Inert anode for electrochemical process

Abstract

An anode structure suitable for an electrochemical process is disclosed. The anode comprises a primary anode structure, also referred to as an anode frame, and a secondary metal substrate attached to the anode frame. The anode frame is a structural support and suitable electrical conductor. The metal substrate has an electrocatalytic coating and provides the anode with an anodic surface. The metal substrate is easily removable from the anode frame. Also disclosed is a method for refurbishing anodes according to the present invention. An anode comprising an anode frame and a metal substrate is refurbished by removing a depleted metal substrate from the frame and attaching a separate precoated metal substrate to the frame. The method of refurbishing optionally includes refurbishing the depleted metal substrate and using the refurbished substrate to refurbish the anode structure. A method for providing replacement anodes is also disclosed. The method includes supplying a user with an anode comprising an anode frame and a metal substrate attached thereto. The method also includes supplying one or more additional pre-coated substrates to the user, such that the user may refurbish the anode when necessary.

What is claimed:  
     
         1 . An anode for an aqueous electrochemical process, the anode comprising: 
 an anode frame; and    a titanium mesh or sheet substrate including an electrocatalytic coating, said titanium mesh substrate attached to the anode frame, wherein the anode frame provides electrical conductivity and the titanium mesh substrate provides an anodic surface.    
     
     
         2 . The anode according to  claim 1 , wherein the anode frame is substantially free of an electrocatalytic coating.  
     
     
         3 . The anode according to  claim 1 , wherein the electrocatalytic coating is a metal oxide selected from the group consisting of iridium oxide, tantalum oxide, ruthenium oxide, platinum oxide, and combinations thereof.  
     
     
         4 . The anode according to  claim 1 , wherein the anode frame exhibits a geometry complimentary to a corresponding cathode.  
     
     
         5 . The anode according to  claim 1 , wherein the titanium substrate is a flexible mesh sheet.  
     
     
         6 . The anode of  claim 5 , wherein the titanium mesh sheet exhibits a geometry complimentary to a corresponding anode.  
     
     
         7 . The anode according to  claim 1 , wherein the titanium mesh substrate is removable from the anode frame.  
     
     
         8 . The anode according to  claim 1 , wherein the thickness of the titanium mesh substrate is less than about 0.00165 meters.  
     
     
         9 . The anode according to  claim 1 , wherein said anode frame comprises titanium.  
     
     
         10 . A method for refurbishing an anode comprising the steps of: 
 1) providing a anode comprising an anode frame and a removable metal substrate attached thereto, the metal substrate comprising an electrocatalytic coating;    2) employing the anode of step (1) in an electrochemical process and depleting the electrocatalytic coating from the metal substrate;    3) removing the metal substrate from the anode frame;    4) applying an electrocatalytic coating to a second metal substrate;    5) attaching the metal substrate of step (4) to the anode frame of step (3);    6) employing the anode of step (5) in an electrochemical process.    
     
     
         11 . The method according to  claim 10 , wherein step (4) may be performed at any time prior to step (5).  
     
     
         12 . The method according to  claim 10 , further comprising the step of disposing of the first metal substrate after removing the first metal substrate from the anode frame.  
     
     
         13 . The method according to  claim 10 , further comprising the steps of: 
 providing a refurbished first metal substrate by applying a fresh electrocatalytic coating to the first metal substrate; 
 depleting the electrocatalytic coating from the second metal substrate by an electrochemical process;  
 removing the second metal substrate from the anode frame; and  
 attaching the refurbished first metal substrate to the anode frame thereby providing a refurbished anode.  
   
     
     
         14 . A method for providing replacement anodes for electrochemical processing, the method comprising; 
 supplying an anode to a user, the anode comprising an anode frame and a metal substrate having an electrocatalytic coating attached thereto; and    supplying one or more additional pre-coated metal substrates to the user, wherein the user a) depletes the electrocatalytic coating from the metal substrate during an electrochemical process, b) removes the metal substrate from the anode frame after the electrochemical process, c) refurbishes the anode by attaching one of the one or more additional metal substrates to the anode frame, and d) repeats a-c as desired.    
     
     
         15 . The method according to  claim 14 , wherein the user returns the metal substrate and the one or more additional metal substrates having a depleted electrocatalytic coating.  
     
     
         16 . The method according to  claim 15 , further comprising applying a fresh electrocatalytic coating to the metal substrate and the one or more additional metal substrates returned by the user.  
     
     
         17 . The method according to  claim 14 , wherein the one or more additional metal substrates supplied to the user are replacement disposable anodes.