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

A process for production of concentrated alkali metal hydroxide aqueous solution and electrical energy utilizing a plurality of hybrid cells operated hydrodynamically in series, each hybrid cell having an anode compartment and a cathode compartment separated by a diffusion barrier which is selectively permeable to cations, each said anode compartment being defined, in part, by a first surface of a gas diffusion anode and a first surface of a diffusion barrier, each said cathode compartment being defined, in, part, by a first surface of a gas diffusion cathode and a second surface of a diffusion barrier, 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;

• (a) introducing flow of an aqueous alkali metal hydroxide solution as anolyte to the anode compartment of said first hybrid cell, said anolyte flowing through the anode compartments of the hybrid cells in sequence from the first hybrid cell to the last hybrid cell of the series;
• (b) introducing flow of an aqueous fluid medium receptive to alkali metal ions as catholyte to the cathode compartment of the last hybrid, said catholyte flowing through the cathode compartments of the hybrid cells in sequence from the last hybrid cell of the series to the first hybrid cell of the series;
• (c) supplying hydrogen gas to a second surface of each said gas diffusion anodes;
• (d) supplying oxygen-containing gas to a second surface of each said gas diffusion cathodes;
• (e) causing alkali metal cations to pass from the anolyte through each cation selective diffusion barrier into the catholyte by electrically interconnecting each gas diffusion anode and each gas diffusion cathode through an external load, thereby generating electrical energy by oxidation of the hydrogen gas supplied to each gas diffusion anode second surface and the reduction of the oxygen in the oxygen-containing gas supplied to each gas diffusion cathode second surface;
• (f) withdrawing catholyte, which is more concentrated in respect to alkali metal hydroxide than the aqueous fluid medium introduced to the cathode compartment of the last hybrid cell of the series, from the cathode compartment of the first hybrid cell of the series;
• and,
• (g) withdrawing 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, from the anode compartment of the last hybrid cell of the series.

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 first surface of a gas diffusion cathode and a second surface of a said diffusion barrier;
• (c) supplying hydrogen gas to a second surface of said diffusion anode;
• (d) supplying oxygen-containing gas to a second surface of said gas diffusion cathode;
• (e) 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-containing gas supplied to the gas diffusion cathode second surface;
• (f) withdrawing, from between the gas diffusion cathode first surface and the diffusion barrier second surface, a concentrated alkali metal hydroxide aqueous solution.

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 first surface of a gas diffusion cathode and a second surface of a said diffusion barrier;
• (c) supplying hydrogen gas to a second surface of said diffusion anode;
• (d) supplying oxygen-containing gas to a second surface of said gas diffusion cathode;
• (e) 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 supplied to the gas diffusion cathode second surface;
• (f) withdrawing, from between the gas diffusion cathode first surface and the diffusion barrier 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,
• (g) withdrawing, from between the gas diffusion anode first surface and the diffusion barrier first surface, and 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.

A process for production of concentrated sodium hydroxide 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 first surface of a gas diffusion cathode and a second surface of said diffusion barrier;
• (c) supplying hydrogen gas to a second surface of said gas diffusion anode;
• (d) supplying oxygen-containing gas to a second surface of said gas diffusion cathode;
• (e) causing sodium ions to pass from the anolyte through the sodium ion selective diffusion barrier and into the catholyte 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 the oxygen in the oxygen-containing gas supplied to the gas diffusion cathode second surface;
• (f) withdrawing, from between the gas diffusion cathode first surface and the diffusion barrier second surface, catholyte, which is more concentrated in sodium hydroxide than the aqueous effluent of said chloralkali cell introduced between the gas diffusion anode first surface and the diffusion barrier first surface;
• and,
• (g) withdrawing, from between the gas diffusion anode first surface and the diffusion barrier first surface, anolyte, which is less concentrated in sodium hydroxide than the aqueous effluent of said chloralkali cell introduced between the gas diffusion anode first surface and the diffusion barrier first surface.

A process for production of concentrated alkali metal hydroxide aqueous solution and electrical energy utilizing at least one hybrid cell having an anode compartment and a cathode compartment separated by a diffusion barrier which is selectively permeable to cations, said anode compartment being defined, in part, by a first surface of a gas diffusion anode and a first surface of the diffusion barrier, said cathode compartment being defined, in part, by a first surface of a gas diffusion cathode and a second surface of the diffusion barrier, said process comprising the steps of:

• (a) introducing flow of an aqueous alkaline metal hydroxide solution as anolyte into said anode compartment;
• (b) introducing flow of an aqueous fluid medium receptive to alkali metal ions as catholyte into said cathode compartment;
• (c) supplying hydrogen gas to a second surface of said gas diffusion anode;
• (d) supplying oxygen-containing gas to second surface of said gas diffusion cathode;
• (e) 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;
• (f) withdrawing, from said cathode compartment, catholyte which is more concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced into the anode compartment;
• and,
• (g) withdrawing, from said anode compartment, anolyte which is less concentrated in alkali metal hydroxide than the aqueous alkali metal hydroxide solution introduced into the anode compartment.

A process for production of concentrated alkali metal aqueous solution from the aqueous effluent of a chloralkali cell and electrical energy utilizing at least one hybrid cell having an anode compartment and a cathode compartment separated by a diffusion barrier which is selectively permeable to cations, said anode compartment being defined, in part, by a first surface of a gas diffusion anode and a first surface of the diffusion barrier, said cathode compartment being defined, in part, by a first surface of a gas diffusion cathode and a second surface of the diffusion barrier, said process comprising the steps of:

• (a) introducing flow of the chloralkali cell aqueous effluent as anolyte into said anode compartment, said chloralkali cell aqueous effluent comprising sodium hydroxide and sodium chloride;
• (b) introducing flow of an aqueous fluid medium receptive to sodium ions as catholyte into said cathode compartment;
• (c) supplying hydrogen gas generated by said chloralkali cell to a second surface of said gas diffusion anode;
• (d) supplying air to a second surface of said gas diffusion cathode;
• (e) causing sodium ions 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 to the chloralkali cell thereby generating electrical energy by oxidation of the hydrogen gas supplied to the gas diffusion and reduction of oxygen gas from the air supplied to the gas diffusion cathode;
• (f) withdrawing, from said cathode compartment, catholyte which is more concentrated in sodium hydroxide than the aqueous effluent from the chloralkali cell introduced into the anode compartment;
• and,
• (g) withdrawing, from said anode compartment, anolyte which is less concentrated in sodium hydroxide than the aqueous effluent from the chloralkali cell introduced into the anode compartment.

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 and disposed between said gas diffusion anode first surface and said gas diffusion cathode first surface;
• (d) 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;
• (e) means for introducing flow of an aqueous fluid medium receptive to alkali metal ions as catholyte between the gas diffusion cathode first surface and the diffusion barrier second surface;
• (f) means for supplying hydrogen gas to the gas diffusion anode second surface;
• (g) means for supplying oxygen-containing gas to the gas diffusion cathode second surface;
• (h) 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;
• (i) means for withdrawing, from between the gas diffusion cathode first surface and the diffusion barrier second surface, a concentrated alkali metal hydroxide solution.

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 and disposed between said gas diffusion anode first surface and said gas diffusion cathode first surface;
• (d) 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;
• (e) means for introducing flow of an aqueous fluid medium receptive to alkali metal ions as catholyte between the gas diffusion cathode first surface and the diffusion barrier second surface;
• (f) means for supplying hydrogen gas to the gas diffusion anode second surface;
• (g) means for supplying oxygen-containing gas to the gas diffusion cathode second surface;
• (h) 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;
• (i) means for withdrawing, from between the gas diffusion cathode first surface and the diffusion barrier 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,
• (g) means for withdrawing, from between the 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.

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 a first and a second surface;
• (c) 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, and said gas diffusion cathode first surface and said diffusion barrier second surface defining, in part, a cathode compartment;
• (d) means for introducing flow of an alkaline metal hydroxide solution, as anolyte, into said anode compartment;
• (e) means for introducing flow of an aqueous fluid medium receptive to alkali metal ions, as catholyte, into said cathode compartment;
• (f) means for supplying hydrogen gas to the gas diffusion anode second surface;
• (g) means for supplying oxygen-containing gas to the gas diffusion cathode second surface;
• (h) means, electrically interconnecting the gas diffusion anode and the gas diffusion cathode through an external load for causing alkali metal cations to pass from the anolyte through the cation selective diffusion barrier into the catholyte, 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;
• (i) 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
• (j) 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.

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 diffusion barrier having a first and a second surface, said diffusion barrier being selectively permeable to cations and disposed between said gas diffusion anode first surface and said gas diffusion cathode first surface;
• (c) means, interconnected with the chloralkali cell cathode compartment outlet means for introducing flow of the aqueous alkali metal hydroxide solution from the chloralkali 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 gas diffusion cathode first surface and the diffusion barrier second surface;
• (e) means interconnected with said chloralkali cell anode for withdrawing hydrogen gas therefrom and supplying said hydrogen gas to the gas diffusion anode second surface;
• (f) means for supplying oxygen-containing gas to the gas diffusion cathode second surface;
• (g) 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 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;
• (h) means for withdrawing, from between the gas diffusion cathode first surface and the diffusion barrier 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
• (i) 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.