Bipolar electrolyzer process

Claim 2

In a method of operating a bipolar electrolyzer comprising feeding a brine electrolyte to anolyte compartments of the individual electrolytic cells and an aqueous electrolyte to catholyte compartments of the individual electrolytic cells, imposing an electrical potential across the electrolyzer, recovering chlorine and anolyte liquor from the anolyte compartment, and hydrogen and aqueous alkali metal hydroxide from the catholyte compartment, the improvement comprising: (1) recovering chlorine and anolyte liquor from individual cells of the electrolyzer through individual vertical risers at an anolyte liquor flow rate sufficient to provide flow characterized by bubbles of gas moving along at substantially the same velocity as the anolyte liquor, while substantially avoiding flow characterized by periodic waves of high velocity frothy slugs and alternating plugs of liquid and gas; (2) collecting the chlorine and anolyte liquor from the individual risers in a substantially horizontal header; (3) transporting the collected chlorine and anolyte liquor from all of the cells in the electrolyzer through the substantially horizontal header to a chlorine disengaging chamber; (4) separating the chlorine from the anolyte liquor in the disengaging chamber; (5) recovering chlorine from the disengaging chamber; (6) recovering anolyte liquor from the disengaging chamber; (7) adding concentrated brine to the anolyte liquor whereby to form feed brine; (8) returning the feed brine to the electrolyzer; (9) separating hydrogen from the aqueous alkali metal hydroxide whereby to recover the hydrogen; and (10) separating the aqueous alkali metal hydroxide into product alkali metal hydroxide and return catholyte liquor, recovering the product alkali metal hydroxide, adding water to the return cell liquor, and returning the water and return cell liquor to the electrolyzer.

Claim 3

The method of claim 1 comprising adding concentrated brine to the anolyte liquor in the ratio of 1 part of concentrated brine per part of return anolyte liquor to about 1 part of concentrated brine per 20 parts of return anolyte liquor, whereby to enrich the return anolyte liquor in alkali metal chloride content.

Claim 4

The method of claim 1 comprising maintaining a head of about 10 to about 30 inches of water on the anolyte liquor.

Claim 5

The method of claim 1 wherein the anolyte liquor in the vertical risers has a void fraction of about 75 to about 95 percent.

Claim 6

The method of claim 1 comprising: (a) recovering hydrogen and catholyte liquor from individual cells of the electrolyzer through individual vertical risers at a catholyte liquor flow rate sufficient to provide flow characterized by bubbles of gas moving along at substantially the same velocity as the catholyte liquor while substantially avoiding flows characterized by periodic waves of high velocity frothy slugs and alternating plugs of liquid and gas; (b) collecting the hydrogen and catholyte liquor from the individual risers in a substantially horizontal header; (c) transporting the collected hydrogen and catholyte liquor from all of the cells in the electrolyzer through the substantially horizontal header to a hydrogen disengaging chamber; (d) recovering hydrogen from the disengaging chamber; (e) recovering catholyte liquor from the disengaging chamber; (f) adding water to the catholyte liquor in the ratio of 1 part of water per 40 parts of return catholyte liquor to part 1 part of water per 200 parts of return catholyte liquor; and (g) returning the return catholyte liquor to the individual electrolytic cells.

Claim 7

The method of claim 5 wherein the flow rate of catholyte liquor through the individual vertical riser is from about 50,000 to about 500,000 pounds per square foot per hour.

Claim 8

The method of claim 5 comprising maintaining a head of about 0 to about 40 inches of water on the catholyte liquor.

Claim 9

The method of claim 5 wherein the catholyte liquor in the vertical riser has a void fraction of about 75 to about 95 percent.

Claim 10

In a method of operating a bipolar electrolyzer comprising feeding a brine electrolyte to anolyte compartments of the individual electrolytic cells and an aqueous electrolyte to catholyte compartments of the individual electrolytic cells, imposing an electrical potential across the electrolyzer, recovering chlorine and anolyte liquor from the anolyte compartment and hydrogen and aqueous alkali metal hydroxide from the catholyte compartment, the improvement comprising: (1) recovering chlorine and anolyte liquor from individual cells of the electrolyzer through individual vertical risers at an anolyte liquor flow rate sufficient to provide flow characterized by bubbles of gas moving along at substantially the same velocity as the anolyte liquor, while substantially avoiding flow characterized by periodic waves of high velocity frothy slugs and alternating plugs of liquid and gas; (2) collecting the chlorine and anolyte liquor from the individual risers in a substantially horizontal header; (3) transporting the collected chlorine and anolyte liquor from all of the cells in the electrolyzer through the substantially horizontal header to a chlorine disengaging chamber; (4) separating the chlorine from the anolyte liquor in the chlorine disengaging chamber; (5) recovering chlorine from the chlorine disengaging chamber; (6) recovering anolyte liquor from the chlorine disengaging chamber; (7) adding concentrated brine to the anolyte liquor whereby to form feed brine; (8) returning the feed brine to the electrolyzer; (9) recovering hydrogen and catholyte liquor from individual cells of the electrolyzer through individual vertical risers at a catholyte liquor flow rate sufficient to provide flow characterized by bubbles of gas moving along at substantially the same velocity as the catholyte liquor while substantially avoiding flows characterized by periodic waves of high velocity frothy slugs and alternating plugs of liquid and gas; (10) collecting the hydrogen and catholyte liquor from the individual risers in a substantially horizontal header; (11) transporting the collected hydrogen and catholyte liquor from all of the cells in the electrolytzer through the substantially horizontal header to a hydrogen disengaging chamber; (12) recovering hydrogen from the hydrogen disengaging chamber; (13) recovering catholyte liquor from the hydrogen disengaging chamber. (14) adding water to the catholyte liquor in the ratio of 1 part of water per 40 parts of return catholyte liquor to part 1 part of water per 200 parts of return catholyte liquor; and (15) returning the return catholyte liquor to the individual electrolytic cells.

Claim 11

In a method of operating a bipolar electrolyzer comprising feeding a brine electrolyte to anolyte compartments of the individual electrolytic cells and an aqueous electrolyte to catholyte compartments of the individual electrolytic cells, imposing an electrical potential across the electrolyzer, recovering chlorine and anolyte liquor from the anolyte compartment and hydrogen and aqueous alkali metal hydroxide from the catholyte compartment, the improvement comprising: (1) recovering chlorine and anolyte liquor from individual cells of the electrolyzer through individual vertical risers at an anolyte liquor flow rate sufficient to provide flow characterized by bubbles of gas moving along at substantially the same velocity as the anolyte liquor, while substantially avoiding flow characterized by periodic waves of high velocity frothy slugs and alternating plugs of liquid and gas; (2) collecting the chlorine and anolyte liquor from the individual risers in a substantially horizontal header; (3) transporting the collected chlorine and anolyte liquor from all of the cells in the electrolyzer through the substantially horizontal header to a chlorine disengaging chamber; (4) separating the chlorine from the anolyte liquor in the chlorine disengaging chamber; (5) recovering chlorine from the chlorine disengaging chamber; (6) recovering anolyte liquor from the chlorine disengaging chamber; (7) adding concentrated brine to the anolyte liquor whereby to form feed brine; (8) returning the feed brine to the electrolyzer; (9) recovering hydrogen and catholyte liquor from individual cells of the electrolyzer through individual vertical risers at a catholyte liquor flow rate sufficient to provide flow characterized by bubbles of gas moving along at substantially the same velocity as the catholyte liquor while substantially avoiding flows characterized by periodic waves of high velocity frothy slugs and alternating plugs of liquid and gas; (10) collecting the hydrogen and catholyte liquor from the individual risers in a substantially horizontal header; (11) transporting the collected hydrogen and catholyte liquor from all of the cells in the electrolytzer through the substantially horizontal header to a hydrogen disengaging chamber; (12) recovering hydrogen from the hydrogen disengaging chamber; (13) recovering catholyte liquor from the hydrogen disengaging chamber. (14) adding water to the catholyte liquor in the ratio of 1 part of water per 40 parts of return catholyte liquor to part 1 part of water per 200 parts of return catholyte liquor; and (15) returning the return catholyte liquor to the individual electrolytic cells.