metal such as platinum, palladium, ruthenium, iridium, copper, silver, tin, nickel, cobalt, and lead, or a mixture or mixed oxide thereof alone.

The electrolytic cell of the present invention comprises an anode, a cathode, and an ion exchange membrane disposed between the anode and the cathode, and constitutes an anode chamber having the anode and a cathode chamber having the cathode. A predetermined number of electrode units are arranged in series in an electrolytic cell so as to have the same polarity, and an ion exchange membrane is arranged in an adjacent unit, whereby a bipolar electrolytic cell can be formed. In the case of a monopolar electrolytic cell, a monopolar electrolytic cell can be formed by forming either an anode or a cathode on both sides of one electrode unit and disposing the electrode units alternately with an ion exchange membrane interposed therebetween. The electrolytic cell of the present invention can be applied to any of single-pole type and multi-pole type electrolytic cells. In addition, in the assembled state of the electrolytic cell, the anode and cathode may be classified into a normal pole pitch type, a narrow pole pitch type, a limited pole pitch type, and a zero pole pitch type according to the pole pitch, but the positional relationship of the gasket is not affected by the pole pitch, and therefore the electrolytic cell of the present invention can be applied to any of these types.

In the electrolytic cell of the present invention, it is preferable that the electrolytic cell gaskets provided in the cathode chamber frame and the anode chamber frame are the same, and it is more preferable that the gasket surfaces formed in contact with the press mold surface are arranged in an opposing (facing) relationship. In the present invention, when the gasket surface is press-molded using the mold, there are a gasket surface molded in contact with the press surface and a gasket surface molded in contact with the die surface. In this case, when the gasket is molded using a mold or the like, a manufacturing tolerance is generated. By using the same gasket and arranging the gasket surfaces formed in contact with the die surfaces in a facing relationship, the tolerance can be reduced, and the effect is increased as the number of gaskets used in the electrolytic cell is increased.

Electrode chamber frame and method for manufacturing electrolytic cell

The method for manufacturing the electrode chamber frame and the electrolytic cell according to the present invention includes a step of providing the gasket on the flange surface of the electrode chamber frame, and as the step of providing the gasket on the flange surface, a step of applying an adhesive or a sticking agent (coating step) is preferable. The above-mentioned adhesive or bonding agent can be used as the adhesive or bonding agent.

When the gasket is provided in the coating step, the gasket may be coated on both or one of the gasket and the flange surface of the electrode chamber frame, and the coating may be performed on the entire surface or a part of the surface on which the gasket is provided. In addition, the adhesive is generally applied by: an adhesive product such as a double-sided tape using a support such as a film and having an adhesive applied to the support.

In the method for manufacturing an electrode chamber frame and an electrolytic cell according to the present invention, it is preferable that the step (coating step) of providing the gasket in the electrode chamber includes a step (cleaning step) of cleaning the gasket with a solvent selected from an alcohol solvent such as ethanol, a ketone solvent such as acetone or methyl ethyl ketone, and water. A rubber molded article as a material of the gasket is generally manufactured through a crosslinking step using a mold, and a release agent is used to facilitate taking out the rubber molded article from the mold in the crosslinking step. When a gasket is provided on the flange surface of the electrode chamber frame, if a release agent remains on the gasket surface, the effect of the adhesive may be reduced. At this time, the release agent remaining on the surface of the gasket is removed by wiping (by washing), and the effect of the adhesive/bonding agent can be improved. When wiping the surface of the pad, water, alcohol, or a highly volatile ketone solvent, which is less likely to cause damage to the pad, is preferably used, and in order to effectively and easily remove the fluorine-based or silicon-based release agent, ethanol or acetone is preferably used. For the purpose of removing impurities on the flange surface of the electrode chamber frame, the cleaning may be performed using a solvent selected from an alcohol solvent, a ketone solvent, and water, and preferably, the cleaning is performed.

Electrolysis method

Caustic soda, chlorine and/or hydrogen can be produced from the electrolytic cell, and the electrolytic method includes a step of supplying a salt solution to the electrolytic cell and electrolyzing the salt solution by passing a direct current between the cathode and the anode. The electrolysis conditions are not particularly limited, and can be carried out by a known method. Hydrogen gas and caustic soda can be obtained from the cathode chamber by the electrolysis step. The dilute brine in which the concentrations of chlorine and common salt are reduced by electrolysis can be obtained from the anode chamber. The obtained caustic soda, chlorine gas and hydrogen gas may be purified by a known method.

Examples

The present invention will be described more specifically with reference to the following examples, but the technical scope of the present invention is not limited to these examples.

<Preparation of gasket composition for electrolytic cell>

The respective admixtures shown in Table 1 were kneaded with a mixed rubber of ethylene-propylene rubber (hereinafter, also referred to as EPDM) and bromobutyl rubber (hereinafter, also referred to as Br-IIR) containing 5-ethylidene-2-norbornene as a diene component by using a 1L kneader and a 6-inch roll to obtain a gasket composition for an electrolytic cell.

< evaluation method >

(1) Compression set

According to JIS K6262: 2013 was performed. The obtained gasket composition for electrolytic cell was used to prepare a test piece (diameter 29mm, height 12.5mm, cylindrical shape) for compression set test under the crosslinking condition of 170 ℃ for 15 minutes, and the thickness h0 before the test was measured. The test piece was held in the thickness direction by a compression plate (compression device) composed of two stainless steel plates, and compressed to a thickness with a compression rate of 25% with respect to the thickness h0 before the test, and the compression device with the test piece embedded therein was placed in a thermostatic chamber in which the temperature was kept at 125 ℃ in advance, and was left to stand for 72 hours. At this time, the thickness h2 of the separator used was measured. After 72 hours had elapsed, the compression apparatus was taken out of the thermostatic chamber, released from the compression state, and left to stand for 30 minutes, and then the post-test thickness h1 of the test piece was measured. The compression set was calculated according to the following equation.

Compression set (%) [ (h0-h1)/(h0-h2) ] x 100

(2) Corrosion resistance

The obtained gasket composition for electrolytic cell was used to prepare a test piece (10mm × 40mm × 2mm) under the condition of 170 ° × 15 minutes of crosslinking, and a cell for evaluation was provided on the anode side of the salt electrolytic cell in actual operation, and exposed to the electrolyte in operation, and the change in appearance was visually observed after 4 weeks. And evaluated on the following criteria.

Very good: appearance was not changed by ≈: slightly whitened in appearance

And (delta): whitening on appearance x: whitening and cracking in appearance

(3) Weight change

The obtained gasket composition for electrolytic cell was used to prepare a test piece (10 mm. times.40 mm. times.2 mm) under the condition of crosslinking at 170 ℃ for 15 minutes, and the weight W0 before the test was measured. On the anode side of the salt electrolyzer in actual operation, a cell for evaluation was placed and exposed to the electrolyte during operation, and the weight W1 after 4 weeks was measured. Evaluation was performed according to the following equation.

Weight change (%) [ (W1-W0)/W0] x 100

[ Table 1]

[ Table 2]

*1: EP65 manufactured by JSR corporation

*2: BUROMOBUTYL 2244 manufactured by JSR corporation

*3: manufactured by Tokai Carbon Co., Ltd

*4: burgess quality #30 manufactured by Burgess quality corporation

As is clear from Table 1, examples 1 to 4 maintained compression set and suppressed corrosion due to the electrolyte as compared with comparative example 1 in which no brominated butyl rubber was incorporated. However, when the bromobutyl rubber is excessively blended as in comparative example 2, the corrosion resistance is improved, but the compression set exceeds 20%, and the performance as a gasket is impaired.

As is clear from table 2, even in the gasket composition using carbon black and hard clay as fillers, good compression set and corrosion resistance were obtained, and a variety of fillers were used. However, since the weight change before and after the test was 40%, when carbon black and another filler were used together, it was preferable that the other filler was 7 parts by mass or less with respect to 100 parts by weight of the ethylene-propylene rubber.

The gasket of the present invention can exhibit good performance even in the anode side which is severer than the cathode side, and therefore can be used as a gasket for the cathode side.

Industrial applicability

The gasket composition for an electrolytic cell of the present invention can provide a gasket for an electrolytic cell having further improved chemical resistance without impairing the physical properties of the conventional gasket, and can reduce maintenance costs because the gasket has a long life in the electrolytic cell and the frequency of replacement of members is low.