Method of concentrating alkali metal hydroxide in hybrid cells having cation selective diffusion barriers

Claim 2

A process for production of concentrated alkali metal hydroxide aqueous solution and electrical energy comprising the steps of: (a) introducing flow of an aqueous alkali metal hydroxide solution as anolyte between a first surface of a gas diffusion anode and a first surface of a diffusion barrier; said diffusion barrier being selectively permeable to cations; (b) introducing flow of an aqueous fluid medium receptive to alkali metal ions, as catholyte, between a second surface of said diffusion barrier and a first surface of a diaphram permeable to cations and anions. (c) withdrawing catholyte from between the diffusion barrier second surface and the diaphram first surface; (d) introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between a second surface of the diaphram and a first surface of a gas diffusion cathode; (e) supplying hydrogen gas to a second surface of said gas diffusion anode; (f) supplying oxygen-containing gas to a second surface of said gas diffusion cathode; (g) causing alkali metal ions to pass from the anolyte through the diffusion barrier and into the catholyte flowing between the diaphram first surface and the diffusion barrier second surface by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a concentrated alkali metal hydroxide aqueous solution.

Claim 3

A process for production of concentrated alkali metal hydroxide aqueous solution and electrical energy comprising the steps of: (a) introducing flow of an aqueous alkali metal hydroxide solution as anolyte between a first surface of a gas diffusion anode and a first surface of a diffusion barrier; said diffusion barrier being selectively permeable to cations; (b) introducing flow of an aqueous fluid medium receptive to alkali metal ions, as catholyte, between a second surface of said diffusion barrier and a first surface of a diaphram permeable to cations and anions; (c) withdrawing catholyte from between the diffusion barrier second surface and the diaphram first surface; (d) introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between a second surface of the diaphram and a first surface of a gas diffusion cathode; (e) supplying hydrogen gas to a second surface of said gas diffusion anode; (f) supplying oxygen-containing gas to a second surface of said gas diffusion cathode; (g) causing alkali metal ions to pass from the anolyte through the diffusion barrier and into the catholyte flowing between the diaphram first surface and the diffusion barrier second surface by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a catholyte, which is more concentrated in alkali metal hydroxide than the aqueous metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface; and, (i) withdrawing, from between the gas diffusion anode first surface and the diffusion membrane first surface, an anolyte, which is less concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface.

Claim 4

A process for production of concentrated alkali metal hydroxide aqueous solution and electrical energy comprising the steps of: (a) introducing flow of an aqueous alkali metal hydroxide solution as anolyte between a first surface of a gas diffusion anode and a first surface of a diffusion barrier; said diffusion barrier being selectively permeable to cations; (b) introducing flow of an aqueous fluid medium receptive to alkali metal ions, as catholyte, between a second surface of said diffusion barrier and a first surface of a diaphram permeable to cations and anions; (c) withdrawing catholyte from between the diffusion barrier second surface and the diaphram first surface; (d) introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between a second surface of the diaphram and a first surface of a gas diffusion cathode; (e) supplying hydrogen gas to a second surface of said gas diffusion anode; (f) supplying oxygen-containing gas to a second surface of said gas diffusion cathode; (g) causing alkali metal ions to pass from the anolyte through the diffusion barrier and into the catholyte flowing between the diaphram first surface and the diffusion barrier second surface by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a catholyte, which is more concentrated in alkali metal hydroxide than the aqueous metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface; and, (i) withdrawing, from between the gas diffusion anode first surface and the diffusion membrane first surface, an anolyte, which is less concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface.

Claim 5

The process of claim 2 wherein the oxygen-containing gas comprises air.

Claim 6

The process of claim 3 wherein the air supplied to the gas diffusion cathode second surface is of sufficient quantity to pass thereover and concentrate catholyte flowing between the gas diffusion cathode first surface and the diaphram second surface by removing water passing through the gas diffusion cathode second surface, said water being removed by evaporation from said gas diffusion cathode second surface.

Claim 7

The process of claim 2 wherein the aqueous alkali metal hydroxide solution introduced between the gas diffusion first surface and the diffusion barrier first surface is a solution comprising up to approximately 25 percent by weight alkali metal hydroxide.

Claim 8

The process of claim 5 wherein the anolyte withdrawn from between the gas diffusion anode first surface and its diffusion barrier first surface contains alkali metal hydroxide in a concentration above about 0.01 percent by weight.

Claim 9

The process of claim 5 wherein the anolyte withdrawn from between the gas diffusion anode first surface and the diffusion barrier first surface contains alkali metal hydroxide in a concentration above about 0.5 percent by weight.

Claim 10

The process of claim 2 or 4 wherein the catholyte withdrawn from between the diaphram second surface and the gas diffusion cathode first surface contains alkali metal hydroxide in an amount up to about 40 percent by weight.

Claim 11

The process of claim 2 wherein the flow of anolyte between the gas diffusion anode first surface and the diffusion barrier first surface is cocurrent with both the flow of catholyte between the diffusion barrier second surface and the diaphram first surface and the flow of catholyte between the diaphram second surface and the gas diffusion cathode first surface.

Claim 12

The process of claim 2 wherein the flow of anolyte between the gas diffusion anode first surface and the diffusion barrier first surface is cocurrent with the flow of catholyte between the diffusion barrier second surface and the diaphram first surface and countercurrent to the flow of catholyte between the diaphram second surface and the gas diffusion cathode first surface.

Claim 13

The process of claim 2 where the flow of anolyte and catholyte is substantially without appreciable mixing or back convection.

Claim 14

A process for production of concentrated sodium hydride solution from the aqueous effluent of a chloralkali cell and electrical energy comprising the steps of: (a) introducing flow of said chloralkali cell aqueous effluent as anolyte between a first surface of a gas diffusion anode and a first surface of a diffusion barrier, said diffusion barrier being selectively permeable to sodium ions, said chloralkali aqueous effluent including sodium hydroxide and sodium chloride; (b) introducing flow of an aqueous fluid medium receptive to sodium ions as catholyte between a second surface of said diffusion barrier and a first surface of a diaphram permeable to cations and anions; (c) withdrawing flow of catholyte from between the diffusion barrier second surface and the diaphram first surface; (d) introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between a second surface of the diaphram and a first surface of a gas diffusion cathode; (e) supplying hydrogen gas to a second surface of said gas diffusion anode; (f) supplying oxygen containing gas to a second surface of said gas diffusion cathode; (g) causing sodium ions to pass from the anolyte through the diffusion barrier and into the catholyte flowing between the diaphram first surface and the diffusion barrier second surface by electrically interconnecting the gas diffusion anode and the gas diffusion cathode to the chloralkali cell, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a catholyte, which is more concentrated in sodium hydroxide than the aqueous effluent introduced between the gas diffusion anode first surface and the diffusion barrier first surface; and, (i) withdrawing, from between the gas diffusion anode first surface and the diffusion barrier first surface, an anolyte, which is less concentrated in sodium hydroxide than the aqueous effluent introduced between the gas diffusion anode first surface and the diffusion barrier first surface.

Claim 15

A process for production of concentrated sodium hydride solution from the aqueous effluent of a chloralkali cell and electrical energy comprising the steps of: (a) introducing flow of said chloralkali cell aqueous effluent as anolyte between a first surface of a gas diffusion anode and a first surface of a diffusion barrier, said diffusion barrier being selectively permeable to sodium ions, said chloralkali aqueous effluent including sodium hydroxide and sodium chloride; (b) introducing flow of an aqueous fluid medium receptive to sodium ions as catholyte between a second surface of said diffusion barrier and a first surface of a diaphram permeable to cations and anions; (c) withdrawing flow of catholyte from between the diffusion barrier second surface and the diaphram first surface; (d) introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between a second surface of the diaphram and a first surface of a gas diffusion cathode; (e) supplying hydrogen gas to a second surface of said gas diffusion anode; (f) supplying oxygen containing gas to a second surface of said gas diffusion cathode; (g) causing sodium ions to pass from the anolyte through the diffusion barrier and into the catholyte flowing between the diaphram first surface and the diffusion barrier second surface by electrically interconnecting the gas diffusion anode and the gas diffusion cathode to the chloralkali cell, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a catholyte, which is more concentrated in sodium hydroxide than the aqueous effluent introduced between the gas diffusion anode first surface and the diffusion barrier first surface; and, (i) withdrawing, from between the gas diffusion anode first surface and the diffusion barrier first surface, an anolyte, which is less concentrated in sodium hydroxide than the aqueous effluent introduced between the gas diffusion anode first surface and the diffusion barrier first surface.

Claim 16

The process of claim 12 wherein the oxygen-containing gas comprises air.

Claim 17

The process of claim 13 wherein the air is supplied to the second surface of said gas diffusion cathode is of sufficient quantity to pass thereover and concentrate the catholyte flowing between the gas diffusion cathode first surface and the diaphram second surface by removing water passing through the gas diffusion cathode second surface, said water being removed by evaporation from said gas diffusion cathode second surface.

Claim 18

The process of claim 12 wherein the aqueous effluent introduced between the gas diffusion first surface and the diffusion barrier first surface is a solution comprising up to approximately 25 percent by weight sodium hydroxide.

Claim 19

The process of claim 15 wherein the anolyte withdrawn from between the gas diffusion anode first surface and the diffusion barrier first surface contains sodium hydroxide in a concentration above about 0.01 percent by weight.

Claim 20

The process of claim 15 wherein the anolyte withdrawn from between the gas diffusion anode first surface and the diffusion barrier first surface contains sodium hydroxide in a concentration above about 0.5 percent by weight.

Claim 21

The process of claim 12 or 14 wherein the catholyte withdrawn from between the diaphram second surface and the gas diffusion cathode first surface contains sodium hydroxide in a an amount up to about 40 percent by weight.

Claim 22

The process of claim 12 wherein the flow of anolyte between the gas diffusion anode first surface and the diffusion barrier first surface is cocurrent with both the flow of catholyte between the diffusion barrier second surface and the diaphram first surface and the flow of catholyte between the diaphram second surface and the gas diffusion cathode first surface.

Claim 23

The process of claim 12 wherein the flow of anolyte between the gas diffusion anode first surface and the diffusion barrier first surface is cocurrent with the flow of catholyte between the diffusion barrier second surface and the diaphram first surface and countercurrent to the flow of catholyte between the diaphram second surface and the gas diffusion cathode first surface.

Claim 24

The process of claim 12 where the flow of anolyte and catholyte is substantially without appreciable mixing or back convection.

Claim 25

A process for production of concentrated alkali metal hydroxide and electrical energy utilizing at least one hybrid cell having a gas diffusion anode, a gas diffusion cathode, a diffusion barrier selectively permeable to cations and a diaphram permeable to cations and anions, said gas diffusion anode, gas diffusion cathode, diffusion barrier and diaphram each having first and second surfaces, each hybrid cell having an anode compartment defined, in part, by the gas diffusion anode first surface and the diffusion barrier first surface, a central compartment defined, in part, by the diffusion barrier second surface and the diaphram first surface, and a cathode compartment defined, in part, by the diaphram second surface and the gas diffusion cathode first surface, the anode, central and cathode compartments each having a inlet and an outlet, said process comprising the steps of: (a) introducing flow of an aqueous alkali metal hydroxide solution, as anolyte, into the anode compartment inlet; (b) introducing flow of an aqueous fluid medium receptive to alkali metal ions, as catholyte, into the central compartment inlet; (c) withdrawing catholyte from the central compartment outlet; (d) introducing flow of the catholyte, withdrawn from the central compartment outlet, into the cathode compartment inlet; (e) supplying hydrogen gas to the gas diffusion anode second surface; (f) supplying oxygen-containing gas to the gas diffusion cathode second surface; (g) causing alkali metal ions to pass from the anolyte compartment through the diffusion membrane and into the catholyte compartment by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reducing oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing from the cathode compartment outlet, a catholyte, which is more concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced into the anode compartment inlet; (i) withdrawing from the anode compartment outlet, an anolyte, which is less concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced into the anode compartment inlet.

Claim 26

A process for production of concentrated alkali metal hydroxide and electrical energy utilizing at least one hybrid cell having a gas diffusion anode, a gas diffusion cathode, a diffusion barrier selectively permeable to cations and a diaphram permeable to cations and anions, said gas diffusion anode, gas diffusion cathode, diffusion barrier and diaphram each having first and second surfaces, each hybrid cell having an anode compartment defined, in part, by the gas diffusion anode first surface and the diffusion barrier first surface, a central compartment defined, in part, by the diffusion barrier second surface and the diaphram first surface, and a cathode compartment defined, in part, by the diaphram second surface and the gas diffusion cathode first surface, the anode, central and cathode compartments each having a inlet and an outlet, said process comprising the steps of: (a) introducing flow of an aqueous alkali metal hydroxide solution, as anolyte, into the anode compartment inlet; (b) introducing flow of an aqueous fluid medium receptive to alkali metal ions, as catholyte, into the central compartment inlet; (c) withdrawing catholyte from the central compartment outlet; (d) introducing flow of the catholyte, withdrawn from the central compartment outlet, into the cathode compartment inlet; (e) supplying hydrogen gas to the gas diffusion anode second surface; (f) supplying oxygen-containing gas to the gas diffusion cathode second surface; (g) causing alkali metal ions to pass from the anolyte compartment through the diffusion membrane and into the catholyte compartment by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reducing oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing from the cathode compartment outlet, a catholyte, which is more concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced into the anode compartment inlet; (i) withdrawing from the anode compartment outlet, an anolyte, which is less concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced into the anode compartment inlet.

Claim 27

A process for production of concentrated alkali metal hydroxide solution from the aqueous effluent of a chloralkali cell and electrical energy utilizing at least one hybrid cell having a gas diffusion anode, a gas diffusion cathode, a diffusion barrier selectively permeable to cations and a diaphram permeable to cations and anions, said gas diffusion anode, gas diffusion cathode, diffusion barrier and diaphram each having first and second surfaces, each hybrid cell having an anode compartment defined, in part, by the gas diffusion anode first surface and the diffusion barrier first surface, a central compartment defined, in part, by the diffusion barrier second surface and the diaphram first surface, and the cathode compartment defined, in part, by the diaphram second surface and the gas diffusion cathode first surface, the anode, central and cathode compartments each having an inlet and an outlet, said chloralkali cell aqueous effluent comprising sodium hydroxide and sodium chloride, said process comprising the steps of: (a) introducing flow of the chloralkali cell aqueous effluent as anolyte into the anode compartment inlet; (b) introducing flow of an aqueous fluid medium receptive to sodium ions, as catholyte, into the central compartment inlet; (c) withdrawing catholyte from the central compartment; (d) introducing flow of the catholyte, withdrawn from the central compartment outlet, into the cathode compartment inlet; (e) supplying hydrogen gas to gas diffusion anode second surface; (f) supplying oxygen-containing gas to the gas diffusion cathode second surface; (g) causing alkali metal ions to pass from the anolyte compartment through the diffusion membrane and into the catholyte compartment by electrically interconnecting the gas diffusion anode and the gas diffusion cathode to the chloralkali cell, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing from the cathode compartment outlet, a catholyte, which is more concentrated in alkali metal hydroxide than the chloralkali cell aqueous effluent introduced into the anode compartment inlet; (i) withdrawing from the anode compartment outlet, an anolyte, which is less concentrated in sodium hydroxide than the chloralkali cell aqueous effluent introduced into the anode compartment inlet.

Claim 28

A process for production of concentrated alkali metal hydroxide solution from the aqueous effluent of a chloralkali cell and electrical energy utilizing at least one hybrid cell having a gas diffusion anode, a gas diffusion cathode, a diffusion barrier selectively permeable to cations and a diaphram permeable to cations and anions, said gas diffusion anode, gas diffusion cathode, diffusion barrier and diaphram each having first and second surfaces, each hybrid cell having an anode compartment defined, in part, by the gas diffusion anode first surface and the diffusion barrier first surface, a central compartment defined, in part, by the diffusion barrier second surface and the diaphram first surface, and the cathode compartment defined, in part, by the diaphram second surface and the gas diffusion cathode first surface, the anode, central and cathode compartments each having an inlet and an outlet, said chloralkali cell aqueous effluent comprising sodium hydroxide and sodium chloride, said process comprising the steps of: (a) introducing flow of the chloralkali cell aqueous effluent as anolyte into the anode compartment inlet; (b) introducing flow of an aqueous fluid medium receptive to sodium ions, as catholyte, into the central compartment inlet; (c) withdrawing catholyte from the central compartment; (d) introducing flow of the catholyte, withdrawn from the central compartment outlet, into the cathode compartment inlet; (e) supplying hydrogen gas to gas diffusion anode second surface; (f) supplying oxygen-containing gas to the gas diffusion cathode second surface; (g) causing alkali metal ions to pass from the anolyte compartment through the diffusion membrane and into the catholyte compartment by electrically interconnecting the gas diffusion anode and the gas diffusion cathode to the chloralkali cell, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (h) withdrawing from the cathode compartment outlet, a catholyte, which is more concentrated in alkali metal hydroxide than the chloralkali cell aqueous effluent introduced into the anode compartment inlet; (i) withdrawing from the anode compartment outlet, an anolyte, which is less concentrated in sodium hydroxide than the chloralkali cell aqueous effluent introduced into the anode compartment inlet.

Claim 29

A process as claimed in claim 22 or 23 in which; (a) a plurality of hybrid cells are operated hydrodynamically in series, the plurality including a first hybrid cell at one end of the series and a last hybrid cell at an opposite end of the series; (b) said anolyte is introduced to the anode compartment of said first hybrid cell of the series and flows sequentially from the first hybrid cell to the last hybrid cell of the series; (c) said catholyte is introduced to the central compartment of said first hybrid cell and flows to the cathode compartment of said first hybrid cell, then sequentially to the central compartment and cathode compartment of each hybrid cell of the series including the last hybrid cell of the series; (d) catholyte which is more concentrated in respect to alkali metal hydroxide than the aqueous fluid medium introduced to the central compartment of the first hybrid cell of the series is withdrawn from the cathode compartment of the last hybrid cell; and, (e) anolyte, which is more depleted in respect to alkali metal hydroxide than the aqueous solution introduced to the anode compartment of the first hybrid cell of the series is withdrawn from the anode compartment of the last hybrid cell of the series.

Claim 30

A process as claimed in claim 24 in which the flow of anolyte through the anode compartments is substantially in one direction without appreciable mixing, back convection or diffusion of molecules and ions contained in said anolyte and the flow of catholyte through the control and cathode compartments is substantially in one direction without appreciable mixing, back convection or diffusion of molecular and ions contained in said catholyte.

Claim 31

A process as claimed in claim 22 or 23 in which; (a) a plurality of hybrid cells is operated hydrodynamically in series, the plurality including a first hybrid cell at one end of the series and a last hybrid cell at an opposite end of the series; (b) said anolyte is introduced to the anode compartment of said first hybrid cell of the series and flows sequentially from the first hybrid cell to the last hybrid cell of the series; (c) said catholyte is introduced to the central compartment of said last hybrid cell and flows to the cathode compartment of said last hybrid cell and flows to the cathode compartment of said last hybrid cell, then sequentially to the central compartment of and cathode compartment of each hybrid cell of the series including the first hybrid cell of the series; and is withdrawn from the first hybrid cell of the series; (d) catholyte which is more concentrated in respect to alkali metal hydroxide; than the aqueous solution introduced to the anode compartment of the last hybrid cell of the series is withdrawn from the cathode compartment of the first hybrid cell; and, (e) anolyte, which is more depleted in respect to alkali metal hydroxide than the aqueous solution introduced to the anode compartment of the first hybrid cell of the series is withdrawn from the anode compartment of the last hybrid cell of the series.

Claim 32

A process as claimed in 26 in which the flow of anolyte through the anode compartments is substantially in one direction without appreciable mixing, back convection or diffusion of molecules and ions contained in said anolyte and the flow of catholyte through the central and cathode compartments is substantially in one direction without appreciable mixing, back convections or diffusion of molecular and ions contained in said catholyte.

Claim 33

Apparatus for the production of concentrated alkali metal hydroxide solution and electrical energy comprising: (a) a gas diffusion anode having a first and a second surface; (b) a gas diffusion cathode having a first and a second surface; (c) a diffusion barrier having a first and a second surface, said diffusion barrier being selectively permeable to cations; (d) a diaphram having a first and a second surface, said diaphram being permeable to cation and anions, said diffusion barrier and said diaphram being disposed between said gas diffusion anode and said gas diffusion cathode with the diffusion barrier being adjacent the gas diffusion anode and the diaphram being adjacent the gas diffusion cathode; (e) means for introducing flow of an aqueous alkali metal hydroxide solution as anolyte between the gas diffusion anode first surface and the diffusion barrier first surface; (f) means for introducing flow of an aqueous fluid medium receptive to alkali metal ion as catholyte between the diffusion barrier second surface and the diaphram first surface; (g) means for withdrawing catholyte from between the diffusion barrier second surface and the diaphram first surface; (h) means for introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the daiphram first surface, between the diaphram second surface and the gas diffusion cathode first surface; (i) means for supplying hydrogen gas to the gas diffusion anode second surface; (j) means for supplying oxygen-containing gas to the gas diffusion cathode second surface; (k) means for causing alkali metal cations to pass from the anolyte through the cation selective diffusion barrier and into the catholyte by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of the oxygen in the oxygen-containing gas to the gas diffusion cathode second surface, (1) means for withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a concentrated alkali metal hydroxide aqueous solution.

Claim 34

Apparatus for the production of concentrated alkali metal hydroxide solution and electrical energy comprising: (a) a gas diffusion anode having a first and a second surface; (b) a gas diffusion cathode having a first and a second surface; (c) a diffusion barrier having a first and a second surface, said diffusion barrier being selectively permeable to cations; (d) a diaphram having a first and a second surface, said diaphram being permeable to cation and anions, said diffusion barrier and said diaphram being disposed between said gas diffusion anode and said gas diffusion cathode with the diffusion barrier being adjacent the gas diffusion anode and the diaphram being adjacent the gas diffusion cathode; (e) means for introducing flow of an aqueous alkali metal hydroxide solution as anolyte between the gas diffusion anode first surface and the diffusion barrier first surface; (f) means for introducing flow of an aqueous fluid medium receptive to alkali metal ion as catholyte between the diffusion barrier second surface and the diaphram first surface; (g) means for withdrawing catholyte from between the diffusion barrier second surface and the diaphram first surface; (h) means for introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the daiphram first surface, between the diaphram second surface and the gas diffusion cathode first surface; (i) means for supplying hydrogen gas to the gas diffusion anode second surface; (j) means for supplying oxygen-containing gas to the gas diffusion cathode second surface; (k) means for causing alkali metal cations to pass from the anolyte through the cation selective diffusion barrier and into the catholyte by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of the oxygen in the oxygen-containing gas to the gas diffusion cathode second surface, (1) means for withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a concentrated alkali metal hydroxide aqueous solution.

Claim 35

Apparatus for the production of concentrated alkali metal hydroxide solution and electrical energy comprising: (a) a gas diffusion anode having a first and a second surface; (b) a gas diffusion cathode having a first and a second surface; (c) a diffusion barrier having a first and a second surface, said diffusion barrier being selectively permeable to cations; (d) a diaphram having a first and a second surface, said diaphram being permeable to cation and anions, said diffusion barrier and said diaphram being disposed between said gas diffusion anode and said gas diffusion cathode with the diffusion barrier being adjacent the gas diffusion anode and the diaphram being adjacent the gas diffusion cathode; (e) means for introducing flow of an aqueous alkali metal hydroxide solution as anolyte between the gas diffusion anode first surface and the diffusion barrier first surface; (f) means for introducing flow of an aqueous fluid medium receptive to alkali metal ion as catholyte between the diffusion barrier second surface and the diaphram first surface; (g) means for withdrawing catholyte from between the diffusion barrier second surface and the diaphram first surface; (h) means for introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between the diaphram second surface and the gas diffusion cathode first surface; (i) means for supplying hydrogen gas to the gas diffusion anode second surface; (j) means for supplying oxygen-containing gas to the gas diffusion cathode second surface; (k) means for causing alkali metal cations to pass from the anolyte through the cation selective diffusion barrier and into the catholyte by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of the oxygen in the oxygen-containing gas to the gas diffusion cathode second surface, (l) means for withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a catholyte, which is more concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface; and, (m) means for withdrawing, from between the gas diffusion anode first surface and the diffusion barrier first surface, an anolyte, which is less concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface.

Claim 36

Apparatus for the production of concentrated alkali metal hydroxide solution and electrical energy comprising: (a) a gas diffusion anode having a first and a second surface; (b) a gas diffusion cathode having a first and a second surface; (c) a diffusion barrier having a first and a second surface, said diffusion barrier being selectively permeable to cations; (d) a diaphram having a first and a second surface, said diaphram being permeable to cation and anions, said diffusion barrier and said diaphram being disposed between said gas diffusion anode and said gas diffusion cathode with the diffusion barrier being adjacent the gas diffusion anode and the diaphram being adjacent the gas diffusion cathode; (e) means for introducing flow of an aqueous alkali metal hydroxide solution as anolyte between the gas diffusion anode first surface and the diffusion barrier first surface; (f) means for introducing flow of an aqueous fluid medium receptive to alkali metal ion as catholyte between the diffusion barrier second surface and the diaphram first surface; (g) means for withdrawing catholyte from between the diffusion barrier second surface and the diaphram first surface; (h) means for introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between the diaphram second surface and the gas diffusion cathode first surface; (i) means for supplying hydrogen gas to the gas diffusion anode second surface; (j) means for supplying oxygen-containing gas to the gas diffusion cathode second surface; (k) means for causing alkali metal cations to pass from the anolyte through the cation selective diffusion barrier and into the catholyte by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of the oxygen in the oxygen-containing gas to the gas diffusion cathode second surface, (l) means for withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a catholyte, which is more concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface; and, (m) means for withdrawing, from between the gas diffusion anode first surface and the diffusion barrier first surface, an anolyte, which is less concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface.

Claim 37

The apparatus of claim 29 further icluding means for causing the flow of alkali metal hydroxide solution between the gas diffusion anode first surface and the diffusion barrier first surface to be substantially in one direction without appreciable mixing, back convection or diffusion of molecules and ions contained in the alkali metal hydroxide solution, means for causing the flow of the aqueous fluid medium between the diffusion barrier second surface and the diaphram first surface to be substantially in one direction without appreciable mixing, back convection or diffusion of molecules and ions contained in the aqueous fluid medium, and means for causing the flow of the catholyte between the diaphram second surface and the gas diffusion cathode first surface to be substantially in one direction without appreciable mixing, back convection or diffusion of molecular and ions contained in the catholyte.

Claim 38

The apparatus of claim 29 further including means for causing the flow of the alkali metal hydroxide solution between the gas diffusion anode first surface and the diffusion barrier first surface to be plug type flow, means for causing the flow of the aqueous fluid medium between the diffusion barrier second surface and the diaphragm first surface to be plug type flow, and means for causing the flow of catholyte between the diaphram second surface and the gas diffusion cathode first surface to be plug type flow.

Claim 39

The apparatus of claim 29 wherein said means for supplying hydrogen gas to the gas diffusion anode second surface and said means for supplying oxygen-containing gas to the gas diffusion cathode second surface both include means for forming channels adjacent the gas diffusion anode second surface and the gas diffusion cathode second surface respectively.

Claim 40

Apparatus for the production of concentrated alkali metal hydroxide solution and electrical energy comprising a plurality of hybrid cells connected hydrodynamically in series, each hybrid cell comprising: (a) a gas diffusion anode having a first and a second surface; (b) a gas diffusion cathode having first and a second surface; (c) a diaphram which is permeable to cations and anions and having a first and a second surface; (d) a diffusion barrier which is selectively permeable to cations and having a first and a second surface, said gas diffusion anode first surface and said diffusion barrier first surface defining, in part, an anode compartment, said diffusion barrier second surface and said diaphram first surface defining, in part, a central compartment, and said gas diffusion cathode first surface and said diaphram second surface defining, in part, a cathode compartment; (e) means for introducing flow of an alkaline metal hydroxide solution, as anolyte, into said anode compartment; (f) means for introducing flow of an aqueous fluid medium receptive to alkali ions, as catholyte, into said central compartment; (g) means for withdrawing catholyte from the central compartment; (h) means for introducing catholyte withdrawn from the central compartment into the cathode compartment; (i) means for supplying hydrogen gas to the gas diffusion anode second surface, (j) means for supplying oxygen-containing gas to the gas diffusion cathode second surface; (k) means for causing alkali metal cations to pass from the anolyte through the cation selective diffusion barrier into the catholyte by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and the reduction of the oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (l) means for withdrawing, from said cathode compartment, catholyte which is more concentrated in alkali metal hydroxide than the alkali metal hydroxide solution introduced into the anode compartment; and (m) means for withdrawing, from said anode compartment, anolyte which is less concentrated in alkali metal hydroxide than the aqueous solution of alkali metal hydroxide introduced into the anode compartment.

Claim 41

Apparatus for the production of concentrated alkali metal hydroxide solution and electrical energy comprising a plurality of hybrid cells connected hydrodynamically in series, each hybrid cell comprising: (a) a gas diffusion anode having a first and a second surface; (b) a gas diffusion cathode having first and a second surface; (c) a diaphram which is permeable to cations and anions and having a first and a second surface; (d) a diffusion barrier which is selectively permeable to cations and having a first and a second surface, said gas diffusion anode first surface and said diffusion barrier first surface defining, in part, an anode compartment, said diffusion barrier second surface and said diaphram first surface defining, in part, a central compartment, and said gas diffusion cathode first surface and said diaphram second surface defining, in part, a cathode compartment; (e) means for introducing flow of an alkaline metal hydroxide solution, as anolyte, into said anode compartment; (f) means for introducing flow of an aqueous fluid medium receptive to alkali ions, as catholyte, into said central compartment; (g) means for withdrawing catholyte from the central compartment; (h) means for introducing catholyte withdrawn from the central compartment into the cathode compartment; (i) means for supplying hydrogen gas to the gas diffusion anode second surface, (j) means for supplying oxygen-containing gas to the gas diffusion cathode second surface; (k) means for causing alkali metal cations to pass from the anolyte through the cation selective diffusion barrier into the catholyte by electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and the reduction of the oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (l) means for withdrawing, from said cathode compartment, catholyte which is more concentrated in alkali metal hydroxide than the alkali metal hydroxide solution introduced into the anode compartment; and (m) means for withdrawing, from said anode compartment, anolyte which is less concentrated in alkali metal hydroxide than the aqueous solution of alkali metal hydroxide introduced into the anode compartment.

Claim 42

The apparatus of claim 31 wherein the plurality of hybrid cells includes a first hybrid cell at one end of the series and a last hybrid cell at an opposite end of the series and, said means for introducing flow of an alkali metal hydroxide solution is operative for introducing said alkali metal hydroxide solution into an anode compartment of said first hybrid cell, said alkali metal hydroxide solution flowing therethrough and thereafter flowing through anode compartments of the hybrid cells in the hydrodynamic series and into an anode compartment of the last hybrid cell, said means for introducing flow of an aqueous fluid medium is operative for introducing said aqueous fluid medium into a central compartment of said first hybrid cell, said aqueous fluid medium flowing therethrough and thereafter flowing through a cathode compartment of the first hybrid cell, through the central and cathode compartments of the hybrid cells in the hydrodynamic series and then into a central compartment and thereafter a cathode compartment of the last hybrid cell, said means for withdrawing anolyte is operative for withdrawing catholyte from the cathode compartment last hybrid cell; and said means for withdrawing anolyte is operative for withdrawing anolyte from the anode compartment last hybrid cell.

Claim 43

The apparatus of claim 31 wherein the plurality of hybrid cells includes a first hybrid cell at one end of the series and a last hybrid cell at an opposite end of the series and, said means for introducing flow of an alkali metal hydroxide solution is operative for introducing said alkali metal hydroxide solution into an anode compartment of said first hybrid cell, said alkali metal hydroxide solution flowing therethrough and thereafter flowing through anode compartments of the hybrid cells in the hydrodynamic series and into an anode compartment of the last hybrid cell; said means for introducing flow of an aqueous fluid medium is operative for introducing said aqueous fluid medium into a central compartment of said last hybrid cell, said aqueous fluid medium flowing therethrough and thereafter flowing through a cathode compartments of the last hybrid cell, through the central and cathode compartments of the hybrid cells in the hydrodynamic series and then into a central compartment and thereafter a cathode compartment of the first hybrid cell, said means for withdrawing catholyte is operative for withdrawing catholyte from the first hybrid cell; and said means for withdrawing anolyte is operative for withdrawing anolyte from the last hybrid cell.

Claim 44

Apparatus for the production of concentrated alkali metal hydroxide, comprising, in combination: (a) a chloralkali cell having an anode, cathode, and a cathode compartment, said cathode compartment being configured for containing an aqueous alkali metal hydroxide solution and including outlet means for withdrawing said aqueous alkali metal hydroxide solution from the chloralkali cell cathode compartment; (b) a hybrid cell comprising: (i) a gas diffusion anode having a first and a second surface; (ii) a gas diffusion cathode having a first and a second surface; (iii) a diaphram permeable to cations and anions having a first and a second surface; (iv) a diffusion barrier having a first and a second surface, said diffusion barrier being selectively permeable to cations, said diaphram and diffusion barrier being disposed between the gas diffusion anode and gas diffusion cathode with the diffusion barrier adjacent the gas diffusion anode and the diaphram adjacent the gas diffusion cathode; (c) means, interconnected with the chloroalkali cell cathode compartment outlet means for introducing flow of the aqueous alkali metal hydroxide solution from the chloroalkali cell as anolyte between the gas diffusion anode first surface and the diffusion barrier first surface; (d) means for introducing flow of an aqueous fluid medium receptive to alkali metal ions as catholyte between the diaphram first surface and the diffusion barrier second surface; (e) means for withdrawing catholyte from between the diffusion barrier second surface and its diaphram first surface; (f) means for introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between the diaphram second surface and the gas diffusion cathode first surface; (g) means interconnected with said chloroalkali cell anode for withdrawing hydrogen gas therefrom and supplying said hydrogen gas to the gas diffusion anode second surface; (h) means for supplying oxygen-containing gas to the gas diffusion cathode second surface; (i) means for causing alkali metal cations to pass form the anolyte through the cation selective diffusion barrier and into the catholyte by electrically interconnecting the gas diffusion anode to the chloralkali cell cathode and the gas diffusion cathode to the chloralkali cell anode, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of the oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (j) means for withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a catholyte which is more concentrated in alkali metal hydroxide than the alkali metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface; and, (k) means for withdrawing from between the gas diffusion anode first surface and the diffusion barrier first surface, an anolyte, which is less concentrated in alkali metal hydroxide than the aqueous solution of alkali metal hydroxide introduced between the gas diffusion anode first surface and the diffusion barrier first surface.

Claim 45

Apparatus for the production of concentrated alkali metal hydroxide, comprising, in combination: (a) a chloralkali cell having an anode, cathode, and a cathode compartment, said cathode compartment being configured for containing an aqueous alkali metal hydroxide solution and including outlet means for withdrawing said aqueous alkali metal hydroxide solution from the chloralkali cell cathode compartment; (b) a hybrid cell comprising: (i) a gas diffusion anode having a first and a second surface; (ii) a gas diffusion cathode having a first and a second surface; (iii) a diaphram permeable to cations and anions having a first and a second surface; (iv) a diffusion barrier having a first and a second surface, said diffusion barrier being selectively permeable to cations, said diaphram and diffusion barrier being disposed between the gas diffusion anode and gas diffusion cathode with the diffusion barrier adjacent the gas diffusion anode and the diaphram adjacent the gas diffusion cathode; (c) means, interconnected with the chloroalkali cell cathode compartment outlet means for introducing flow of the aqueous alkali metal hydroxide solution from the chloroalkali cell as anolyte between the gas diffusion anode first surface and the diffusion barrier first surface; (d) means for introducing flow of an aqueous fluid medium receptive to alkali metal ions as catholyte between the diaphram first surface and the diffusion barrier second surface; (e) means for withdrawing catholyte from between the diffusion barrier second surface and its diaphram first surface; (f) means for introducing flow of the catholyte, withdrawn from between the diffusion barrier second surface and the diaphram first surface, between the diaphram second surface and the gas diffusion cathode first surface; (g) means interconnected with said chloroalkali cell anode for withdrawing hydrogen gas therefrom and supplying said hydrogen gas to the gas diffusion anode second surface; (h) means for supplying oxygen-containing gas to the gas diffusion cathode second surface; (i) means for causing alkali metal cations to pass form the anolyte through the cation selective diffusion barrier and into the catholyte by electrically interconnecting the gas diffusion anode to the chloralkali cell cathode and the gas diffusion cathode to the chloralkali cell anode, thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion anode second surface and reduction of the oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface; (j) means for withdrawing, from between the gas diffusion cathode first surface and the diaphram second surface, a catholyte which is more concentrated in alkali metal hydroxide than the alkali metal hydroxide solution introduced between the gas diffusion anode first surface and the diffusion barrier first surface; and, (k) means for withdrawing from between the gas diffusion anode first surface and the diffusion barrier first surface, an anolyte, which is less concentrated in alkali metal hydroxide than the aqueous solution of alkali metal hydroxide introduced between the gas diffusion anode first surface and the diffusion barrier first surface.