Magnetically-enhanced electrolytic cells for generating chlor-alkali and methods related thereto

Abstract

An electrolytic cell for producing a chlor-alkali including at least two electrodes in reactive contact with an aqueous liquid containing a chloride salt, wherein at least one of the electrodes is within a magnetic field is described herein.

What is claimed is:  
     
         1 . An electrolytic cell for producing a chlor-alkali comprising at least two electrodes in reactive contact with an aqueous liquid containing a chloride salt, wherein at least one of the electrodes is within a magnetic field.  
     
     
         2 . The electrolytic cell of  claim 1  wherein said chlor-alkali is chlorine gas.  
     
     
         3 . The electrolytic cell of  claim 1  wherein said chlor-alkali is hydrogen gas.  
     
     
         4 . The electrolytic cell of  claim 1  wherein said chlor-alkali is sodium hydroxide.  
     
     
         5 . The electrolytic cell of  claim 1  wherein said chlor-alkali is potassium hydroxide.  
     
     
         6 . The electrolytic cell of  claim 1  wherein said chlor-alkali is a hypochlorite.  
     
     
         7 . The electrolytic cell of  claim 1  wherein said chlor-alkali is a chlorate.  
     
     
         8 . The electrolytic cell of  claim 1  wherein said chlor-alkali is a chlorite.  
     
     
         9 . The electrolytic cell of  claim 1  wherein said chlor-alkali is a perchlorate.  
     
     
         10 . The electrolytic cell of  claim 1  wherein said electrode is a platinum working cathode.  
     
     
         11 . The electrolytic cell of  claim 1  wherein said electrode is a carbon working anode.  
     
     
         12 . The electrolytic cell of  claim 1  wherein said at least one electrode is formed by applying a magnetic coating onto the surface of the electrode.  
     
     
         13 . The electrolytic cell of  claim 12  wherein said magnetic coating comprises at least one encapsulated magnetic microparticle or microsphere, at least one binding agent and at least one catalyst.  
     
     
         14 . The electrolytic cell of  claim 13  wherein said magnetic coating comprises about 10% to about 20% said encapsulated magnetic microparticle or microsphere, about 10% to about 20% said at least one catalyst and about 65% to about 75% said at least one binding agent.  
     
     
         15 . The electrolytic cell of  claim 13  wherein said catalyst is carbon black.  
     
     
         16 . The electrolytic cell of  claim 13  wherein said catalyst is ruthenium black.  
     
     
         17 . The electrolytic cell of  claim 13  wherein said catalyst is platinum black.  
     
     
         18 . The electrolytic cell of  claim 13  wherein said catalyst is platinized carbon.  
     
     
         19 . The electrolytic cell of  claim 13  wherein said catalyst is a magnetocatalyst.  
     
     
         20 . The electrolytic cell of  claim 13  wherein said catalyst is a metal or metal oxide.  
     
     
         21 . The electrolytic cell of  claim 13  wherein said encapsulated magnetic microparticle or microsphere has a diameter of about 0.5 microns to about 10 microns.  
     
     
         22 . The electrolytic cell of  claim 13  wherein said coated electrode is exposed to an external magnetic field.  
     
     
         23 . The electrolytic cell of  claim 13  wherein said binding agent comprises at least one polymer.  
     
     
         24 . The electrolytic cell of  claim 23  wherein said polymer is polystyrene.  
     
     
         25 . The electrolytic cell of  claim 23  wherein said polymer is polyvinylpropyline.  
     
     
         26 . The electrolytic cell of  claim 23  wherein said polymer is a perfluorinated polymer.  
     
     
         27 . The electrolytic cell of  claim 23  wherein said polymer is a conducting polymer.  
     
     
         28 . The electrolytic cell of  claim 23  wherein said polymer is polytetrafluoroethylene.  
     
     
         29 . The electrolytic cell of  claim 23  wherein said polymer is a co-polymer.  
     
     
         30 . The electrolytic cell of  claim 23  wherein said polymer is a polymer composite.  
     
     
         31 . The electrolytic cell of  claim 13  wherein said binding agent comprises glass.  
     
     
         32 . The electrolytic cell of  claim 13  wherein said binding agent comprises at least one sol-gel material.  
     
     
         33 . The electrolytic cell of  claim 13  wherein said binding agent comprises at least one high-temperature ceramic.  
     
     
         34 . The electrolytic cell of  claim 13  wherein said binding agent comprises at least one metal.  
     
     
         35 . The electrolytic cell of  claim 13  wherein said at least one encapsulated magnetic microparticle is a silane encapsulated microparticle.  
     
     
         36 . The electrolytic cell of  claim 13  wherein said encapsulated magnetic microparticle comprises at least one substance selected from a group consisting of magnetite, samarium cobalt, neodymium iron boron, an iron based magnet, a magnet semi-conducting material, a molecular magnet and ferro fluids.  
     
     
         37 . The electrolytic cell of  claim 1  wherein said at least one electrode is formed by exposing the electrode to an external magnetic force.  
     
     
         38 . The electrolytic cell of  claim 13  wherein said encapsulated microparticle or microsphere is formed by coating an encapsulating material onto a surface of said microparticle or microsphere, wherein said encapsulating material is impermeable to gases and ions.  
     
     
         39 . The electrolytic cell of  claim 38  wherein said encapsulating material comprises at least one polymer.  
     
     
         40 . The electrolytic cell of  claim 39  wherein said polymer is polystyrene.  
     
     
         41 . The electrolytic cell of  claim 39  wherein said polymer is polyvinylpropyline.  
     
     
         42 . The electrolytic cell of  claim 39  wherein said polymer is a perfluorinated polymer.  
     
     
         43 . The electrolytic cell of  claim 39  wherein said polymer is a conducting polymer.  
     
     
         44 . The electrolytic cell of  claim 39  wherein said polymer is polytetrafluoroethylene.  
     
     
         45 . The electrolytic cell of  claim 39  wherein said polymer is a co-polymer.  
     
     
         46 . The electrolytic cell of  claim 39  wherein said polymer is a composite polymer.  
     
     
         47 . The electrolytic cell of  claim 38  wherein said encapsulating material comprises glass.  
     
     
         48 . The electrolytic cell of  claim 38  wherein said encapsulating material comprises at least one sol-gel material.  
     
     
         49 . The electrolytic cell of  claim 38  wherein said encapsulating material comprises at least one high-temperature ceramic.  
     
     
         50 . The electrolytic cell of  claim 38  wherein said encapsulating material comprises at least one metal.  
     
     
         51 . The electrolytic cell of  claim 38  wherein said at least one encapsulated magnetic microparticle is a silane encapsulated microparticle.  
     
     
         52 . An electrolytic cell for producing a chlor-alkali comprising at least two electrodes in reactive contact with an aqueous liquid containing a chloride salt, wherein at least one of the electrodes is within a magnetic field and formed by applying a magnetic coating onto the surface of the electrode to aid in producing the chlor-alkali.  
     
     
         53 . An electrolytic cell for producing a chlor-alkali comprising at least two electrodes in reactive contact with an aqueous liquid containing a chloride salt, wherein at least one of the electrodes is within a magnetic field and formed by applying a magnetic coating onto the surface of the electrode to aid in producing the chlor-alkali, wherein said magnetic coating comprises at least one encapsulated magnetic microparticle or microsphere, a binding agent and a catalyst.  
     
     
         54 . A method for producing a chlor-alkali from an aqueous liquid containing a chloride salt, comprising inducing an electrolytic reaction between at least two electrodes in reactive contact with the aqueous liquid, at least one of said electrodes being within a magnetic field to aid in producing the chlor-alkali.  
     
     
         55 . The method of  claim 54  wherein said chlor-alkali is chlorine gas.  
     
     
         56 . The method of  claim 54  wherein said chlor-alkali is hydrogen gas.  
     
     
         57 . The method of  claim 54  wherein said chlor-alkali is sodium hydroxide.  
     
     
         58 . The method of  claim 54  wherein said chlor-alkali is a chlorate.  
     
     
         59 . The method of  claim 54  wherein said chlor-alkali is a chlorite.  
     
     
         60 . The method of  claim 54  wherein said chlor-alkali is a perchlorate.  
     
     
         61 . The method of  claim 54  wherein said chlor-alkali is potassium hydroxide.  
     
     
         62 . The method of  claim 54  wherein said chlor-alkali is a hypochlorite.  
     
     
         63 . The method of  claim 54  further comprising purifying said aqueous liquid prior to the electrolytic reaction.  
     
     
         64 . The method of  claim 54  further comprising evaporating said aqueous liquid prior to the electrolytic reaction.  
     
     
         65 . The method of  claim 54  wherein said electrode is a platinum working cathode.  
     
     
         66 . The method of  claim 54  wherein said electrode is a carbon working anode.  
     
     
         67 . The method of  claim 54  wherein at least one of said electrodes that is within a magnetic field has a magnetic coating thereon.  
     
     
         68 . The method of  claim 67  wherein said magnetic coating comprises at least one encapsulated magnetic microparticle or microsphere, a binding agent and a catalyst.  
     
     
         69 . The method of  claim 68  wherein said magnetic coating comprises about 10% to about 20% said encapsulated magnetic microparticle or microsphere, about 10% to about 20% said at least one catalyst and about 65% to about 75% said at least one binding agent.  
     
     
         70 . The method of  claim 68  wherein the electrode that has a magnetic coating is a platinum working cathode.  
     
     
         71 . The method of  claim 68  wherein the electrode that has a magnetic coating is a carbon working anode.  
     
     
         72 . The method of  claim 68  wherein said catalyst is carbon black.  
     
     
         73 . The method of  claim 68  wherein said catalyst is ruthenium black.  
     
     
         74 . The method of  claim 68  wherein said catalyst is platinum black.  
     
     
         75 . The method of  claim 68  wherein said catalyst is platinized carbon.  
     
     
         76 . The method of  claim 68  wherein said catalyst is a magnetocatalyst.  
     
     
         77 . The method of  claim 68  wherein said catalyst is a metal or metal oxide.  
     
     
         78 . The method of  claim 68  wherein said magnetic microparticle or microsphere has a diameter of about 0.5 microns to about 12 microns.  
     
     
         79 . The method of  claim 68  wherein the electrode that has a magnetic coating is exposed to an external magnetic field during the electrolytic reaction.  
     
     
         80 . The method of  claim 68  wherein said binding agent comprises at least one polymer.  
     
     
         81 . The method of  claim 80  wherein said polymer is polystyrene.  
     
     
         82 . The method of  claim 80  wherein said polymer is polyvinylpropyline.  
     
     
         83 . The method of  claim 80  wherein said polymer is a perfluorinated polymer.  
     
     
         84 . The method of  claim 80  wherein said polymer is a conducting polymer.  
     
     
         85 . The method of  claim 80  wherein said polymer is polytetrafluoroethylene.  
     
     
         86 . The method of  claim 80  wherein said polymer is a co-polymer.  
     
     
         87 . The method of  claim 80  wherein said polymer is a composite polymer.  
     
     
         88 . The method of  claim 68  wherein said binding agent comprises glass.  
     
     
         89 . The method of  claim 68  wherein said binding agent comprises at least one sol-gel material.  
     
     
         90 . The method of  claim 68  wherein said binding agent comprises at least one high-temperature ceramic.  
     
     
         91 . The method of  claim 68  wherein said binding agent comprises at least one metal.  
     
     
         92 . The method of  claim 68  wherein said at least one encapsulated magnetic microparticle or microsphere is a silane encapsulated microparticle.  
     
     
         93 . The method of  claim 68  wherein said encapsulated magnetic microparticle or microsphere comprises at least one substance selected from a group consisting of magnetite, samarium cobalt, neodymium iron boron, an iron based magnet, a magnet semi-conducting material, a molecular magnet and ferro fluids.  
     
     
         94 . The method of  claim 54  wherein at least one of said electrodes that is within a magnetic field is formed by exposing the electrode to an external magnetic force.  
     
     
         95 . The method of  claim 54  wherein at least one of said electrodes is formed by coating at least one encapsulated magnetic microparticle or microsphere onto the electrode that is within a magnetic field, wherein said microparticle is coated with a catalyst.  
     
     
         96 . The method of  claim 95  wherein at least one of said electrodes is a platinum working cathode.  
     
     
         97 . The method of  claim 95  wherein at least one of said electrode is a carbon working anode.  
     
     
         98 . The method of  claim 95  wherein said catalyst is carbon black.  
     
     
         99 . The method of  claim 95  wherein said catalyst is ruthenium black.  
     
     
         100 . The method of  claim 95  wherein said catalyst is a metal or metal oxide.  
     
     
         101 . The method of  claim 95  wherein said catalyst is a magnetocatalyst.  
     
     
         102 . The method of  claim 95  wherein said catalyst is platinum black.  
     
     
         103 . The method of  claim 95  wherein said catalyst is platinized carbon.  
     
     
         104 . The method of  claim 95  wherein said encapsulated magnetic microparticle or microsphere has a diameter of about 0.5 microns to about 10 microns.  
     
     
         105 . The method of  claim 95  wherein the electrode that has a magnetic coating is exposed to an external magnetic field during the electrolytic reaction.  
     
     
         106 . The method of  claim 95  wherein said encapsulated microparticle or microsphere is formed by coating an encapsulating material onto a surface of said microparticle or microsphere, wherein said encapsulating material is impermeable to gases and ions.  
     
     
         107 . The method of  claim 106  wherein said encapsulating material comprises at least one polymer.  
     
     
         108 . The method of  claim 107  wherein said polymer is polystyrene.  
     
     
         109 . The method of  claim 107  wherein said polymer is polyvinylpropyline.  
     
     
         110 . The method of  claim 107  wherein said polymer is a perfluorinated polymer.  
     
     
         111 . The method of  claim 107  wherein said polymer is a conducting polymer.  
     
     
         112 . The method of  claim 107  wherein said polymer is polytetrafluoroethylene.  
     
     
         113 . The method of  claim 107  wherein said polymer is a co-polymer.  
     
     
         114 . The method of  claim 107  wherein said polymer is a composite polymer.  
     
     
         115 . The method of  claim 106  wherein said encapsulating material comprises glass.  
     
     
         116 . The method of  claim 106  wherein said encapsulating material comprises at least one sol-gel material.  
     
     
         117 . The method of  claim 106  wherein said encapsulating material comprises at least one high-temperature ceramic.  
     
     
         118 . The method of  claim 106  wherein said encapsulating material comprises at least one metal.  
     
     
         119 . The method of  claim 95  wherein said at least one encapsulated magnetic microparticle is a silane encapsulated microparticle.  
     
     
         120 . The method of  claim 54  wherein said at least one of said electrode is in reactive contact with at least one catalyst.  
     
     
         121 . The method of  claim 120  wherein said catalyst is a magnetocatalyst.  
     
     
         122 . The method of  claim 120  wherein said catalyst is metal or metal oxide.  
     
     
         123 . The method of  claim 120  wherein said catalyst is platinum black.  
     
     
         124 . The method of  claim 120  wherein said catalyst is platinized carbon.  
     
     
         125 . The method of  claim 120  wherein said electrode is a platinum working cathode.  
     
     
         126 . The method of  claim 120  wherein said electrode is a carbon working anode.  
     
     
         127 . The method of  claim 120  wherein said catalyst is carbon black.  
     
     
         128 . The method of  claim 120  wherein said catalyst is ruthenium black.  
     
     
         129 . The method of  claim 54  wherein the electrode that is within a magnetic field is coated with a magnetic catalyst.  
     
     
         130 . The method of  claim 129  wherein said magnetic catalyst is a lanthanide-based semiconducting catalyst.  
     
     
         131 . The method of  claim 129  wherein said magnetic catalyst is nickel.  
     
     
         132 . The method of  claim 129  wherein said magnetic catalyst is cobalt.  
     
     
         133 . The method of  claim 54  wherein the electrode that is within the magnetic field is coated with a magnetic binding agent.  
     
     
         134 . A method for producing a chlor-alkali from an aqueous liquid containing a chloride salt, comprising inducing an electrolytic reaction between at least two electrodes in reactive contact with the aqueous liquid, wherein at least one of said electrodes is within a magnetic field and formed by applying a magnetic coating onto the surface of the electrode to aid in producing the chlor-alkali.  
     
     
         135 . A method for producing a chlor-alkali from an aqueous liquid containing a chloride salt, comprising inducing an electrolytic reaction between at least two electrodes in reactive contact with the aqueous liquid, wherein at least one of said electrodes is within a magnetic field and formed by applying a magnetic coating onto the surface of the electrode to aid in producing the chlor-alkali, wherein said magnetic coating comprises at least one encapsulated magnetic microparticle or microsphere, a binding agent and a catalyst.  
     
     
         136 . A chlor-alkali produced by the method of  claim 54 .  
     
     
         137 . A chlor-alkali produced by the method of  claim 68 .  
     
     
         138 . A chlor-alkali produced by the method of  claim 95 .  
     
     
         139 . A chlor-alkali produced by the method of  claim 120 .  
     
     
         140 . A chlor-alkali produced by the method of  claim 133.