1. Field of the Invention
This invention relates to an electrode assembly for metal oxide reduction, and more specifically, this invention relates to a method and device for continuous replenishment of consumable anodes during electrolytic reduction of metal oxides.
2. Background of the Invention
Electrolysis drives a myriad of non-spontaneous processes, including the generation of hydrogen from water, reclamation of metal from their salts and oxides, and redox reactions generally. For example, electrochemical processes recover high purity metal/metals from waste feeds or ores. Aluminum production is one instance. Reclamation of uranium from used nuclear fuel is another.
Uranium metal reclamation via electrolysis requires specialized conditions, including the use of a molten salt (500-650° C.) electrolyte bath, an inert atmosphere environment, and a remotely operated facility if the uranium has been irradiated. Hazardous off-gases are also generated during electrolysis, including, but not limited to CO, CO2, O2 and Cl2, and combinations thereof.
A myriad of systems and methods exist for subjecting used nuclear fuel to redox reactions associated with electrolysis. Unfortunately, there are drawbacks to many of these systems. For example, the size and bulk of the anodes becomes a limiting factor as to how long the process can continue. Once the anodes are consumed, the process needs to be stopped and new anodes installed before reassembly and start-up can occur.
In other applications, non-consumable anodes fabricated from precious metal are used. This substantially increases the cost of the conversion process, especially if the anode is consumed during an off-normal cell operation. In addition, this possibility necessitates implementing a secondary protective circuit to avoid anode failure.
A need exists in the art for an anode assembly in electrolytic systems that does not need constant, direct hands-on supervision. The system should allow continuous redox processes by automatically deploying replacement anodes into an electrolyte (for example via gravity) without the need to first remove the assembly from the salt bath or otherwise shut down the reaction. Further, the system should effectively remove or otherwise manage any corrosive off-gases while confined to hot-cells, gloveboxes, and/or other enclosures.
An object of the invention is to provide anode assemblies for electrolytic reactions that overcome many of the disadvantages of the prior art.
Another object of the invention is to provide anode assemblies for use in electrolytic reduction systems. A feature of the invention is that the anode assemblies are removed only for system maintenance or anode replenishment. An advantage of the invention is that the system confers continual use, and consumption, of several anodes in serial physical contact with each other during electrolytic processes.
Still another object of the invention is to provide efficient anode assemblies for use in electrolytic processes. A feature of the invention is inclusion of a secondary electrical circuit. An advantage of the invention is that the secondary circuit mitigates parasitic electrochemical reactions at the anode.
Yet another object of the present invention is to provide an anode storage, transport, and consumption assembly. A feature of the invention is that it enables additional anodes to be added to a salt bath without removing the entire assembly from the bath. Anode replenishment may occur while the system continues to operate. Another feature is that it yields less corrosive off-gas compared to state of the art systems. An advantage of the invented system is that it is a self-perpetuating anode supply system that can be used in a hot-cell facility designed for treating irradiated materials.
Briefly, the invention provides an anode assembly comprising a pair of channels; anodes in slidable communication with the channel, conduit to direct carrier gas to the anode; and conduit to remove reaction gas from the anode.
Also provided is a method for continuously feeding anodes into a electrolytic bath, the method comprising stacking the anodes such that all of the anodes reside in the same plane and wherein the stack includes a bottom anode; contacting the bottom anode with the electrolytic bath for a time and at a current sufficient to cause the bottom anode to be consumed during an electrolytic process; conduit to direct carrier gas to the anode; and conduit to remove reaction gas; using gravity to replace the bottom anode with other anodes defining the stack, whereby the method can be operated remotely.
The invention together with the above and other objects and advantages will be best understood from the following detailed description of the preferred embodiment of the invention shown in the accompanying drawings, wherein:
The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings.
All numeric values are herein assumed to be modified by the term “about”, whether or not explicitly indicated. The term “about” generally refers to a range of numbers that one skilled in the art would consider equivalent to the recited value (e.g., having the same function or result). In many instances, the terms “about” may include numbers that are rounded to the nearest significant figure.
The recitation of numerical ranges by endpoints includes all numbers within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5).
The following detailed description should be read with reference to the drawings in which similar elements in different drawings are numbered the same. The drawings, which are not necessarily to scale, depict illustrative embodiments and are not intended to limit the scope of the invention.
As used herein, an element or step recited in the singular and preceded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly stated. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property.
The invented anode assembly is a salient feature of an electrolytic reducer. The electrolytic reducer converts the oxide fuel particles (e.g., used nuclear fuel, ore, etc.) in baskets to a metallic product. It comprises the following elements:
Typical electrolytic reactions for which the invented assembly facilitates include the cathodic reduction of metal salts or oxides (e.g., uranium oxides) such as those depicted in Equations 1-3, to wit:
UO2(s)+4e−=U(s)+2O2−(l) cathode reaction Eq. 1
C(s)+2O2−=CO2(g)+4e− anode reaction Eq. 2
UO2(s)+C(s)=U(s)+CO2(g) overall reaction Eq. 3
wherein Li2O—LiCl molten salt is utilized as the electrolytic bath. CO or CO2 gas is generated at the anode, while uranium ions (or whichever target metal) are converted to metal at the cathodic reduction surface.
Several anode assemblies, one such assembly depicted as numeral 10 in
Generally, the configuration of the assembly allows its depending end to become immersed in the crucible containing the electrolyte bath. It is generally flat or planar in construction so that it does not physically contact the sides, bottom or top of the crucible. Optionally, the crucible is surrounded by a spill container or overflow vessel (not shown) so as to contain any wayward electrolyte (due to splashing or a crucible breach) within its confines. During electrolysis, the bottom end (e.g., depending end) of the anode is consumed in a tapered fashion, thereby resulting in the formation of a horizontally extending “knife edge.” The anode continues to be consumed in this matter until it is replaced by a second, downwardly biased anode.
Each of the assemblies are adapted to receive a plurality of anode slabs 12; for example slabs comprising graphite. In the embodiment as shown, the anode containment structure defines opposing channels 14 (serving as anode slab guides) to provide a means for the slabs 12 to be slidably received by the assembly 10, such that the slabs 12 are loaded into the assembly from above. As such, the channels are spaced apart at a distance slightly greater than the width of the slabs. It should be noted that while the anodes are loaded with the intention that they do not have to be unloaded, the instant configuration allows for any loaded anode slabs to be easily removed, without the need for disassembly of the system. In summary of this point, a feature of the invention is that the invented configuration allows continual easy access to the anode feed mechanism to confer easy manipulation and continual replenishment of the anodes.
The slabs 12 are stacked upon each other with the upwardly extending edge of a first slab in physical contact with the depending (i.e., downwardly facing) edge of a second slab positioned above the first slab. Opposing edges of adjacent slabs define a tongue and groove configuration. This configuration confers additional stability and alignment to the stack of anode slabs, and also enhances electrical conductivity between slabs. (The maximum number of slabs simultaneously loaded within the assembly is dependent upon the dimensions of the assembly.)
In an embodiment of the invention, the channels are adapted to receive brushes or other electricity conducting structures. Upwardly extending portions 16 of the channels 14 are lined with electrical isolators 44 (
As the bottom most anode 12 is consumed during electrolytic processes, the anodes above it slide downwardly and toward the salt bath. This motion is caused by gravity, i.e., by the weight of superior positioned anodes relative to those anodes contacting (and being consumed) in the salt bath
Current is provided to each anode stack via a brush-type contact situated along each channel. These brushes are designated as numeral 22 in
As depicted in
Electron transfer occurs only at the salt/graphite interface. While the system can function with the brushes contacting the salt bath, in other instances, the brushes do not contact the salt bath; otherwise, they may become anodes as well and subject to corrosion/oxidation.
Finally, the off gas egress point 26 removes the sweep gas (plus off-gasses (e.g., CO and CO2) released as part of the oxidation reaction occurring at the anode) out of the system. To facilitate carrier gas and off gas flow through the system, the sweep gas can be supplied at a positive pressure. Alternatively, a vacuum pull or other means for negative pressure, can be applied to the off gas egress point. The arrows in
A generally horizontally disposed nonelectrically conductive substrate/baffle 53 is situated above the anode/electrolyte bath interface to provide a headspace 54 through which carrier and off gas may travel between the weep apertures 51. The substrate/baffle 53 may be positioned at an angle ϕ off of horizontal to assure rapid evacuation. The baffle is further positioned and constructed to deflect gas flow off the ceiling of the headspace and toward the laminar flow region of the headspace.
Optionally, ambient cell gas is added to the off gas manifold to keep outlet temperatures below a certain point, that point predetermined by the particular site and to keep carbon monoxide, carbon dioxide, and oxygen concentrations at nonhazardous levels. In an embodiment of the invention, ambient cell gas is added to the egress manifold to assure a maximum outlet temperature of about 150° C.
The anode assembly 10 is depicted in crosshatching in
Lifting rings 48 may be provided to facilitate replacement of the assembly 10 in the event of a failure or off normal occurrence. The rings 48 may be threadably and removably received by a threaded aperture formed in the power supply block 42 or integrally molded with the block.
In an embodiment of the invention, the manifold is rectangular in configuration so as to be mounted on both sides of the anode assembly. As such, the insulation pad 34 is rectangular in configuration, thereby resembling a flat rectangular gasket.
Another electrical insulator gasket 38 is positioned on an upwardly facing surface of the power supply block 42 so as to be sandwiched between the supply block 42 and medially biased extending support struts 15 for the upwardly extending regions 16 of the anode support channels 14. The entire structure is supported by rigid, thermal insulating support blocks 32, discussed infra.
Shroud Detail
The lowest graphite slab (i.e., the one that is immersed in the salt) is maintained within the salt bath via the vertically extending members of the anode support channels 14, such that these lower extending channels are not in electrical communication with the upwardly extending channels 16 discussed supra. Preferably, the brushes are not immersed in the salt. Electrical contact between the upper anode slabs (e.g., those not contacting the bath) and lower immersed slabs is facilitated by contact of horizontally extending edges of adjacent slabs. During portions of an electrolysis run, only one slab may contact the salt bath at any one time. However, depending on the depth of the salt bath crucible, more than one slab may be in contact with the salt bath at a time. If the lower slab has been consumed more than ⅓ its vertical length, then two slabs may be in contact with the salt.
The channels 14 support a porous metal shroud or sleeve 28 (
As illustrated in
The shroud 28 is adapted to receive and direct any gas generated at the anode surface during the electrolytic process and expel it (along with any sweep gas) from the system. The shroud can also be polarized (e.g. negatively charged) to cathodically reduce any carbonate that forms in the molten salt by a chemical reaction between COx and O2− ions.
A salient feature of the shroud 28 is that it prevents pieces of anode from intermingling within the bulk of the electrolyte. Rather, the shroud 28 maintains any anode pieces (which may clone off the bulk anode) in close spatial relation with the bulk of the anode such that those wayward anode pieces continue to facilitate the oxidation reactions occurring at the positive electrode.
The shroud 28 features its own current source, designated as secondary bus 46 in
The shroud 28 in combination with the channels 14 also define longitudinally extending troughs. Feed gas enters the sweep gas intake 24 and travels down one of the troughs and over the anode surfaces to sweep out oxidized moieties (such as CO and CO2). An egress avenue for these oxidized moieties is the second trough, that egress avenue terminating in the off gas egress 26 depicted in
Generally the sweep gas traverses down the vertically disposed channel region proximal to the intake 24, then horizontally above the salt bath surface. Finally, the sweep gas (now entrained with any off gases) traverses up the second vertically disposed channel region proximal to the off gas egress point 26. A means for venting the entrained gas to the atmosphere or a collection system (not shown) may be provided for any additional processing.
Turning back to
Suitable electrical insulators 44 are comprised of material having a melting temperature above that of the melt, and include ceramic. As such, this catch tray provides additional means for allowing the loose material too remain in close proximity of the main anode monolith 12 so as to continue to participate in the oxidation processes occurring at the anode. This participation in the oxidation process is facilitated if the loose material is in electrical contact with the anode monolith. This loose material can be consumed by the same anode process as the monolith, instead of being lost in the electrolyte bath.
The entire anode assembly 10 is electrically isolated from aspects of the electro-reducer, such as the crucible, by insulator blocks 32. The insulator blocks are rigid constructs providing electrical isolation from the surrounding objects and capable of withstanding the heating from the mounted surface. Suitable material comprising the insulator blocks include, but are not limited to alumina, zirconia, beryllia, calcium silicate and combinations thereof. Marinite (e.g., BNZ board), for example, is formed from calcium silicate and inert fillers and reinforcing agents.
The insulator blocks 32 are positioned above the insulating vessel cover so as to be in thermal communication with the cover. Aspects of the invention may have the insulator blocks physically contacting the cover. The insulator blocks 32 also minimize upward heat transfer which would otherwise occur via thermal conduction through the anode assembly 10.
In an embodiment of the invention, the insulator blocks are a more permanent part of the entire structure, such that the insulator blocks removably receive the anode assemblies during initial construction and allow for removal of the anode assemblies for maintenance.
An embodiment of the invention supports high purity graphite slabs approximately 4 inches thick, by approximately 26 inches wide by approximately 36 inches tall. These dimensions are chosen to fit an assembly 10 of given dimensions. As such, the dimensions provided here are for illustrative purposes only. The graphite serves as the electrical conductor. That portion of the graphite immersed or otherwise in contact with the electrolyte serves as the anode.
The graphite slabs are slidably received by the slab guide channels 14 lined with electrical isolators/insulators. The graphite slab is initially received by upward extending regions 16 of the anode guide channel 14 and as the lower slab is consumed by the reaction, the upper slab slides into the guide channel 14 and contacts the brush assembly. The channels 14 support the superiorly positioned anode slabs until the slabs engage the brushes. The channels may be comprised of any rigid or semi rigid material. The channels may be overlaid with electrically conductive material at regions designated for directly electrifying the graphite slabs from the main bus 36 supply.
There can be a number of graphite slabs coplanarly arranged to each other, depending on the height of the assembly. For illustrative purposes the inventors envision approximately two or more slabs positioned end to end. The slabs gradually slide down into the salt bath as they are consumed by the conversion of oxide ions from the salt into CO (g) and CO2(g).
Opposing ends of two adjacent slabs are configured in a tongue and groove configuration to enhance electrical conductivity to each other. With the above dimensions of the slabs in this example, and given a current of 1000 amps, each slab lasts approximately 1000 hours. As such, consumption of the slabs is occurring at rate of about 9000 amp-hours per kg of anode.
The slabs are constantly sliding down during the electrolysis process, with the rate of movement depending on the consumption of the material.
The assembly can accept one slab or simultaneously accept a plurality of slabs. Also, the slabs may be removed once inserted into the assembly. Optionally, regions of top edges of the slabs may be configured as apertures or some other shape so as to be easily grabbed and pulled from the stack via an overhead handling system, if the slabs need to be removed from the system.
The figures show the block 42 in physical and electrical communication with the brushes 22. The brush comprises a base substrate 18 bisected by a protuberance 20. The base substrate 18 and protuberance 20 may be integrally molded from electrically conductive material. Alternatively, the protuberance 20 may be removably attached to the base substrate. The base substrate 18 is in electrical communication with the power block 42, and is depicted in physical contact with medially facing aspects of the power block 42. The brush depicted in
The anode guide frame/gas manifold construct, 14/23, is in fluid communication with the gas egress manifold via a conduit 50 (e.g., a tube) extending from the manifold 23 to the gas egress manifold 26. One end of the conduit is sealed (e.g., hermetically) to an opening in the manifold 23 so as to be in fluid communication with the interior of the manifold. The conduit 50 is routed from the manifold 23 to the gas egress manifold 26. The conduit could extend around the bus bar (as shown) or through the secondary bus bar, 46, to mate with the gas egress manifold 26. If the conduit travels through the bus bar, it would do so via a transversely extending aperture or hole through that secondary bus bar 46. The hole in the secondary bus bar, 46, is sized slightly larger than the connecting tube. A similar connection is found between the anode guide frame/gas manifold, 14/23, and the gas ingress manifold 24.
The inter-manifold connection 50 described supra may be reversible, such that either or both ends of the conduit 50 may be detached from their respective manifold terminus point so as to facilitate easy dissembly of the system. Standard plumbing couplers, snap-fit configurations and other reversible connection configurations are suitable means for attaching and detaching the conduit 50 to and from the manifolds.
The conduit 50 connecting the manifold to the ingress or egress portals can be constructed of electrically conductive material or electrically insulative material.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. While the dimensions and types of materials described herein are intended to define the parameters of the invention, they are by no means limiting, but are instead exemplary embodiments. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” “more than” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. In the same manner, all ratios disclosed herein also include all subratios falling within the broader ratio.
One skilled in the art will also readily recognize that where members are grouped together in a common manner, such as in a Markush group, the present invention encompasses not only the entire group listed as a whole, but each member of the group individually and all possible subgroups of the main group. Accordingly, for all purposes, the present invention encompasses not only the main group, but also the main group absent one or more of the group members. The present invention also envisages the explicit exclusion of one or more of any of the group members in the claimed invention.
The U.S. Government has rights in this invention pursuant to Contract No. DE-AC02-06CH11357 between the U.S. Department of Energy and UChicago Argonne, LLC, representing Argonne National Laboratory.
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4288305 | Garritsen | Sep 1981 | A |
4338177 | Withers | Jul 1982 | A |
4409073 | Goldberger | Oct 1983 | A |
4421830 | Schneider | Dec 1983 | A |
4995948 | Poa | Feb 1991 | A |
5071534 | Holmen | Dec 1991 | A |
5456808 | Juric | Oct 1995 | A |
6063247 | Bergmann | May 2000 | A |
20090301895 | Shimamune | Dec 2009 | A1 |
Number | Date | Country | |
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20170260635 A1 | Sep 2017 | US |