High rate electrochemical devices

Abstract

A device and system useful for highly efficient chemical and electrochemical reactions is described. The device comprises a preferably porous electrode and a plurality of suspended nanoparticles diffused within the void volume of the electrode when used within an electrolyte. The device is suitable within a system having a first and second chamber preferably positioned vertically or in other special arrangements with respect to each other, and each chamber containing an electrode and electrolyte with suspended nanoparticles therein. When reactive metal particles are diffused into the electrode structure and suspended in electrolyte by gasses, a fluidized bed is established. The reaction efficiency is increased and products can be produced at a higher rate. When an electrolysis device can be operated such that incoming reactants and outgoing products enter and exit from opposite faces of an electrode, reaction rate and efficiency are improved. Ideally, this device and system can be used to rapidly produce significant quantities of high purity hydrogen gas with minimal electricity cost.

1 . A device suitable for use in an electrochemical and/or catalytic application, the device comprising a first component and a second component, said first component being at least partially exposed to a reaction medium during use, the second component comprising a plurality of reactive metal nanoparticles suspended in the reaction medium and diffused into the first component when the device is in use. 
     
     
         2 . The device of  claim 1 , wherein the first component comprising a metal having a substantial void volume. 
     
     
         3 . The device of  claim 1 , wherein at least a substantial portion of the plurality of reactive metal particles comprises particles have an average diameter of less than about 100 nm. 
     
     
         4 . The device of  claim 1 , wherein at least a portion of the reactive metal particles comprise nanoparticles having an oxide shell. 
     
     
         5 . The device of  claim 1 , wherein the plurality of reactive metal particles comprise one or more of the metals from groups 3-16, lanthanides, combinations thereof, and alloys thereof. 
     
     
         6 . The device of  claim 2 , wherein the first component is a sintered porous metal plate. 
     
     
         7 . The device of  claim 2 , wherein the first component is a reticulate metal plate. 
     
     
         8 . The device of  claim 1 , wherein the first component comprises one or more of the metals from groups 3-16, lanthanides, combinations thereof, and alloys thereof. 
     
     
         9 . The device of  claim 1 , wherein the device comprises an electrolysis cell whereby reaction products are produced when energy is applied. 
     
     
         10 . The device of  claim 9 , wherein the device is configured to generate hydrogen from water. 
     
     
         11 . An electrochemical system, comprising: a first chamber comprising an electrode, electrolyte, and metal catalyst particles arranged such that, when in operation, a zone in the nature of a fluidized bed may be established in the electrolyte and gaseous products produced by the supply of electricity to the system may be removed from the first chamber; 
     
     
         12 . The electrochemical system of  claim 11 , further comprising: a second chamber, the first chamber being partitioned from the second chamber by a separator, the second chamber comprising an electrode, electrolyte, and metal catalyst particles arranged such that, when in operation, a fluidized bed may be established, and gaseous products are removed from the second chamber. 
     
     
         13 . The electrochemical system of  claim 12 , wherein the first and second chambers are arranged with the first chamber at least partially above the second chamber, at least partially around the second chamber, at least partially displaced laterally with respect to the second chamber, or at least partially coiled around the second chamber. 
     
     
         14 . The electrochemical system of  claim 13 , wherein the first chamber is positioned at least partially above the second chamber, the second chamber having an inlet and an outlet and being configured such that electrolyte circulated through the second chamber when in use may flow from the inlet past the second chamber electrode to the outlet in a generally transverse direction and, when in use, reactants may flux in the first chamber and gases generated in the first chamber may move upwardly for collection. 
     
     
         15 . The electrochemical system of  claim 14 , further comprising a pump to circulate at least a portion of the electrolyte in the second chamber. 
     
     
         16 . The electrochemical system of  claim 13 , wherein the system is configured and adapted to permit useful operation while being oriented such that the first chamber is positioned at least partially horizontally displaced from the second chamber. 
     
     
         17 . The electrochemical system of  claim 11 , wherein the electrolyte in the first chamber is generally confined to that space. 
     
     
         18 . The electrochemical system of  claim 14 , further comprising a plurality of reactive metal particles in the upper chamber suitably sized to permit particle diffusion into voids within one or both of the electrodes. 
     
     
         19 . The system of  claim 11 , wherein at least a substantial portion of the reactive metal particles have an average diameter of less than one micrometer. 
     
     
         20 . The system of  claim 19 , wherein the nanoparticles have an average diameter of less than about 100 nm. 
     
     
         21 . The system of  claim 11 , wherein the plurality of reactive metal particles comprises a metal selected from the group consisting of metals from groups 3-16, lanthanides, combinations thereof, and alloys thereof. 
     
     
         22 . The system of  claim 3 , wherein the separator comprises a membrane formed from an ionically conductive material. 
     
     
         23 . The system of  claim 22 , wherein the separator membrane comprises multiple layers of ionically conductive material to increase mechanical, chemical, and electrochemical durability. 
     
     
         24 . The system of  claim 22 , wherein the separator membrane is capable of at least 5 A/cm 2  flux. 
     
     
         25 . The system of  claim 14 , wherein the electrolyte flow channel of the second chamber contains a deflector to aid in transport to the separator surface. 
     
     
         26 . The system of  claim 3 , wherein the first chamber electrode is configured to generate hydrogen from water and the second chamber electrode is configured to generate oxygen from water. 
     
     
         27 . An electrochemical system, comprising: a first chamber and a second chamber, the first chamber being disposed within the second chamber when the system is oriented such that it can be used in at least one useful purpose, the first chamber comprising an electrode, electrolyte, and metal catalyst particles arranged such that, when in operation, a fluidized bed may be established, and gaseous products may be removed from the upper portion of the first chamber; the second outer chamber comprising an electrode, electrolyte, and metal catalyst particles arranged such that, when in operation, a fluidized bed may be established, and gaseous products are removed from the upper portion of the second chamber. 
     
     
         28 . The system of  claim 27 , further comprising a separator membrane disposed between the first and second chambers. 
     
     
         29 . The system of  claim 27 , further comprising electrical contacts on the first and second electrodes to permit the flow of electricity therebetween. 
     
     
         30 . The system of  claim 27 , wherein the electrolyte in the first chamber is generally confined to that space. 
     
     
         31 . The system of  claim 27 , wherein the electrolyte in the second chamber is generally confined to that space. 
     
     
         32 . The system of  claim 27 , wherein at least a substantial portion of the reactive metal particles have an effective diameter of less than one micrometer. 
     
     
         33 . The system of  claim 27 , wherein the particles have a diameter of less than about 100 nm. 
     
     
         34 . The system of  claim 27 , wherein the plurality of reactive metal particles comprises a metal selected from the group consisting of metals from groups 3-16, lanthanides, combinations thereof, and alloys thereof. 
     
     
         35 . The system of  claim 28 , wherein the separator membrane comprises an ionically conductive material. 
     
     
         36 . The system of  claim 35 , wherein the separator membrane comprises multiple layers of ionically conductive material to increase mechanical, chemical, and electrochemical durability. 
     
     
         37 . The system of  claim 27 , wherein the first chamber electrode is configured to generate hydrogen from water and the second chamber electrode is configured to generate oxygen from water. 
     
     
         38 . The system of  claim 27 , wherein a multiple of first inner chambers are placed within a single outer chamber, and where each inner chamber is electrically connected in a circuit with the outer chamber. 
     
     
         39 . The system of  claim 38 , wherein the first chamber electrode is configured to generate hydrogen from water and the second chamber electrode is configured to generate oxygen from water. 
     
     
         40 . An electrochemical system, comprising: a first chamber and a second chamber, the first chamber being separated from the second chamber by a separator membrane when the system is oriented such that it can be used in at least one useful purpose, the first chamber comprising a current collector, electrolyte, and metal catalyst particles arranged such that, when in operation, a fluidized bed may be established, and gaseous products may be removed from the upper portion of the first chamber; the second outer chamber comprising an electrode, electrolyte, and metal catalyst particles arranged such that, when in operation, a fluidized bed may be established, and gaseous products are removed from the upper portion of the second chamber. 
     
     
         41 . The system of  claim 40 , further comprising electrical contacts on the first and second electrodes to permit the flow of electricity therebetween. 
     
     
         42 . The system of  claim 40 , wherein the current collector and separator is wound into a spiral. 
     
     
         43 . The system of  claim 40 , wherein the electrolyte in the first chamber is generally confined to that space. 
     
     
         44 . The system of  claim 40 , wherein the electrolyte in the second chamber is generally confined to that space. 
     
     
         45 . The system of  claim 40 , wherein the separator is microporous. 
     
     
         46 . The system of  claim 40 , wherein the separator is nonporous and ion-conducting. 
     
     
         47 . The system of  claim 40 , wherein the separator membrane comprises multiple layers of ionically conductive material to increase mechanical, chemical, and electrochemical durability. 
     
     
         48 . The system of  claim 40 , wherein the separator is capable of permitting the transport of at least 5 A/cm 2  current flux. 
     
     
         49 . The system of  claim 40 , wherein the current collector is generally horizontal and the separator is generally vertical. 
     
     
         50 . The system of  claim 40 , wherein the current collector and separator are generally vertical. 
     
     
         51 . The system of  claim 40 , wherein the current collector and separator are conical. 
     
     
         52 . The system of  claim 40 , further comprising an insulating sheet. 
     
     
         53 . The system of  claim 40 , wherein the current collector is porous or reticulate. 
     
     
         54 . The system of  claim 40 , wherein the current collector protrudes into the fluidized bed. 
     
     
         55 . The system of  claim 40 , wherein at least a substantial portion of the reactive metal particles have an average diameter of less than one micrometer. 
     
     
         56 . The system of  claim 40 , wherein the particles have an average diameter of less than about 100 nm. 
     
     
         57 . The system of  claim 40 , wherein the plurality of reactive metal particles comprises a metal selected from the group consisting of metals from groups 3-16, lanthanides, combinations thereof, and alloys thereof. 
     
     
         58 . The system of  claim 40 , wherein the first chamber electrode is configured to generate hydrogen from water and the second chamber electrode is configured to generate oxygen from water. 
     
     
         59 . A method of operating an electrochemical cell, which cell comprises an anode chamber containing electrolyte and an anode, a cathode chamber containing electrolyte and a cathode, which method comprises suspending reactive metal particles in the anode chamber and/or the cathode chamber electrolyte, and applying electricity such that a circuit is formed. 
     
     
         60 . A method of  claim 59 , comprising suspending reactive nanoparticles in at least the cathode chamber and forming in the electrolyte in the cathode chamber a reaction zone in the nature of a fluidized bed to increase the effective area of the cathode and transport gas produced by the reaction from the chamber. 
     
     
         61 . A method of  claim 59 , comprising also suspending reactive nanoparticles in the anode chamber and forming therein a reaction zone in the nature of a fluidized bed to transport gas formed in the anode chamber from the chamber. 
     
     
         62 . A method of  claim 60 , wherein the electrolyte comprises an aqueous salt solution and the method comprises producing hydrogen in the cathode chamber and forming in that chamber from the hydrogen, electrolyte and particles a system akin to a fluidized bed whereby the hydrogen bubbles upwardly through the electrolyte, the method further comprising collecting the hydrogen so produced. 
     
     
         63 . A method of  claim 59 , wherein the particles have an average diameter of less than about 100 nm. 
     
     
         64 . A method of  claim 59 , wherein the particles have an average diameter of less than about 50 nm.