Apparatus, system, and method for a dynamic rotational electrochemical reactor

Abstract

A dynamic rotational electrochemical reactor, system and process, for treatment of liquids and gases, can function as a rotational electrochemical-coagulation-reactor or a rotational electrochemical-oxidation reactor. An electrochemical reactor can include a reactor vessel with a fluid inlet and a fluid outlet; a reactor body, having an inlet turbine, such that the reactor body is rotatably attached to a drive shaft within the reactor vessel, the drive shaft connected to a plate-stack comprising electrode plates; and a voltage source connected to the electrodes, wherein the plate-stack includes angled channels for accepting the fluid, such that the fluid flows between sets of positive and negative electrode plates. The plate-stack can be connected with conductive studs and support studs, and can include pairs of intermediate electrode plates, mounted on top and bottom sides of an intermediate plastic support plate, and connected via an electric conductive spring.

What is claimed is: 
     
         1 . An electrochemical reactor, comprising:
 a. a reactor vessel having a top end, a bottom end, and side walls, defining a generally closed region for containing a fluid to be treated, the reactor vessel comprising a fluid inlet and a fluid outlet;   b. a pump mechanism arranged in fluid flow connection with the fluid inlet;   c. a rotatable reactor body configured in the reactor vessel along a central axes of the reactor vessel, comprising a plate-stack comprising electrode plates, the plate-stack comprising angled channels for accepting the fluid, such that the fluid flows between sets of positive and negative electrode plates; and   d. a voltage source, which is electrically connected to the electrode plates.   
     
     
         2 . The electrochemical reactor of  claim 1 , wherein the fluid outlet is located above the fluid inlet. 
     
     
         3 . The electrochemical reactor of  claim 1 , wherein the pump mechanism is an inlet turbine. 
     
     
         4 . The electrochemical reactor of  claim 1 , wherein the fluid inlet is mounted at the bottom end of the reactor vessel. 
     
     
         5 . The electrochemical reactor of  claim 1 , further comprising a drive shaft, such that the reactor body is attached to the drive shaft, which is configured centrally and extending vertically within the reactor vessel, along the central axis of the reactor vessel, wherein the drive shaft is connected to the plate-stack. 
     
     
         6 . The electrochemical reactor of  claim 5 , wherein the electrode plates each have a proximal end, which is mechanically connected to the drive shaft, and a distal portion, which is distal to the drive shaft, and wherein each of the electrode plates, are parallel and raised at an angle towards the top end of the reactor body. 
     
     
         7 . The electrochemical reactor of  claim 5 , wherein the electrode plates further comprise at least one pair of intermediate electrode plates, which are mounted together, such that an intermediate plastic support plate is mounted between a top intermediate electrode plate and a bottom intermediate electrode plate, and such the top intermediate electrode plate and the bottom intermediate electrode plate are electrically connected via an electric conductive spring, such that a first channel is formed above the top intermediate electrode plate, and a second channel is formed below the bottom intermediate electrode plate. 
     
     
         8 . The electrochemical reactor of  claim 5 , further comprising a drive motor, which is mounted to the reactor vessel and connected to the drive shaft, such that the drive motor rotates the drive shaft, whereby the reactor body rotates. 
     
     
         9 . The electrochemical reactor of  claim 8 , wherein the drive motor is an electric motor. 
     
     
         10 . The electrochemical reactor of  claim 1 , wherein the reactor vessel further comprises a cylindrical space between side walls of the reactor vessel and the reactor body. 
     
     
         11 . The electrochemical reactor of  claim 1 , wherein the reactor body is configured to function as a Tesla pump, during rotation of the reactor body, such that the fluid is pumped in direction from the fluid inlet to the fluid outlet. 
     
     
         12 . The electrochemical reactor of  claim 1 , further comprising a ventilation inlet, wherein the ventilation inlet is located above the fluid outlet. 
     
     
         13 . The electrochemical reactor of  claim 12 , further comprising a forced ventilation blower, wherein the forced ventilation blower is configured in fluid connection with the ventilation inlet. 
     
     
         14 . The electrochemical reactor of  claim 12 , further comprising at least one ventilation outlet, wherein the at least one ventilation outlet is located above the ventilation inlet. 
     
     
         15 . The electrochemical reactor of  claim 5 , wherein the electrode plates are parallel electrode plates and the parallel electrode plates are connected to the drive shaft. 
     
     
         16 . The electrochemical reactor of  claim 15 , wherein the parallel electrode plates are configured with gaps between the parallel electrode plates, such that the gaps form channels between each of the parallel electrode plates. 
     
     
         17 . The electrochemical reactor of  claim 16 , wherein the channels are in fluid connection with a cylindrical space between the reactor vessel and the reactor body. 
     
     
         18 . The electrochemical reactor of  claim 16 , wherein each of the gaps is between 2-10 mm. 
     
     
         19 . The electrochemical reactor of  claim 1 , wherein the voltage source is a direct current power supply, which supplies a direct current. 
     
     
         20 . The electrochemical reactor of  claim 19 , wherein the voltage source is configured such that a polarity of the direct current is reversible. 
     
     
         21 . The electrochemical reactor of  claim 19 , wherein the voltage source is configured to provide variable voltage and control of voltage pulse duration. 
     
     
         22 . The electrochemical reactor of  claim 1 , further comprising a particle size sensor, which is mounted within the fluid inlet. 
     
     
         23 . The electrochemical reactor of  claim 1 , further comprising a pre-filtration screen, which is attached to the fluid inlet, such that the fluid entering the fluid inlet passes through the pre-filtration screen. 
     
     
         24 . The electrochemical reactor of  claim 1 , wherein the electrode plates further comprise a top electrode plate and a bottom electrode plate. 
     
     
         25 . The electrochemical reactor of  claim 24 , wherein the electrode plates further comprise at least one intermediate electrode plate, mounted between the top electrode plate and the bottom electrode plate. 
     
     
         26 . The electrochemical reactor of  claim 25 , wherein the top electrode plate and the bottom electrode plate are mono-polar electrode plates, and wherein the at least one intermediate electrode plate is a bi-polar electrode plate. 
     
     
         27 . The electrochemical reactor of  claim 26 , wherein one of the mono-polar electrode plates is a positive electrode plate and the other of the mono-polar electrode plates is a negative electrode plate, whereby current flows from the positive mono-polar electrode plate to the at least one intermediate electrode plate and subsequently to the negative electrode plate, whereby current passes through the fluid in the channels. 
     
     
         28 . The electrochemical reactor of  claim 6 , wherein the angle is 5 to 25 degrees. 
     
     
         29 . The electrochemical reactor of  claim 8 , wherein the drive motor is configured to be speed adjustable, such that a rotation speed of the drive shaft is adjustable. 
     
     
         30 . The electrochemical reactor of  claim 1 , further comprising a rotational contact, which is mounted at the top end of the reactor vessel, wherein the voltage source provides electric current to the reactor body through a positive and a negative contact of the rotational contact. 
     
     
         31 . The electrochemical reactor of  claim 30 , wherein the electric current is guided from the rotational contact to the reactor body by insulated wires. 
     
     
         32 . The electrochemical reactor of  claim 31 , further comprising an electrical contact chamber, wherein the electric current is guided from the rotational contact to the reactor body by insulated wires, which pass through a drive shaft, such that the insulated wires connect to positive and negative electrical contacts in the electrical contact chamber. 
     
     
         33 . The electrochemical reactor of  claim 32 , wherein the reactor body further comprises a first conductive stud; and a second conductive stud;
 wherein the plate stack further comprises a top electrode plate and a bottom electrode plate;   wherein a positive lead of the positive electrical contact is connected via the first conductive stud, which is connected to an electric contact bushing, which is connected to a top electric contact plate, which is connected to electric conductive springs that are connected to the top electrode plate in the plate stack;   wherein a negative lead of the negative electrical contact is connected via the second conductive stud to an electric contact bushing, which is connected to a bottom current distributor ring, which is connected to an electric conductive spring, which is connected to the bottom electrode plate.   
     
     
         34 . The electrochemical reactor of  claim 1 , wherein the reactor body further comprises a plurality of support studs;
 wherein each support stud is mounted through each electrode plate in the plate stack, whereby the support studs mechanically connect the contact plates, and stabilize the plate-stack;   wherein each support stud is electrically isolated from the contact plates, with top and bottom isolation bushings and with isolation tubes.   
     
     
         35 . The electrochemical reactor of  claim 1 , wherein each electrode plate in the plate stack is a circular angled plate, with an inner aperture formed by an inner periphery, such that the inner periphery is lower than an outer periphery, whereby the contact plate is angled upwards from the inner periphery, whereby the plate stack of circular angled plates has a central chamber formed by a plurality of inner apertures. 
     
     
         36 . The electrochemical reactor of  claim 1 , wherein the reactor vessel comprises at least two reactor bodies arranged in series. 
     
     
         37 . The electrochemical reactor of  claim 1 , wherein the electrode plates comprise a solid material selected from the group consisting of Boron doped diamond, platinum, lead oxide, ruthenium oxide, iridium oxide, and combinations thereof. 
     
     
         38 . The electrochemical reactor of  claim 1 , wherein the electrode plates comprise a crystalline material selected from the group consisting of Boron doped diamond, platinum, lead oxide, ruthenium oxide, iridium oxide, and combinations thereof. 
     
     
         39 . The electrochemical reactor of  claim 38 , wherein the crystalline material is coated onto a wafer made from a material selected from the group consisting of silicium, selenium, and palladium. 
     
     
         40 . The electrochemical reactor of  claim 38 , wherein the crystalline material is embedded in a polymeric film or matrix. 
     
     
         41 . The electrochemical reactor of  claim 1 , wherein the electrode plate is made from a material selected from the group consisting of aluminum, stainless steel, titanium, graphite, graphene, iron, magnesium, copper, and combinations thereof. 
     
     
         42 . The electrochemical reactor of  claim 3 , wherein the inlet turbine is constructed from plastic materials. 
     
     
         43 . The electrochemical reactor of  claim 1 , wherein the reactor body further comprises a central chamber, which is encircled by the plate-stack, wherein the electrochemical reactor is configured such that the fluid flows from the fluid inlet to the central chamber, then via the angled channels in the plate-stack, to the fluid outlet. 
     
     
         44 . A dynamic electrocoagulation process for treating a fluid, comprising:
 a. providing an electrochemical reactor, comprising:
 i. a reactor vessel constructed from one or more plastic materials having a top end and a bottom end, and comprising a fluid inlet and a fluid outlet, wherein the fluid outlet is provided above the fluid inlet; 
 ii. a reactor body arranged in the reactor vessel along a central axis of the reactor vessel, the reactor body having an inlet turbine configured at the bottom end of the reactor vessel, in fluid flow connection with the fluid inlet, wherein the reactor body is rotatably attached to a drive shaft arranged centrally and extending vertically within the reactor vessel, wherein the drive shaft is connected to a plate-stack comprising electrode plates, and a voltage source; 
 wherein the plate-stack comprises angled channels for accepting the fluid, such that the fluid flows between sets of positive and negative electrode plates; 
 wherein the electrochemical reactor is configured for electrocoagulation; 
   b. conveying a fluid into the reactor vessel through the fluid inlet;   c. pressurizing the reactor body via rotation of the inlet turbine;   d. applying electric current to the reactor body, wherein the plate-stack comprises positive and negative electrode plates, and rotating the reactor body in the reactor vessel to cause a hydraulic movement of the fluid through the reactor body;   e. reacting the fluid with the electrode plates to form treated fluid;   f. controlling a velocity of rotation of the reactor body to move the treated fluid through the channels formed by gaps between the positive and negative electrode plates and out of the reactor body through the channels into a cylindrical space between the reactor body and the reactor vessel;   g. conveying the treated fluid from the cylindrical space through the fluid outlet; and   h. expelling the treated fluid out of the reactor vessel;   wherein electric current supplied to the reactor body is controlled and reversed during the dynamic electrocoagulation process to yield high efficiency electrocoagulation.   
     
     
         45 . The dynamic electrocoagulation process of  claim 44 , further comprising expelling gases produced by the electrocoagulation process out of the reactor vessel through one or more ventilation outlets by feeding a vent gas through a ventilation inlet. 
     
     
         46 . The dynamic electrocoagulation process of  claim 44 , wherein reacting the fluid further comprises determining the a type of undesirable materials in the fluid, selecting rotation acceleration rates and velocities, voltage to be applied, and arranging a predetermined number of intermediate plates between positive and negative electrode plates to yield an intermediate voltage and contact time between the fluid and the electrode plates, in order to create an optimal configuration for formation of suspended particles in the treated fluid. 
     
     
         47 . The dynamic electrocoagulation process of  claim 44 , further comprising reducing a thickness of fluid boundary layers on the electrodes, by increasing rotation velocity of the reactor body. 
     
     
         48 . The dynamic electrocoagulation process of  claim 44 , further comprising recycling treated fluid for one or more additional passes through the electrochemical reactor. 
     
     
         49 . A dynamic electro-oxidation process for treating a fluid comprising:
 a. providing an electrochemical reactor, comprising:
 i. a reactor vessel constructed from one or more plastic materials, having a top end and a bottom end and comprising a fluid inlet and a fluid outlet, wherein the fluid outlet is provided above the fluid inlet; 
 ii. a reactor body arranged in the reactor vessel along a central axis of the reactor vessel, the reactor body having an inlet turbine arranged at the bottom of the reactor vessel in fluid flow connection with the fluid inlet, wherein the reactor body is rotatably attached to a drive shaft arranged centrally and extending vertically within the reactor vessel, wherein the drive shaft is connected to a plate-stack comprising electrode plates, and a voltage source, 
 wherein the plate-stack comprises angled channels for accepting the fluid, such that the fluid flows between sets of positive and negative electrode plates; 
 wherein the electrochemical reactor is configured for electro-oxidation; 
   b. conveying a fluid into the reactor vessel through the fluid inlet;   c. pressurizing the reactor body via rotation of the inlet turbine;   d. applying electric current to the reactor body, wherein the plate-stack comprises positive and negative electrode plates, and rotating the reactor body in the reactor vessel to cause a hydraulic movement of the fluid through the reactor body;   e. reacting the fluid with the electrode plates to form treated fluid;   f. controlling a velocity of rotation of the reactor body to move the treated fluid through the channels formed by gaps between the electrode plates and out of the reactor body through the channels into a cylindrical space between the reactor body and the reactor vessel;   g. conveying the treated fluid from the cylindrical space through the fluid outlet; and   h. expelling the treated fluid out of the reactor vessel;   wherein electric current supplied to the reactor body is controlled and reversed during the dynamic electro-oxidation process to yield high efficiency electro-oxidation.   
     
     
         50 . The dynamic electro-oxidation process of  claim 49 , comprising reducing a thickness of fluid boundary layers on the electrodes by increasing rotation velocity of the reactor body.