Monopolar electrochemical cell having a novel electric current transmission element

Claim 2

A monopolar cell of the type having two end members and at least one monopolar unit positioned between said end members, said monopolar unit comprising: two substantially parallel, substantially planar electrode components spaced from each other; a sealing means around the perimeter of the unit; and a means to distribute electrical energy to each of said electrode components, said distributing means comprising: an electrically conductive, substantially rigid, one-piece, cast metal, electric current transmission elemetn disposed in the space between said spaced electrode components, said transmission element being at least co-extensive with said electrode components and having at least one metallic electrical connection means suitable for conducting electrical current into or out of said transmission element; wherein said transmission element has a plurality of substantially solid electrically conductive bosses spaced from each other vertically and horizontally and distributed over each of its surfaces co-extensive with said electrode components; said bosses projecting a predetermined distance outwardly from the one-piece, cast metal, electric current transmission element into electrolyte chambers adjacent to the one-piece, cast metal, electric current transmission element, wherein at least a portion of said bosses support said electrode components and are mechanically and electrically connected either directly or indirectly to the electrode components.

Claim 3

A monopolar electrochemical cell assembly wherein a plurality of monopolar units of claim 1 are positioned between two end members.

Claim 4

The monopolar electrochemical cell assembly of claim 2 wherein said electrode units are separated by an ion exhange membrane.

Claim 5

The monopolar unit of claim 1 wherein at least one electrode component is an electrode.

Claim 6

The monopolar unit of claim 4 wherein at least one electrode is catalytically coated.

Claim 7

The monopolar unit of claim 1 wherein at least one electrode component is hydraulically permeable.

Claim 8

The monopolar unit of claim 1 wherein at least one electrode component is an uncatalyzed current collector.

Claim 9

The monopolar unit of claim 1 wherein at least one electrode component is substantially non-compressible.

Claim 10

The monopolar unit of claim 1 wherein at least one electrode component is resiliently compressible.

Claim 11

The monopolar unit of claim 1 wherein at least one electrode component is directly connected to the electric current transmission element.

Claim 12

The monopolar unit of claim 1 wherein at least one electrode component is indirectly connected to the electric current transmission element through a liner.

Claim 13

The monopolar unit of claim 1 wherein the electric current transmission element is hydraulically impermeable.

Claim 14

The monopolar unit of claim 1 wherein the electric current transmission element is composed of a metal selected from the group consisting of: iron, steel, stainless steel, nickel, aluminum, copper, magnesium, lead, alloys of each and alloys thereof.

Claim 15

The monopolar unit of claim 1 wherein the electric current transmission means is selected from the group consisting of ferrous metals.

Claim 16

The monopolar unit of claim 1 wherein the bosses have a frustroconical shape.

Claim 17

The monopolar unit of claim 1 wherein the bosses have an elongated rib shape.

Claim 18

The monopolar unit of claim 1 including two liners contacting at least the end surface of at least a portion of the bosses on the opposing surfaces of the electric current transmission means which would otherwise be exposed to the electrolyte, said liners being: (a) an electrically conductive, substantially completely corrosion resistant material, (b) formed so as to fit over and around the bosses, (c) connected to the electric current transmission element at the bosses, and (d) depressed sufficiently around the spaced bosses toward the electric current transmission element in the spaces between the bosses so as to allow circulation of the electrolyte between the lined electric current transmission element and the electrode component.

Claim 19

The monopolar unit of claim 17 wherein the liners in opposing compartments have at least one connection to allow electrolyte flow between compartments.

Claim 20

The monopolar unit of claim 17 wherein the liner is metallic and is co-extensive with the sealing means.

Claim 21

The monopolar unit of claim 17 wherein the liner is connected to the bosses by welding through a metal intermediate disposed between the bosses and the liner, the metal of the metal intermediate being not only weldable itself, but also being weldably compatible with both the electric current transmission element and liner to the point of being capable of forming a ductile solid solution with them at welds of them upon their welding.

Claim 22

The monopolar unit of claim 17 wherein the electric current transmission element is a ferrous material and the liner is a metallic material selected from the group consisting of titanium, vanadium, tantalum, columbium, hafnium, zirconium, and alloys thereof.

Claim 23

The monopolar unit of claim 17 wherein the liner is nickel, stainless steel, chromium, monel, or an alloy thereof.

Claim 24

The monopolar unit of claim 1 wherein the metallic electrical connection means is attached to the peripheral edge of the electric current transmission element

Claim 25

The monopolar unit of claim 1 wherein the metallic electrical connection means is attached to a portion of the electric current transmission element co-extensive with the electrode component.

Claim 26

The monopolar unit of claim 1 wherein the sealing means is a peripheral edge of the electric current transmission element and has a thickness at least about two times greater than the thickness of the central portion of the electric current transmission element.

Claim 27

The monopolar unit of claim 1 wherein the sealing means is a peripheral edge of the electric current transmission element and is not more than about 10 centimeters thick and wherein the central portion of the electric current transmission element is at least about 0.5 centimeters thick.

Claim 28

The monopolar unit of claim 1 wherein the electric current transmission element has openings connecting opposing sides of the electric current transmission element.

Claim 29

The monopolar unit of claim 27 wherein the openings occupy no more than about 60 percent of the total surface area of the electric current transmission element.

Claim 30

The monopolar unit of claim 28 wherein the openings occupy no more than about 20 percent of the total surface area of the electric current transmission element.

Claim 31

The monopolar unit of claim 1 wherein the sealing means is a unitized body with the electric current transmission element.

Claim 32

The monopolar unit of claim 1 wherein a portion of the sealing means is unitary with the electric current transmission element and a portion of the sealing means is a separate element.

Claim 33

The monopolar unit of claim 1 wherein the sealing means is a plurality of assembled parts.

Claim 34

The monopolar unit of claim 1 wherein the sealing means is a window-shaped element and covers the electric current transmission element.

Claim 35

The monopolar unit of claim 1 wherein the sealing means is a gasket.

Claim 36

The monopolar unit of claim 1 wherein at least one of the electrode components is hydraulically permeable and contacts a gas chamber positioned between the electric current transmission element and the electrode component.

Claim 37

The monopolar unit of claim 35 wherein each of the electrode components is hydraulically permeable and contacts a gas chamber positioned between the electric current transmission element and the electrode component.

Claim 38

The cell of claim 1, wherein the transmission element is more rigid than said electrode components.

Claim 39

A monopolar unit for an electrolysis cell comprising: an electric current transmission element in the form of a substantially planar, continuous electrically conductive one-piece, cast metal, body having a plurality of bosses over opposite surfaces thereof, stamped metal liners having a profile matching the body wherein said liner is made of a corrosion resistant metal and disposed over the opposite surfaces of said electric current transmission element; foraminous electrode components disposed over said liners and resting over said raised portions, said electrode components, said liners and said body being electrically connected together in correspondence to each of said bosses; and an electrical connection means for connecting a pole of an electric current power supply on at least one of the edges of said body.

Claim 40

A monopolar unit for an electrolysis cell comprising: an electric current transmission element in the form of a substantially planar, continuous electrically conductive one-piece, cast metal, body having a plurality of bosses over opposite surfaces thereof, stamped metal liners having a profile matching the body wherein said liner is made of a corrosion resistant metal and disposed over the opposite surfaces of said electric current transmission element; foraminous electrode components disposed over said liners and resting over said raised portions, said electrode components, said liners and said body being electrically connected together in correspondence to each of said bosses; and an electrical connection means for connecting a pole of an electric current power supply on at least one of the edges of said body.

Claim 41

An electrochemical process in a monopolar electrochemical cell assembly of the type having two end members and one electrode unit positioned between said end members, said unit having at least two substantially parallel, substantially planar, similarly charged electrode components spaced from each other, a sealing means around the perimeter of the unit and a means to distribute electrical energy to each of said electrode components, said distributing means comprising: an electrically conductive, substantially rigid and planar one-piece, cast metal, electric current transmission element disposed in the space between said spaced electrode components, said transmission element at least being co-extensive with said electrode components and having a metallic electrical connection means attached to it, said connection means being suitable for conducting electrical current into or out of said transmission element on at least one side edge thereof said transmission element being electrically and mechanically connected to each of said electrode components at a plurality of points spaced throughout the entire surface of each of said electrode components, said transmission element having a plurality of electrically conductive, substantially solid bosses spaced from each other vertically and horizontally and distributed over each of its surfaces co-extensive with the said electrode components and projecting a predetermined distance outwardly from the electric current transmission elements into electrolyte chamber adjacent to the electric current transmission element, said process comprising: (a) flowing electrical current from a power supply to the electric current transmission element; (b) flowing electrical current from the electric current transmission element to two electrodes electrically attached to said electric current transmission element; (c) flowing electrical current from each of the electrodes through an electrolyte and a separator to an end member, said electrical current being of a sufficient voltage to cause electrolysis of the electrolyte to occur; (d) removing the products of electrolysis from the cell; and (e) removing depleted electrolyte from the cell.

Claim 42

An electrochemical process in a monopolar electrochemical cell assembly of the type having two end members and one electrode unit positioned between said end members, said unit having at least two substantially parallel, substantially planar, similarly charged electrode components spaced from each other, a sealing means around the perimeter of the unit and a means to distribute electrical energy to each of said electrode components, said distributing means comprising: an electrically conductive, substantially rigid and planar one-piece, cast metal, electric current transmission element disposed in the space between said spaced electrode components, said transmission element at least being co-extensive with said electrode components and having a metallic electrical connection means attached to it, said connection means being suitable for conducting electrical current into or out of said transmission element on at least one side edge thereof said transmission element being electrically and mechanically connected to each of said electrode components at a plurality of points spaced throughout the entire surface of each of said electrode components, said transmission element having a plurality of electrically conductive, substantially solid bosses spaced from each other vertically and horizontally and distributed over each of its surfaces co-extensive with the said electrode components and projecting a predetermined distance outwardly from the electric current transmission elements into electrolyte chamber adjacent to the electric current transmission element, said process comprising: (a) flowing electrical current from a power supply to the electric current transmission element; (b) flowing electrical current from the electric current transmission element to two electrodes electrically attached to said electric current transmission element; (c) flowing electrical current from each of the electrodes through an electrolyte and a separator to an end member, said electrical current being of a sufficient voltage to cause electrolysis of the electrolyte to occur; (d) removing the products of electrolysis from the cell; and (e) removing depleted electrolyte from the cell.

Claim 43

An electrochemical process in a monopolar electrochemical cell assembly of the type having two end members and a plurality of electrode units positioned between said end members, said unit having at least two substantially parallel, substantially planar, similarly charged electrode components spaced from each other, a sealing means around the perimeter of the unit and a means to distribute electrical energy to each of said electrode components, said distributing means comprising: an electrically conductive, substantially rigid and planar one-piece, cast metal, electric current transmission element disposed in the space between said spaced electrode components, said transmission element at least being co-extensive with said electrode components and having a metallic electrical connection means attached to it, said connection means being suitable for conducting electrical current into or out of said element on at least one side edge of said transmission element said transmission element being electrically and mechanically connected to each of said electrode components at a plurality of points spaced throughout the entire surface of each of said electrode components, wherein the said element has a plurality of electrically conductive, substantially solid bosses spaced from each other vertically and horizontally and distributed over each of its surfaces co-extensive with the said electrode components and projecting a predetermined distance outwardly from the electric current transmission element into electrolyte chamber adjacent to the electric current transmission element, wherein the process comprises: (a) flowing electrical current from a power supply to the electric current transmission element; (b) flowing electrical current from the electric current transmission element to two electrodes electrically attached to said electric current transmission element; (c) flowing electrical current from each of the electrodes through an electrolyte and a separator to an adjacent electrode unit, said electrical current being of a sufficient voltage to cause electrolysis of the electrolyte to occur; and (d) removing the products of electrolysis from the cell.

Claim 44

An electrochemical process in a monopolar electrochemical cell assembly of the type having two end members and a plurality of electrode units positioned between said end members, said unit having at least two substantially parallel, substantially planar, similarly charged electrode components spaced from each other, a sealing means around the perimeter of the unit and a means to distribute electrical energy to each of said electrode components, said distributing means comprising: an electrically conductive, substantially rigid and planar one-piece, cast metal, electric current transmission element disposed in the space between said spaced electrode components, said transmission element at least being co-extensive with said electrode components and having a metallic electrical connection means attached to it, said connection means being suitable for conducting electrical current into or out of said element on at least one side edge of said transmission element said transmission element being electrically and mechanically connected to each of said electrode components at a plurality of points spaced throughout the entire surface of each of said electrode components, wherein the said element has a plurality of electrically conductive, substantially solid bosses spaced from each other vertically and horizontally and distributed over each of its surfaces co-extensive with the said electrode components and projecting a predetermined distance outwardly from the electric current transmission element into electrolyte chamber adjacent to the electric current transmission element, wherein the process comprises: (a) flowing electrical current from a power supply to the electric current transmission element; (b) flowing electrical current from the electric current transmission element to two electrodes electrically attached to said electric current transmission element; (c) flowing electrical current from each of the electrodes through an electrolyte and a separator to an adjacent electrode unit, said electrical current being of a sufficient voltage to cause electrolysis of the electrolyte to occur; and (d) removing the products of electrolysis from the cell.

Claim 45

The process of claim 40 including maintaining the electrolyte at a temperature greater than about 80° celcius.

Claim 46

The process of claim 40 including maintaining the electrolyte under a pressure of from about one Kg/cm 2 to about 7 Kg/cm 2 .

Claim 47

The process of claim 40 wherein a cation exchange membrane is the separator.

Claim 48

The process of claim 43 wherein the cation exchange membrane has sulfonic acid groups as its functional groups.

Claim 49

The process of claim 43 wherein the cation exchange membrane has carboxylic acid groups as its functional groups.

Claim 50

The process of claim 43 wherein the cation exchange membrane comprises a combination of sulfonic acid groups and carboxylic acid groups.

Claim 51

The process of claim 43 wherein the cation exchange membrane is reinforced to impair deforming during electrolysis conditions.

Claim 52

The process of claim 43 wherein the cation exchange membrane is reinforced to decrease the electrical resistivity of said membrane.

Claim 53

The process of claim 40 wherein sodium chloride aqueous solution electrolyzed is maintained at a pH between about 0.5 and about 5.0 during electrolysis.

Claim 54

The process of claim 40 wherein the brine solution electrolyzed in the cells contains no more than about 0.08 milligram per liter of calcium ion.

Claim 55

The process of claim 40 wherein calcium ion is removed from the brine to a level of concentration of no greater than about 0.08 milligram per liter prior to the brine being electrolyzed by a multivalent cation removal process which includes passage of the brine through at least one chelating ion exchange resin bed.

Claim 56

The process of claim 40 which includes electrolyzing brine which contains carbon dioxide in concentrations no greater than about 70 parts per million as measured just prior to the brine being electrolyzed when the pH of the brine is maintained at a level lower than 3.5 by a process which includes the addition of hydrochloric acid to the brine prior to its being electrolyzed.

Claim 57

The process of claim 40 which further comprises operating the electrolysis cell at an electrical current density of from about 0.5 to about 5.0 amperes per square inch of anode surface.

Claim 58

The process of claim 40 wherein the electrolysis is carried out while circulating the electrolyte through the electrolyte chamber via forced circulation.

Claim 59

The process of claim 40 wherein aqueous sodium hydroxide solution is produced with a sodium chloride content of no more than 350 ppm based on 100% sodium hydroxide.

Claim 60

The process of claim 40 wherein the electrolysis is carried out while circulating the electrolyte through the electrolyte chamber via a gas lift method.

Claim 61

The process of claim 40 wherein at least one of the electrode components is pressed against or bonded to the separator.

Claim 62

An electrolyte monopolar cell having two end members and at least one monopolar unit positioned between said end members, said unit comprising: (a) a pair of substantially planar, parallel relatively less massive electrode sheets; and (b) means to distribute electrical energy to each of said electrode sheets disposed between said pair and comprising a relatively more massive, one-piece, cast metal, electroconductive plate extending along and between said electrode sheets and having a plurality of electroconductive projections extending outwardly from said plate and into electrical and supporting contact with said less massive electrode sheets and providing electrolyte space between the plate and the sheet and the ion exchange membranes separating said unit from said end members.

Claim 63

An electrolyte monopolar cell having two end members and at least one monopolar unit positioned between said end members, said unit comprising: (a) a pair of substantially planar, parallel relatively less massive electrode sheets; and (b) means to distribute electrical energy to each of said electrode sheets disposed between said pair and comprising a relatively more massive, one-piece, cast metal, electroconductive plate extending along and between said electrode sheets and having a plurality of electroconductive projections extending outwardly from said plate and into electrical and supporting contact with said less massive electrode sheets and providing electrolyte space between the plate and the sheet and the ion exchange membranes separating said unit from said end members.

Claim 64

The cell of claim 58 wherein the more massive plate is covered with a thin layer which protects the metal plate from electrolyte corrosion.

Claim 65

The cell of claim 58 wherein the thickness of the plate is great enough to provide substantially lower electrical resistance than that of the electrode sheet.

Claim 66

The cell of claim 58 wherein the plate comprises a ferrous metal and one of the electrode sheets is nickel.