U.S. patent application number 17/413544 was filed with the patent office on 2022-02-24 for membrane electrolysis processes for akaline chloride solutions, using a gas-diffusion electrode.
The applicant listed for this patent is COVERSTRO INTELLECTUAL PROPERTY GMBH & CO. KG. Invention is credited to Andreas BULAN, Michael GROBHOLZ.
Application Number | 20220056594 17/413544 |
Document ID | / |
Family ID | |
Filed Date | 2022-02-24 |
United States Patent
Application |
20220056594 |
Kind Code |
A1 |
BULAN; Andreas ; et
al. |
February 24, 2022 |
MEMBRANE ELECTROLYSIS PROCESSES FOR AKALINE CHLORIDE SOLUTIONS,
USING A GAS-DIFFUSION ELECTRODE
Abstract
The invention relates to processes for the electrolysis of
alkali chlorides by means of oxygen-depolarized electrodes, said
processes having specific operating parameters for shut-down and
restarting.
Inventors: |
BULAN; Andreas; (Lnngenfeld,
DE) ; GROBHOLZ; Michael; (Leverkusen, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
COVERSTRO INTELLECTUAL PROPERTY GMBH & CO. KG |
Leverkusen |
|
DE |
|
|
Appl. No.: |
17/413544 |
Filed: |
December 16, 2019 |
PCT Filed: |
December 16, 2019 |
PCT NO: |
PCT/EP2019/085312 |
371 Date: |
June 12, 2021 |
International
Class: |
C25B 1/46 20060101
C25B001/46; C25B 15/031 20060101 C25B015/031; C25B 9/19 20060101
C25B009/19; C25B 13/00 20060101 C25B013/00; C25B 11/081 20060101
C25B011/081; C25B 11/032 20060101 C25B011/032; C25B 9/65 20060101
C25B009/65; C25B 15/027 20060101 C25B015/027 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 18, 2018 |
EP |
18213272.0 |
Claims
1.-8. (canceled)
9. A process for chloralkali electrolysis using an electrolysis
cell in a gap arrangement, in particular with a spacing of from
0.01 mm to 3 mm between ion exchange membrane and gas diffusion
electrode, where the cell comprises at least one anode space with
anode and an anolyte containing alkali metal chloride, an ion
exchange membrane, a cathode space with a gas diffusion electrode
as cathode which comprises a silver-containing catalyst and an in
particular from 0.01 mm to 3 mm thick sheet-like porous element
through which catholyte flows between gas diffusion electrode and
membrane, the electrolysis process comprises at least the following
steps in this order: a) lowering of the electrolysis voltage and
removal of chlorine from the anolyte so that less than 10 mg/l of
active chlorine is present in the anolyte by maintaining an
electrolysis voltage per element of from 0.1 to 1.4 V and a current
density which is greater than zero, b) and setting of the pH of the
anolyte to a value in the range from pH 2 to pH 12 during step a),
c) residence under these conditions as long as electrolyte is
present in the catholyte gap (or electrolyte flows through the
latter), and optionally for emptying of the electrolysis cell the
further steps: d) cooling of the anolyte to a temperature below
70.degree. C. with maintenance of the electrolysis voltage in the
range from 0.1 to 1.4 V, e) switching off of the electrolysis
voltage at an electrolyte temperature of <55.degree. C., f)
emptying of the cathode gap, g) emptying of the anode space, h)
preferably renewed filling of the anode space with one of the
following liquids: dilute alkali metal chloride solution having a
maximum concentration of 4 mol/l or deionized water, and subsequent
emptying of the anode space, i) filling of the cathode space with
one of the following liquids: dilute alkali metal hydroxide
solution having a maximum concentration of 10 mol/l or deionized
water, with subsequent emptying of the cathode space.
10. The process as claimed in claim 9, wherein the alkali metal
chloride is sodium chloride or potassium chloride.
11. The process as claimed in claim 9, wherein the alkali metal
hydroxide is sodium hydroxide or potassium hydroxide.
12. The process as claimed in claim 9, wherein the gas diffusion
electrode is supplied with oxygen gas on its side facing away from
the catholyte.
13. The process as claimed in claim 9, wherein the oxygen gas flow
to the gas diffusion electrode is maintained when the electrolysis
is switched off.
14. A process for chloralkali electrolysis using a membrane
electrolysis cell in a gap arrangement between ion exchange
membrane and gas diffusion electrode, in particular with a spacing
of from 0.01 mm to 3 mm between ion exchange membrane and gas
diffusion electrode, where the cell has at least one anode space
with anode for accommodating an anolyte containing alkali metal
chloride, an ion exchange membrane, a cathode space with a gas
diffusion electrode as cathode, which comprises a silver-containing
catalyst, and a sheet-like, porous element in the gap between ODE
and membrane, which element has a thickness of, in particular, from
0.01 mm to 3 mm and through which catholyte flows during operation,
wherein, for start-up of the electrolysis process, at least the
following steps are carried out in this order: j) filling of the
anode space with anolyte having a temperature of at least
50.degree. C. and passage of the anolyte through it, k) preheating
of catholyte to a temperature of at least 50.degree. C., l) filling
of the cathode space and the porous element with preheated
catholyte having a concentration of from 7.5 to 10.5 mol/l and
passage of the catholyte through them, m) setting of the
electrolysis voltage to a value in the range from 0.1 to 1.4 V, n)
setting and maintenance of the temperature of the catholyte and
anolyte leaving the cell independently of one another to a
temperature in the range from 70 to 100.degree. C., o) setting of
the concentration of the catholyte in the feed to the cell so that
an alkali metal hydroxide concentration in the range from 7.5 to 12
mol/l is obtained in the output, p) setting of the concentration of
the anolyte in the feed to the cell so that an alkali metal
chloride concentration in the range from 2.9 to 4.3 mol/l is
obtained in the output, q) setting of the production current
density to a value of at least 2 kA/m.sup.2, preferably at least 4
kA/m.sup.2.
15. The process as claimed in claim 14, wherein the increase in the
current density to the production current density in step q) is
carried out at a rate of from 0.018 kA/(m.sup.2*min) to 0.4
kA/(m.sup.2*min) until the current density at the electrolysis
element is at least 2 kA/m.sup.2.
16. The process as claimed in claim 14, wherein the start-up is a
restarting of an electrolysis cell which has been shut down
according to a process comprising at least the following steps in
this order: a) lowering of the electrolysis voltage and removal of
chlorine from the anolyte so that less than 10 mg/l of active
chlorine is present in the anolyte by maintaining an electrolysis
voltage per element of from 0.1 to 1.4 V and a current density
which is greater than zero, b) and setting of the pH of the anolyte
to a value in the range from pH 2 to pH 12 during step a), c)
residence under these conditions as long as electrolyte is present
in the catholyte gap (or electrolyte flows through the latter), and
optionally for emptying of the electrolysis cell the further steps:
d) cooling of the anolyte to a temperature below 70.degree. C. with
maintenance of the electrolysis voltage in the range from 0.1 to
1.4 V, e) switching off of the electrolysis voltage at an
electrolyte temperature of <55.degree. C., f) emptying of the
cathode gap, g) emptying of the anode space, h) preferably renewed
filling of the anode space with one of the following liquids:
dilute alkali metal chloride solution having a maximum
concentration of 4 mol/l or deionized water, and subsequent
emptying of the anode space, i) filling of the cathode space with
one of the following liquids: dilute alkali metal hydroxide
solution having a maximum concentration of 10 mol/l or deionized
water, with subsequent emptying of the cathode space.
Description
[0001] The invention relates to a process for the electrolysis of
aqueous solutions of alkali metal chlorides by means of gas
diffusion electrodes with adherence to particular operating
parameters.
[0002] The invention proceeds from electrolysis processes known per
se, e.g. for the electrolysis of aqueous alkali metal chloride
solutions by means of gas diffusion electrodes which usually
comprise an electrically conductive support and a gas diffusion
layer having a catalytically active component. The arrangement is
such that there is a narrow gap through which an electrolyte flows
between gas diffusion electrode and ion exchange membrane.
[0003] Various proposals for operating the gas diffusion electrode
as oxygen-depolarized electrode in electrolysis cells of industrial
size are known in principle from the prior art. The basic idea here
is to replace the hydrogen-evolving cathode of the electrolysis
(for example in chloralkali electrolysis) by the oxygen-depolarized
electrode (cathode). An overview of possible cell designs and
solutions may be found in the publication by Moussallem et al.,
"Chlor-Alkali Electrolysis with Oxygen Depolarized Cathodes:
History, Present Status and Future Prospects", J. Appl.
Electrochem. 38 (2008) 1177-1194.
[0004] The gas diffusion electrode, hereinafter also referred to as
GDE for short, has to meet a number of requirements in order to be
able to be used in industrial electrolyzers. Thus, the catalyst and
all other materials used have to be chemically stable to the
electrolyte used and the gases supplied to the electrode and also
the compounds formed at the electrode, e.g. hydroxide ions or
hydrogen, at a temperature of typically up to 90.degree. C. A high
degree of mechanical stability is likewise required so that the
electrodes can be installed and operated in electrolyzers having a
size of usually more than 2 m.sup.2 in area (industrial size).
Further desirable properties are: a high electrical conductivity, a
low layer thickness, a high internal surface area and a high
electrochemical activity of the electrocatalyst. Suitable
hydrophobic and hydrophilic pores and an appropriate pore structure
for the conduction of gas and electrolyte are necessary. The
long-term stability and low production costs are further particular
requirements which an industrially usable oxygen-depolarized
electrode has to meet.
[0005] WO 2001/57290 A1 describes a cell for chloralkali
electrolysis in which the liquid is conveyed from the top downward
over a sheet-like porous element, known as a percolator, installed
between gas diffusion electrode and ion exchange membrane in a type
of free-falling liquid film, referred to as falling film for short,
along the gas diffusion electrode (minigap arrangement). In this
arrangement, only a very small column of liquid acts on the liquid
side of the gas diffusion electrode and no high hydrostatic
pressure profile is built up over the construction height of the
cell.
[0006] A further arrangement, which is sometimes also referred to
as "zero gap" but would be more precisely formulated as "microgap",
is described in JP 3553775 and U.S. Pat. No. 6,117,286 A1. In this
arrangement a further layer composed of a porous hydrophilic
material which takes up the alkali metal hydroxide solution formed
due to its suction force and from which at least part of the alkali
can flow away in a downward direction is located between the ion
exchange membrane and the GDE. The possibility of the alkali metal
hydroxide solution flowing away is determined by the installation
of the GDE and the cell design. In contrast to the above-described
arrangements in the minigap design, no aqueous alkali metal
hydroxide solution (alkali) is conveyed by supply and discharge
through the gap between the GDE and ion exchange membrane; the
porous material present in the microgap takes up the alkali metal
hydroxide solution formed and conducts it further in the horizontal
or vertical direction.
[0007] An oxygen-depolarized electrode typically consists of a
support element, for example a plate of porous metal or a woven
fabric made of metal wires, and an electrochemically catalytically
active coating. The electrochemically active coating is microporous
and consists of hydrophilic and hydrophobic constituents. The
hydrophobic constituents make penetration of electrolyte difficult
and thus keep the appropriate pores in the GDE free for transport
of oxygen to the catalytically active sites. The hydrophilic
constituents allow passage of the electrolyte to the catalytically
active sites and outward transport of the hydroxide ions from the
GDE. A fluorine-containing polymer such as polytetrafluoroethylene
(PTFE) is generally used as hydrophobic component and additionally
serves as polymeric binder for particles of the catalyst. In the
case of electrodes having a silver catalyst, the silver serves, for
example, as hydrophilic component. Many compounds have been
described as electrochemical catalyst for the reduction of oxygen.
However, only platinum and silver have attained practical
importance as catalyst for the reduction of oxygen in alkaline
solutions.
[0008] Platinum has a very high catalytic activity for the
reduction of oxygen. Owing to the high cost of platinum, this is
used exclusively in supported form. A preferred support material is
carbon. However, the stability of platinum-based electrodes
supported on carbon in long-term operation is unsatisfactory,
presumably because platinum also catalyzes the oxidation of the
support material. In addition, carbon promotes the undesirable
formation of H.sub.2O.sub.2, which likewise brings about oxidation.
Silver likewise has a high electrocatalytic activity for the
reduction of oxygen.
[0009] Silver can be used in carbon-supported form and also as
finely divided metallic silver. Although carbon-supported silver
catalysts are more durable than the corresponding platinum
catalysts, their long-term stability under the conditions in an
oxygen-depolarized electrode, in particular during use for
chloralkali electrolysis, is also limited.
[0010] In the production of GDEs having an unsupported silver
catalyst, the silver is preferably introduced at least partly in
the form of silver oxides which are then reduced to metallic
silver. The reduction generally occurs during the first start-up of
the electrolysis cell. In the reduction of the silver compounds, a
change in the arrangement of the crystallites, in particular bridge
formation between individual silver particles, also occurs. This
leads overall to consolidation of the structure.
[0011] A further central element of the electrolysis cell is the
ion exchange membrane. The membrane is permeable to cations and
water and largely impermeable to anions. The ion exchange membranes
in electrolysis cells are subject to great stress: they have to be
resistant to chlorine on the anode side and strongly alkaline
conditions on the cathode side at temperatures of about 90.degree.
C. Perfluorinated polymers such as PTFE usually withstand these
stresses. Ion transport occurs via acidic sulfonate groups and/or
carboxylate groups polymerized into these polymers. Carboxylate
groups display greater selectivity and the carboxylate-containing
polymers have a smaller water absorption and a higher electrical
resistance than polymers containing sulfonate groups. In general,
multilayer membranes having a thicker layer containing sulfonate
groups on the anode side and a thinner layer containing carboxylate
groups on the cathode side are generally used. The membranes are
provided with a hydrophilic layer on the cathode side or on both
sides. To improve the mechanical properties, the membranes are
reinforced by insertion of woven fabrics or nonwovens, and the
reinforcement is preferably incorporated in the layer containing
sulfonate groups.
[0012] Due to the complex structure, the ion exchange membranes are
sensitive to changes in the media surrounding them. High osmotic
pressure gradients can be built up between anode side and cathode
side as a result of different molar concentrations. When the
electrolyte concentrations decrease, the membrane swells due to
increased water absorption. When the electrolyte concentrations
increase, the membrane releases water and shrinks as a result; in
the extreme case, precipitation of solids in the membrane or
mechanical damage such as cracks in the membrane can occur as a
result of withdrawal of water.
[0013] Concentration changes can thus bring about defects and
damage on the membrane. Delamination of the layer structure
(blister formation) can occur, as a result of which mass transfer
or the selectivity of the membrane is impaired.
[0014] Furthermore, holes (pinholes) and in the extreme case cracks
can occur, and undesirable mixing of anolyte and catholyte can
occur through these.
[0015] When the electrolysis voltage is switched off, the mass
transfer through the membrane brought about by the flow of current
also stops, and in addition undesirable concentration changes in
the alkali metal chloride-containing electrolyte in the anode space
(brine) and the alkali metal hydroxide solution present in the
cathode space can occur. The membrane becomes depleted in water,
and shrinkage and solid precipitates and consequently hole
formation can occur and the passage of anions through the membrane
is made easier. When the electrolysis cell is started up again, a
water content which is too low hinders mass transfer through the
membrane, as a result of which an increase in the osmotic pressure
and delamination at the interfaces between the sulfonic acid
group-containing and carboxylic acid group-containing layers
typically used in such membranes can occur.
[0016] An inhomogeneity of the water and/or ion distribution in the
membrane and/or the gas diffusion electrode can lead to local peaks
in electricity transport and mass transfer on renewed start-up and
consequently to damage to the membrane or the gas diffusion
electrode.
[0017] Problems are also presented by the precipitation of alkali
metal chloride salts on the anode side. The high osmotic gradient
between anolyte and catholyte results in transport of water from
the anode space into the cathode space. As long as the electrolysis
is in operation, the transport of water from the anode space is
countered by a loss of chloride and alkali metal ions, so that the
concentration of alkali metal chloride decreases in the anode space
under customary electrolysis conditions. When the electrolysis is
switched off, the transport of water from the anode space into the
cathode space caused by the osmotic pressure persists. The
concentration in the anolyte increases to above the saturation
limit. Precipitation of alkali metal chloride salts occurs, in
particular in the boundary region to the membrane or even in the
membrane, which can lead to damage to the membrane.
[0018] In production plants, it is desirable to operate
electrolysis cells over periods of a number of years without them
being opened during this time. However, due to fluctuations in
offtake quantities and malfunctions in production regions upstream
or downstream of the electrolysis, electrolysis cells in production
plants inevitably have to be repeatedly shut down and started up
again.
[0019] In the shutting down and restarting of the electrolysis
cells, conditions which lead to damage to the cell elements such as
anode, ion exchange membrane, gas diffusion electrode or further
components used in the cell and can significantly shorten their
life and also impair the performance of the electrolysis occur. In
particular, oxidative damage in the cathode space, damage to the
gas diffusion electrode and damage to the membrane have been
found.
[0020] Few modes of operation by means of which the risk of damage
to the electrolysis cells during start-up and shutdown can be
reduced are known from the prior art.
[0021] The Japanese first publication JP 2004-300510 A describes an
electrolysis process using a microgap arrangement, in which
corrosion in the cathode space on shutdown of the cell is said to
be prevented by flooding of the gas space with sodium hydroxide
solution. The flooding of the gas space with sodium hydroxide
solution protects the cathode space against corrosion according to
this publication, but it offers insufficient protection against
damage to the electrode and the membrane on shutdown and start-up
or during the downtime.
[0022] U.S. Pat. No. 4,578,159 A1 states that damage to membrane
and electrode is avoided in an electrolysis process using a "zero
gap" arrangement by flushing of the cathode space with 35% strength
sodium hydroxide solution before start-up of the cell or by
starting the cell at a low current density and gradually increasing
the current density. This procedures reduces the risk of damage to
membrane and gas diffusion electrode during start-up, but offers no
protection against damage during shutdown and the downtime.
[0023] It is known from the document U.S. Pat. No. 4,364,806 A1
that corrosion in the cathode space is said to be reduced by
replacement of the oxygen by nitrogen after regulating down the
electrolysis current. According to WO 2008009661 A2, the addition
of a small proportion of hydrogen to the nitrogen is said to give
an improvement in protection against corrosive damage. However, the
methods mentioned are complicated, in particular in respect of
safety aspects, and require installation of additional facilities
for introduction of nitrogen and hydrogen. On restarting, the pores
of the gas diffusion electrode are partially filled with nitrogen
and/or hydrogen, which hinders the supply of oxygen to the reactive
sites. In addition, the method does not offer any protection
against damage to the ion exchange membrane and demands a high
level of safety measures in order to avoid explosive gas
mixtures.
[0024] In the Final Technical Report "Advanced Chlor-Alkali
Technology" by Jerzy Chlistunoff (Los Alamos National Laboratory,
DOE Award 03EE-2F/Ed190403, 2004), conditions for temporary
shutdown and switching-on of zero gap cells are described. On
shutdown, the oxygen supply is interrupted and replaced by nitrogen
after interruption of the electrolysis current. The humidification
of the gas stream is increased in order to wash out the remaining
sodium hydroxide solution. On the anode side, the brine is replaced
by hot water (90.degree. C.). The procedure is repeated until a
stable open circuit voltage has been achieved. The cells are then
cooled, and the supply of humid nitrogen and the pumped circulation
of the water on the anode side are then stopped.
[0025] For renewed start-up, the anode side is firstly filled with
brine, and water and nitrogen are introduced on the cathode side.
The cell is then heated to 80.degree. C. The gas supply is then
changed over to oxygen and a polarization voltage is applied at a
low current flow. The current density is subsequently increased and
the pressure in the cathode is increased; the temperature rises to
90.degree. C. Brine and water supply are subsequently adapted so
that the desired concentrations are achieved on the anode side and
cathode side.
[0026] This procedure can be carried out only with extreme
difficulty for operation of an industrial cell and leads to dilute
electrolyte-containing solutions which have to be disposed of being
obtained.
[0027] Start-Up
[0028] For start-up as described in EP 2639337 A2, the volume flow
and/or the composition of the catholyte fed to the gap is set so
that the aqueous solution of alkali metal hydroxide leaving the
cathode gap has a content of chloride ions of not more than 1000
ppm before the electrolysis voltage is applied between anode and
cathode and the electrolysis voltage is applied after introduction
of the anolyte and an oxygen-containing gas into the cathode
space.
[0029] According to the prior art of EP 2639337 A2, humidified
oxygen is introduced before start-up of a cell having a finite gap
arrangement of the catholyte circuit and a gauge pressure
corresponding to the configuration in the cell is set in the
cathode half cell, which gauge pressure is generally 10-100 mbar
relative to the pressure in the anode.
[0030] However, it has been found when carrying out the start-up
and shutdown according to the methods of EP 2639337 A2 that the
performance of the electrolysis is impaired contrary to
expectations when these procedures are carried out repeatedly.
[0031] The fact remains that the techniques for starting up and
shutting down a gas diffusion electrode as described hitherto in
the prior art are found to be disadvantageous and offer only
insufficient protection against damage.
[0032] It is an object of the present invention to find suitable
improved operating parameters for start-up and shutdown, in
particular for shutdown and interim downtimes of an electrolysis
cell for chloralkali electrolysis using a gas diffusion electrode
with minigap arrangement and silver catalyst as electrocatalytic
substance, which improved parameters are simple to carry out and
damage to membrane, electrode and/or other components of the
electrolysis cell is avoided when they are adhered to.
[0033] Minigap arrangement means, for the purposes of the
invention, any arrangement of an electrolysis cell which has an
electrolyte gap through which catholyte flows between
oxygen-depolarized electrode and membrane, where the gap has a gap
width of at least 0.01 mm and in particular has a gap width of not
more than 3 mm. In the electrolysis cell according to the principle
of a falling film cell which is preferably used, catholyte flows
from the top downward in the direction of gravity in a vertically
arranged electrolysis cell. Other arrangements with an alternative
flow direction or a horizontally arranged electrolysis cell are
also intended to be encompassed by the invention.
[0034] The abovementioned problems and disadvantages of the
processes known hitherto are overcome by the provision of the
electrolysis process of the invention.
[0035] It has surprisingly been found that electrolyzers containing
a gas diffusion electrode having a silver catalyst can repeatedly
be started up and shut down without damage by means of the improved
sequence of these steps and also suffer no damage during the
downtime. The process is particularly suitable for the electrolysis
of aqueous sodium chloride and potassium chloride solutions.
[0036] The above-described technical object is achieved according
to the invention by a specific sequence of voltage reduction and
replacement of the electrolytes being adhered to on shutdown of the
electrolysis cell.
[0037] The invention provides a process for chloralkali
electrolysis using an electrolysis cell in a gap arrangement, in
particular with a spacing of from 0.01 mm to 3 mm between ion
exchange membrane and gas diffusion electrode, where the cell
comprises at least one anode space with anode and an anolyte
containing alkali metal chloride, an ion exchange membrane, a
cathode space with a gas diffusion electrode as cathode which
comprises a silver-containing catalyst and an in particular from
0.01 mm to 3 mm thick sheet-like porous element through which
catholyte flows between gas diffusion electrode and membrane,
characterized in that at the end of the electrolysis process, in
particular for shutdown, at least the following steps are carried
out in this order: [0038] a) lowering of the electrolysis voltage
and removal of chlorine from the anolyte so that less than 10 mg/l
of active chlorine is present in the anolyte by maintaining an
electrolysis voltage per element of from 0.1 to 1.4 V and a current
density which is greater than zero, [0039] b) setting of the pH of
the anolyte to a value in the range from pH 2 to pH 12, [0040] c)
residence under these conditions as long as electrolyte is present
in the catholyte gap (or electrolyte flows through the latter),
[0041] and in the case of emptying of the electrolysis cell (e.g.
in the case of maintenance and repair work on the electrolysis cell
in which the electrolysis cell has to be opened): [0042] d) cooling
of the anolyte to a temperature below 70.degree. C. with
maintenance of the electrolysis voltage in the range from 0.1 to
1.4 V, [0043] e) switching off of the electrolysis voltage at a
temperature of <55.degree. C., [0044] f) emptying of the cathode
gap, [0045] g) emptying of the anode space, [0046] h) preferably
renewed filling of the anode space with one of the following
liquids: dilute alkali metal chloride solution having a maximum
concentration of 4 mol/l or deionized water, and subsequent
emptying of the anode space, [0047] i) filling of the cathode space
with one of the following liquids: dilute alkali metal hydroxide
solution having a maximum concentration of 10 mol/l or deionized
water, with subsequent emptying of the cathode space.
[0048] One measure known from conventional membrane electrolysis is
maintenance of a polarization voltage, i.e. the voltage is not
regulated down to zero on ending of the electrolysis but instead a
residual voltage is maintained so that a residual current flows in
the usual electrolysis direction, so that a constant small current
density results and as a result an electrolysis occurs to a small
extent. If the electrolysis is to be shut down, cooling of the
electrolyte is necessary, as a result of which the potentials
change. This measure alone is therefore not sufficient to prevent
damage to the electrode during start-up and shutdown when using gas
diffusion electrodes.
[0049] It has also been observed that oxidation of the silver
catalyst can occur again on switching off the electrolysis current.
The oxidation is obviously promoted by the oxygen and the moisture
in the half cell. In particular immediately after switching off the
electrolysis, chlorine, hypochlorite and chlorate are present in
addition to the sodium chloride-containing brine on the anode side.
On the cathode side, sodium hydroxide solution, an electrocatalyst
such as silver and oxygen are present. Due to switching off of the
electrolysis current, the system is left to itself and
electrochemical reactions which depend on the potential, the
concentrations, the temperatures and pressures occur. As a result
of the oxidation of the cathodic catalyst, e.g. silver to silver
oxide, rearrangements in the catalyst microstructure can occur and
these have adverse effects on the activity of the catalyst and thus
the performance of the gas diffusion electrode.
[0050] In the new process, the alkali metal chloride is preferably
sodium chloride or potassium chloride, particularly preferably
sodium chloride.
[0051] The alkali metal hydroxide is preferably sodium hydroxide or
potassium hydroxide, particularly preferably sodium hydroxide.
[0052] In a preferred new process, the gas diffusion electrode is
supplied with oxygen gas on its side facing away from the catholyte
during operation. The oxygen gas stream to the gas diffusion
electrode is preferably maintained during shutdown of the
electrolysis according to the new process.
[0053] The purity of the oxygen corresponds to the concentrations
and purity requirements customary in electrolysis using a gas
diffusion electrode; oxygen having a content of more than 98.5% by
volume is preferably used.
[0054] The temperature of the catholyte fed in is regulated during
operation so that a temperature of 70-95.degree. C., preferably
75-90.degree. C., is established in the output from the cathode
space. A temperature difference between anolyte output and
catholyte input is preferably set to less than 20.degree. C. during
operation and during shutdown. Such a small temperature difference
avoids damage to the ion exchange membrane.
[0055] To remove chlorine from the anolyte in step a), a brine
having a content of NaCl of from 180 g/l (3.07 mol/l) to 330 g/l
(5.64 mol/l) is fed into the anode space in a preferred embodiment.
In this way, the anode space is freed of chlorine gas present and
the content of dissolved/dispersed chlorine is reduced.
[0056] Determination of the concentrations disclosed in the present
patent application is carried out, in particular, by titration or
another analytical method which is known in principle to a person
skilled in the art.
[0057] To reduce the electrolysis voltage to a range from 0.1 to
1.4 V in step a), a current density of from greater than zero to 20
A/m.sup.2, preferably from 0.1 A/m.sup.2 to 20 A/m.sup.2, is
preferably maintained. Under these conditions, the electrolysis is
operated until the anolyte is Cl.sub.2-free, i.e. the content of
chlorine having the oxidation state zero is from >0 to less than
10 mg/l. The measurement of the absence of chlorine in the anolyte
is, in particular, carried out by means of redox titration such as
iodometry or by testing of the anolyte by means of iodine-starch
paper.
[0058] The maintenance of the brine pH in the range from 2 to 12,
preferably from 6 to 9, during step a) is required in order to
avoid any chlorine evolution at a lower pH.
[0059] The temperature of the anolyte in steps a) and b) is
preferably at least 65.degree. C., particularly preferably at least
70.degree. C.
[0060] Maintenance of a differential pressure of at least 5 mbar
between cathode space and anode space is particularly preferably
ensured during shutdown.
[0061] As preparation for emptying of the electrolysis cell, the
anolyte is cooled in step d) to a temperature below 70.degree. C.
with simultaneous maintenance of an electrolysis voltage of from
0.1 to 1.4 V. This is a further difference from the prior
art--cooling is carried out there without maintenance of the
electrolysis voltage.
[0062] The switching off of the electrolysis voltage in step e) is
carried out at a temperature of the electrolytes of <55.degree.
C., preferably at a temperature of <50.degree. C.
[0063] The cathode gap (minigap) is subsequently emptied in step f)
(e.g. by switching off the pump for the catholyte feed). Here too,
there is a difference from the prior art since in the latter the
minigap is emptied only after emptying of the anode space.
[0064] The emptying of the anode space in step g) is carried out by
draining the anolyte and, in particular, subsequent flushing h) of
the anode space with alkali metal chloride solution having a
maximum concentration of 4 mol/1 or with deionized water.
[0065] Finally, in step i), the cathode gap (minigap) is flushed
with dilute sodium hydroxide solution or deionized water to remove
chloride residues and empty the cathodic minigap. In contrast to
the prior art, the cathode gap here is flushed again in order to
remove chloride after the anode space has been emptied. This
avoids, for example, corrosion on nickel connecting flanges of the
cell by excessively high chloride values in the alkali remaining in
the cathode space.
[0066] If required, residual emptying of the anode space can
particularly preferably then be carried out.
[0067] The difference from the procedure known from the prior art,
in particular relative to EP 263337 A2, is that when the
electrolysis voltage is lowered, the current density is not kept
constant but instead the electrolysis voltage is set in the range
from 0.1 to 1.4 V, in what is known as potentiostatic operation,
regardless of what current density is established. The important
thing here is that a current flows from the anode to the cathode,
i.e. the flow direction in the original electrolysis flow direction
is retained, and that the current is in any case greater than zero.
Furthermore, the cathode gap is emptied immediately after switching
off of the electrolysis voltage rather than the anode space being
emptied first, as described in EP 263337 A. The emptying of the
anode space, particularly in the case of industrial electrolysis
elements, takes up to 150 minutes, depending on cell construction
at an industrial construction size. Likewise, the pH of the brine
is not taken into consideration in the prior art, while according
to the invention this is optimally from 2 to 12.
[0068] The gas diffusion electrode is efficiently protected by the
process of the invention. The cell can also be cooled to below
70.degree. C. without chlorine being evolved on the anode side as a
result of the potentiostatic operation. This is important from
safety aspects if the electrolysis elements are to be opened later
for maintenance work or repair.
[0069] Preferred Details for Shutdown of Membrane Electrolysis
Using a Gas Diffusion Electrode are Described Below
[0070] In a first step, the electrolysis voltage is regulated down.
Here, the voltage is regulated down to a value of from 0.1 to 1.4
V. At a temperature of the anolyte of >65 C..degree. and a
concentration of greater than 200 g/l (3.41 mol/l) of NaCl and an
alkali metal hydroxide concentration in the catholyte of <28% by
weight (9.1 mol/l) at a catholyte temperature of >65.degree. C.,
the chlorine content in the anode space is lowered to <10 mg/l,
preferably less than 1 mg/l. Here, the pH of the anolyte in the
output from the electrolysis cell is from 2 to 12, preferably from
6 to 9.
[0071] For the present purposes, the chlorine content is the total
content of dissolved chlorine in the oxidation state 0 and above.
Removal of the remaining chlorine from the anode space is
preferably effected by chlorine-free anolyte being fed in with
simultaneous discharge of chlorine-containing anolyte, or by
pumping of the anolyte in the anode circuit with simultaneous
removal and discharge of chlorine gas.
[0072] According to the prior art, namely EP 263337 A2, the voltage
is set during flushing free of Cl2 so that a current density of
from 0.01 to 20 A/m.sup.2, preferably from 10 to 18 A/m.sup.2, is
established. Under these conditions, the electrolysis is not
operated below a temperature of 70.degree. C., since otherwise
chlorine evolution recommences. The cooling of the electrolysis can
be carried out according to the process of the invention when the
electrolysis voltage below a temperature of 70.degree. C. is not
more than 1.4 V, with the pH of the brine being in the range from 2
to 12. In this state, the electrolysis can be suspended for many
hours without the gas diffusion electrode being damaged. Relative
to the prior art, the electrolysis voltage continues to be
applied.
[0073] If the electrolysis cell is to be started up again, the load
can be increased again at any time.
[0074] When the electrolysis cell is to be emptied, the following
further steps are particularly preferably carried out: [0075]
switching off of the voltage supply [0076] firstly emptying of the
cathode space within from 0.01 to 2 minutes [0077] after emptying
of the cathode space, emptying of the anode space is carried out
within from 0.01 to 200 minutes; the emptying of cathode space and
anode space can optionally be carried out in parallel after
switching off of the voltage supply [0078] after emptying of the
anode space, optionally flushing of the anode space [0079] flushing
is carried out using greatly diluted brine having an alkali metal
chloride content of from 0.01 to 4 mol/l, with water or,
preferably, with deionized water. Flushing is preferably carried
out by one-off filling of the anode space or else only partial
filling of the anode space and immediate draining of the flushing
liquid. Flushing can also be carried out in two or more stages, for
example by the anode space firstly being filled with a dilute brine
having an alkali metal chloride content of 1.5-2 mol/l and drained
and then being further filled with greatly diluted brine having an
NaCl content of 0.01 mol/l or with deionized water and drained. The
flushing solution can be drained off again immediately after
complete filling of the anode space or remain for up to 200 minutes
in the anode space and then be drained off. After draining, a small
residual amount of flushing solution remains in the anode space.
The anode space then remains piped or shut off without direct
contact with the surrounding atmosphere. The brine is in accordance
with the purity requirements usual for membrane electrolyses in
chloralkali electrolysis. [0080] Flushing of the cathode space is
carried out using an alkali metal hydroxide solution having a
concentration of not more than 12 mol/l, preferably from 0.01 to 4
mol/l, which is fed to the cathode space for from 0.01 minutes to
60 minutes and is subsequently drained off again. Alkali metal
hydroxide solution from normal production is preferably used for
flushing the cathode space. Alkali from shutdown procedures is less
suitable for flushing, mostly because of contamination with
chloride ions. Flushing can likewise be carried out using deionized
water. After the flushing operation, the cathode space is emptied.
[0081] The oxygen supply can be, in particular, shut off with
switching off of the voltage. The oxygen supply is preferably shut
off after emptying and flushing of the cathode space. [0082]
Reduction of the differential pressure between cathode chamber and
anode chamber [0083] Lowering of the pressure at which the
electrolysis element is operated to ambient pressure [0084] Closure
of the electrolysis element in order to avoid entry of air.
[0085] After emptying/flushing of anode space and cathode space,
the electrolysis cell with the moist membrane can be kept ready
over a relatively long period of time in the built-in state for a
quick start-up without the performance capability of the
electrolysis cell being impaired. In the case of downtimes of a
number of weeks, it is advisable to flush or wet the anode space
with dilute aqueous alkali metal chloride solution and the cathode
space with dilute aqueous alkali metal hydroxide solution at
regular intervals in order to effect stabilization. Flushing is
preferably carried out at intervals of 1-12 weeks, particularly
preferably at intervals of 4-8 weeks. The concentration of the
dilute alkali metal chloride solution used for flushing or wetting
is 1-4.8 mol/l. The flushing solution can be drained off again
immediately after complete filling of the anode space or reside in
the anode space for up to 200 minutes and then be drained off. The
concentration of the alkali metal hydroxide solution used for
flushing or wetting is from 0.1 to 10 mol/l, preferably from 1 to 4
mol/l. The temperature of the brine or the alkali metal hydroxide
solution can be in the range from 10 to 80.degree. C., but is
preferably from 15 to 40.degree. C. The flushing of the minigap
cathode shells can be carried out for a period of from 0.1 to 10
minutes.
[0086] The invention also provides a process for start-up, in
particular for restarting after the new process for shutdown.
[0087] It is a process for chloralkali electrolysis using a
membrane electrolysis cell in a minigap arrangement between ion
exchange membrane and gas diffusion electrode, in particular with a
spacing of from 0.01 mm to 3 mm between ion exchange membrane and
gas diffusion electrode, where the cell has at least one anode
space with anode for accommodating an anolyte containing alkali
metal chloride, an ion exchange membrane, a cathode space with a
gas diffusion electrode as cathode, which comprises a
silver-containing catalyst, and a sheet-like, porous element in the
gap between ODE and membrane, which element has a thickness of, in
particular, from 0.01 mm to 3 mm and through which catholyte flows
during operation, characterized in that, for start-up of the
electrolysis process, at least the following steps are carried out
in this order: [0088] j) filling of the anode space with anolyte
having a temperature of at least 50.degree. C. and passage of the
anolyte through it, [0089] k) preheating of catholyte to a
temperature of at least 50.degree. C., [0090] l) filling of the
cathode space and the porous element with preheated catholyte
having a concentration of from 7.5 to 10.5 mol/l and passage of the
catholyte through them, [0091] m) setting of the electrolysis
voltage to a value in the range from 0.1 to 1.4 V, [0092] n)
setting and maintenance of the temperature of the catholyte and
anolyte leaving the cell independently of one another to a
temperature in the range from 70 to 100.degree. C., [0093] o)
setting of the concentration of the catholyte in the feed to the
cell so that an alkali metal hydroxide concentration in the range
from 7.5 to 12 mol/l is obtained in the output, [0094] p) setting
of the concentration of the anolyte in the feed to the cell so that
an alkali metal chloride concentration in the range from 2.9 to 4.3
mol/l is obtained in the output, [0095] q) setting of the
production current density to a value of at least 2 kA/m.sup.2,
preferably at least 4 kA/m.sup.2.
[0096] The restarting of the electrolysis is, in particular,
carried out as follows:
[0097] Anolyte is, as per step j), introduced into the anode space
of the cell and, in particular, heated to at least 50.degree. C. in
a circuit with heat exchanger,
[0098] Catholyte is, for step k), heated to a temperature of at
least 50.degree. C. outside the cell, e.g. in a circuit with
storage vessel and heat exchanger.
[0099] When the anode chamber has been filled and the anolyte has a
temperature of at least 50.degree. C., the cathode gap (minigap) is
filled as per step 1) by the preheated alkali metal hydroxide
solution having a temperature of at least 50.degree. C. being
introduced into the gap. This procedure is different from the prior
art in which the cathode space is filled first and the anode space
is then filled--the procedure according to the invention avoids
excessively high chloride values in the alkali and thus any
corrosion problems.
[0100] As soon as the cathode gap has been filled with alkali metal
hydroxide solution, an electrolysis voltage of at least 0.4 V is
preferably applied in step m), in particular within from 0.01 to 10
minutes, so that a current density of at least 0.2 A/m.sup.2 is
established.
[0101] Anolyte and catholyte are subsequently heated to a
temperature of at least 70.degree. C. as per step n) and the
current density is then preferably increased.
[0102] The increase in the current density to the production
current density in step q) is particularly preferably effected at a
rate of from 0.018 kA/(m.sup.2*min) to 0.4 kA/(m.sup.2*min) until
the current density at the electrolysis element is at least 2
kA/m.sup.2.
[0103] The determination of the concentrations is, unless indicated
otherwise, carried out by titration or another method which is
known in principle to a person skilled in the art.
[0104] The electrolysis cell which has been shut down according to
the above new process is restarted according to the above-described
new process. When the process steps described are adhered to, the
electrolysis cell can go through many start-up and running-down
cycles without the performance of the cell being impaired.
EXAMPLES
[0105] The gas diffusion electrode used in the examples was
produced as described in EP 1728896 B1, as follows: a powder
mixture consisting of 7% by weight of PTFE powder, 88% by weight of
silver(I) oxide and 5% by weight of silver powder was applied to a
gauze made of nickel wires and pressed to give an
oxygen-depolarized electrode.
[0106] The electrode was installed in an electrolysis unit having
an area of 100 cm.sup.2 with a DuPONT type N982 ion exchange
membrane (manufactured by Chemours) and a spacing between gas
diffusion electrode and ion exchange membrane of 3 mm.
[0107] The electrolysis unit has, in the assembled state, an anode
space having an anolyte inlet and outlet and an anode consisting of
titanium expanded metal which was coated with a commercial DSA
coating for chlorine production from Denora, consisting of a mixed
oxide of ruthenium oxide/iridium oxide, and a cathode space having
the gas diffusion electrode as cathode and having a gas space for
the oxygen and oxygen inlets and outlets, a liquid outlet and an
ion exchange membrane, which are arranged between anode space and
cathode space. A lower pressure prevailed in the anode space than
in the cathode space, so that the ion exchange membrane was pressed
onto the anode structure with a pressure of about 30 mbar as a
result of the higher pressure in the cathode chamber.
[0108] The electrolysis cell was operated at a brine concentration
of about 210 g/l (3.58 mol/l) of NaCl and a sodium hydroxide
concentration of about 31% by weight (10.4 mol/l) at electrolyte
temperatures of about 85.degree. C. The cell voltage was corrected
to 32% by weight (10.79 mol/l) of sodium hydroxide and 90.degree.
C. by customary standard methods.
[0109] The electrolytes were each introduced into the cell from
below and taken off again from the top of the cell.
[0110] Oxygen was fed to the gas space of the cathode. An oxygen
having a purity of more than 99.5% by volume of oxygen was used
here. The oxygen was humidified with water at room temperature
before being introduced into the gas space of the cathode half
shell. The amount of oxygen was regulated so that a 1.5-fold
stoichiometric excess over the amount of oxygen required based on
the current strength set was always introduced. The oxygen is fed
from the top into the gas space and discharged at the bottom.
[0111] The electrolysis unit had a gap of about 3 mm between
oxygen-depolarized electrode and ion exchange membrane. This gap
was filled with a porous PTFE woven fabric as percolator and
spacer.
[0112] The production current density was 6 kA/m.sup.2.
Example 1--Start-Up
[0113] Before start-up of the catholyte circuit, oxygen saturated
with water was fed at room temperature into the cathode space so
that the pressure in the cathode gas space was 59 mbar. The
hydrostatic pressure of the sodium hydroxide solution at the lowest
point in the cell was 32 mbar.
[0114] After this, an external catholyte circuit containing an
about 31% strength by weight (10.4 mol/l) sodium hydroxide solution
was started up and the sodium hydroxide solution was heated, but
the sodium hydroxide solution was not yet conveyed through the
cell.
[0115] In the next step, the anolyte circuit was, according to the
invention, started up and the anode space was filled with an
anolyte having a concentration of about 210 g of NaCl/l (3.58
mol/l). While the anode circuit was maintained and the anolyte was
conveyed through the cell, the anolyte was heated to 50.degree. C.
by means of a heat exchanger present in the anode circuit.
[0116] After the sodium hydroxide solution had attained a
temperature of 50.degree. C., the sodium hydroxide solution having
a temperature of 50.degree. C. was fed into the cell and, after
filling of the cathode gap within 30 seconds, an electrolysis
voltage of 1.08 V was applied. This resulted in a current density
of 10 mA/cm.sup.2 being established.
[0117] The pH of the outflowing anolyte was 8.
[0118] The electrolyte was heated from 50.degree. C. to 70.degree.
C. within 1 hour. After the temperature of the outflowing anolyte
and catholyte of 70.degree. C. had been attained, the electrolysis
voltage was increased, with the electrolysis voltage being
increased such that the current density was raised every 2 minutes
by 50 mA/cm.sup.2 up to a current density of 600 mA/cm.sup.2.
[0119] The concentrations were regulated after start-up so that the
concentration of the outflowing brine was about 210 g/l (3.59
mol/l) and that of the sodium hydroxide solution was about 31.5% by
weight (10.6 mol/l).
[0120] The cell was operated for at least 24 hours under these
conditions.
Example 2--Shutdown--According to the Invention
[0121] The electrolysis unit was operated at a current density of
600 mA/cm.sup.2.
[0122] For shutdowns, the current density was reduced to 1.5
mA/cm.sup.2. For this purpose, the main rectifier was disconnected
and the polarization rectifier was switched in. The polarization
rectifier then takes over maintenance of a current density of 1.5
mA/cm.sup.2. The operation at the low current density was
maintained for 1.5 hours. After this, the anolyte is chlorine-free.
This process is carried out in industrial electrolyzers for safety
reasons. One of the reasons is that chlorine or chlorine compounds
such as hypochlorite do not diffuse from the anolyte through the
ion exchange membrane into the catholyte and lead there to
corrosion of cell components or the gas diffusion electrode. On the
basis of experience, the phase of chlorine-free flushing takes
about 1.5 hours in industrial electrolyzers.
[0123] Electrolyte circuits remained in operation with the same
volume flows as in electrolysis operation at 600 mA/cm.sup.2. The
O.sub.2 supply was likewise maintained.
[0124] During the phase of chlorine-free flushing, the temperature
of the anolyte and of the catholyte was reduced from 85.degree. C.
to 70.degree. C. The cell voltage during this phase was about 1.16
V and the pH of the outflowing anolyte from the cell was pH
8.2.
[0125] After 1.5 hours, the temperature of anolyte and catholyte is
reduced to 50.degree. C., with the polarization rectifier being
operated potentiostatically. Here, the voltage of 1.16 V is
maintained and the current is appropriately decreased.
[0126] After cooling of anolyte and catholyte, the polarization
rectifier is disconnected and the catholyte is immediately drained
from the cathode space. This occurs over a time of about 30
seconds. After emptying of the cathode space, the anode space is
drained within 1 hour.
[0127] The anode space is filled with deionized water from below up
to a height of max. 50% of the cell height and immediately drained
off again.
[0128] The cathode gap was likewise flushed by renewed switching-on
of the catholyte pump and feeding of catholyte into the cathode
space. For this purpose, the catholyte pump was switched on for
about 10 seconds. The catholyte gap ran empty within 15
seconds.
[0129] The cell was then allowed to stand for 10 hours.
[0130] The start-up was then carried out as described in Example
1.
[0131] A total of 32 downtimes (shutdown processes) were carried
out.
[0132] At the beginning of the experiment, the cell voltage at a
current density of 600 mA/cm.sup.2 was 2.48 V.
[0133] After 32 downtimes, the cell voltage at a current density of
600 mA/cm.sup.2 was 2.48 V.
[0134] The cell voltage remained unchanged and damage to the gas
diffusion electrode and further components did not occur.
Example 3--Shutdown--Comparative Example
[0135] An electrolysis unit was started up as in Example 1.
Shutdown was carried out according to the prior art, as follows:
[0136] reduction of the electrolysis current to 1.8 mA/cm.sup.2
[0137] electrolyte circuits remained in operation with the same
volume flow as in electrolysis operation, likewise the O.sub.2
supply [0138] the temperature of the electrolytes was reduced to
75.degree. C. within 1.5 hours while a current density of 1.8
mA/cm.sup.2 is maintained. [0139] the voltage supply was switched
off [0140] immediately after switching off of the voltage supply,
the anode space was firstly emptied over a time of about 1 hour.
[0141] after emptying of the anode space, the cathode space was
emptied. [0142] the anode space was then filled from below with
deionized water, with the anode space being filled only halfway and
immediately drained again. [0143] the cathode gap was flushed
further with catholyte. After draining off of the anolyte, the
catholyte was also drained from the cathode gap. [0144] the cell
was then allowed to stand for 10 hours. [0145] start-up was carried
out as described in Example 1. [0146] 5 downtimes according to the
above-described procedure for shutdown were carried out [0147] at
the beginning of the experiment, the cell voltage at a current
density of 400 mA/cm.sup.2 was 2.11 V [0148] after 5 downtimes, the
cell voltage at a current density of 400 mA/cm.sup.2 was 2.14
V.
[0149] The cell voltage increased by 30 mV, and damage to the gas
diffusion electrode occurred.
* * * * *