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WO2024152036A1 - Fusion et production de polysilicium alimentées par hydrox - Google Patents

Fusion et production de polysilicium alimentées par hydrox Download PDF

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Publication number
WO2024152036A1
WO2024152036A1 PCT/US2024/011548 US2024011548W WO2024152036A1 WO 2024152036 A1 WO2024152036 A1 WO 2024152036A1 US 2024011548 W US2024011548 W US 2024011548W WO 2024152036 A1 WO2024152036 A1 WO 2024152036A1
Authority
WO
WIPO (PCT)
Prior art keywords
hydrox
gas
hydrogen
oxygen
charge
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2024/011548
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English (en)
Inventor
James S. Tyler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Erthos IP LLC
Original Assignee
Erthos IP LLC
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Filing date
Publication date
Application filed by Erthos IP LLC filed Critical Erthos IP LLC
Publication of WO2024152036A1 publication Critical patent/WO2024152036A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B3/00—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces
    • F27B3/10—Details, accessories or equipment, e.g. dust-collectors, specially adapted for hearth-type furnaces
    • F27B3/20—Arrangements of heating devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27B—FURNACES, KILNS, OVENS OR RETORTS IN GENERAL; OPEN SINTERING OR LIKE APPARATUS
    • F27B3/00—Hearth-type furnaces, e.g. of reverberatory type; Electric arc furnaces ; Tank furnaces
    • F27B3/10—Details, accessories or equipment, e.g. dust-collectors, specially adapted for hearth-type furnaces
    • F27B3/22—Arrangements of air or gas supply devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D99/00—Subject matter not provided for in other groups of this subclass
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25B—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B1/00—Electrolytic production of inorganic compounds or non-metals
    • C25B1/01—Products
    • C25B1/02—Hydrogen or oxygen
    • C25B1/04—Hydrogen or oxygen by electrolysis of water
    • C25B1/044—Hydrogen or oxygen by electrolysis of water producing mixed hydrogen and oxygen gas, e.g. Brown's gas [HHO]

Definitions

  • Silicon is the second most abundant element on Earth after oxygen. Making polysilicon is the first step in preparing conventional silicon solar cells.
  • the reaction to produce polysilicon is a carbothermic reduction of SiO2.
  • Quartzite or other SiO2 source is mixed with carbon in a submerged-arc electric furnace or blast furnace to heat the mixture to about 2000 °C, reducing the SiO2 to molten silicon.
  • a direct contact furnace is a furnace where a gas-oxygen flame is impinged directly onto ore to heat it.
  • a reverberatory furnace is a furnace used for smelting or refining in which the fuel is not in direct contact with ore but heats it by a flame blown over the ore from another chamber or the flame heats the walls of the reaction vessel, which radiate energy onto the ore to heat it.
  • Solar modules are assemblies of multiple photovoltaic (PV) cells wired to form a single unit, typically rigid but sometimes flexible. Typically, the modules are framed, but frameless panels can also be used. Multiple solar modules are wired together in series to form an array of strings. These strings connect to a power-receiving unit that provides power to a source, typically an inverter or other controller. One or more of these solar arrays compose a solar plant.
  • PV photovoltaic
  • Utility-scale solar PV power plants differ from other solar power and electricity installations. Due to the size, energy cost, safety regulations, and operating requirements of utility-scale power plants, the components, hardware design, construction means and methods, operations, and maintenance all have specific, unique features earning the designation utility-scale.
  • FIG. 2 shows a pictogram of a prior art system 10 that provides power for an electrolyzer 27 by converting DC power to AC power, transmitting power through grid 24, and converting back to DC power.
  • This process is method 301 , shown in flowchart form in FIG. 3.
  • variable DC power generated by one or more DC generators 20 is converted using DC/AC inverter 21.
  • DC/AC inverter 21 has a maximum power point tracker, which adjusts the load on the generators to maximize the power delivered to inverter 21 .
  • Inverter 21 converts the power into AC power, which feeds step-up transformer 22 and is transmitted along or over grid 24. Some versions have a shorter intermediate voltage connection 23 and a second step-up transformer (not shown).
  • step-down transformer 25 and rectifier 26 convert the AC power into DC power suitable for electrolyzer 27 and transfer it to electrolyzer 27.
  • Electrolyzer 27 converts water into a mixture of hydrogen and oxygen or structures in electrolyzer 27 separate the hydrogen and oxygen as they form. Then, the mixture of hydrogen and oxygen or separate streams of hydrogen and oxygen go through further gas separation in gas separator 28. Hydrogen and oxygen are stored separately in tank 11 .
  • Step 320 produces DC electricity.
  • step 330 which converts DC electricity into AC electricity with inverter 21 .
  • This energy is fed into step-up transformer 22 to transform the electricity to high-voltage AC in step 340.
  • the high-voltage electricity is sent across grid 24 to the location of electrolyzer 27 in step 350.
  • step 360 electricity from grid 24 is fed to step-down transformer 25 to transform it into a voltage suitable for electrolyzer 27.
  • step 370 the reduced voltage AC is rectified into DC power with rectifier 26.
  • Electrolyzer 27 uses the electricity from step 370 to electrolyze water in step 380.
  • Hydrogen and oxygen are the products from electrolyzer 27, and at least the hydrogen is collected in step 390.
  • Optional step 300 separates the hydrogen and oxygen generated in step 390 using gas compressor 29.
  • optional step 310 stores the hydrogen and oxygen in tank 11 .
  • FIG. 4 shows a similar system, except that DC generator 26 has been replaced by PV array 40.
  • Prior art solutions to the DC variability described above include using maximum power point trackers that convert the variable DC voltage into a voltage matched to the DC load (inverter) such that the power output is maximized or matched to the load. This arrangement leads to typical electrolyzer operation when using a renewable source.
  • a renewable system generates variable DC power; the variable DC power feeds an expensive, capital-equipment maximum power point tracker, which creates DC power; the DC power feeds an expensive, capital-equipment inverter, which creates AC power; the AC power feeds the AC grid; the AC grid distributes AC power to the electrolyzer site at a grid voltage; an expensive, capital-equipment transformer converts AC grid voltage to an AC voltage suitable for the electrolyzer; an expensive, capital-equipment rectifier converts the AC voltage into a DC voltage for the electrolyzer; and the DC voltage feeds the electrolyzer.
  • hydrox comprises at least 10%, 50%, 60%, 70%, 90%, or 99% by volume or by weight of a material having a stoichiometric ratio of hydrogen gas and oxygen gas.
  • hydrox is a gas comprising a molar ratio of from 1 :1 hydrogen gas to oxygen gas to 4:1 hydrogen gas to oxygen gas, 1 .2:1 hydrogen gas to oxygen gas to 3.75:1 hydrogen gas to oxygen gas, 1.4:1 hydrogen gas to oxygen gas to 3.5:1 hydrogen gas to oxygen gas, 1 .6:1 hydrogen gas to oxygen gas to 3:1 hydrogen gas to oxygen gas, 1 .8:1 hydrogen gas to oxygen gas to 2.5:1 hydrogen gas to oxygen gas, or 1 .9:1 hydrogen gas to oxygen gas to 2.1 :1 hydrogen gas to oxygen gas.
  • the process sometimes further comprises a step of providing an electric hydrox generator (EOG) and some EOGs comprise an electrolyzer to produce hydrox.
  • EOG electric hydrox generator
  • Versions of the electrolyzer have two or more cells, some of which sometimes show a variable resistance function.
  • the variable resistance function is measured or controlled electrically, mechanically, or electro-mechanically.
  • the EOG runs using photovoltaic electricity, which sometimes comes from a group of modules (such as 100 or more modules) arranged flatly on the ground.
  • the power path does not have a device that functions to adjust the voltage of the electricity in the power path.
  • the disclosed methods can combust hydrox such that the combustion process does not generate NOx.
  • the disclosed methods can combust hydrox such that the combustion exhaust has 1 to 1000 NOx ppb or 1 to 1000 NOx ppm.
  • the hydrox feeds a boiler, furnace, turbine, engine, or other device using fuel.
  • FIG. 1 diagram showing prior art method of burning hydrogen.
  • FIG. 2 is a diagram showing prior art methods of generating hydrogen.
  • FIG. 3 is a flowchart showing prior art methods.
  • FIG. 4 is a diagram showing the parts of a prior art process.
  • FIG. 5 is a diagram showing the parts of a process.
  • FIG. 6 is a flowchart.
  • FIG. 7 is a diagram showing a process as disclosed.
  • FIG. 8 is a flowchart.
  • FIG. 9 is a flowchart.
  • FIG. 10 is a diagram showing a process as disclosed.
  • FIG. 11 is a flowchart.
  • FIG. 12 diagram showing a disclosed method of burning hydrogen.
  • FIG. 13 is a schematic perspective view of a module.
  • FIG. 14 is a schematic perspective view of a module array.
  • FIG. 15 is a schematic cross-section of a module array including a prior art module mount.
  • FIG. 16 is a schematic cross-section of a module.
  • FIG. 17 is a schematic view of an Earth Mount PV system.
  • FIG. 18 is a cross-section of a string of modules.
  • FIG. 19 is an expanded view of FIG. 18.
  • FIG. 20 is a schematic view of an edge block.
  • FIG. 21 is a perspective view of a cleaning robot.
  • FIG. 22 depicts a diagram showing a process of smelting SiO2 into Si of the invention.
  • FIG. 23 depicts the first part of a diagram showing a process using PV to provide industrial heating to furnace.
  • FIG. 24 depicts the second part of the diagram of FIG. 23.
  • FIG. 25 is a schematic diagram of the silicon smelting process.
  • FIG. 26 is another schematic diagram of the silicon smelting process showing a reverberatory furnace.
  • component A is chosen from A, B, or C
  • Combinations that one of ordinary skill in the art knows to be incompatible with each other or with the components’ function in the invention are excluded, in some implementations.
  • first, second, third, etc. may describe various elements, components, regions, layers, or sections, these elements, components, regions, layers, or sections should not be limited by these terms. These terms may distinguish only one element, component, region, layer, or section from another region, layer, or section.
  • terms such as “first”, “second”, and other numerical terms do not imply a sequence or order unless indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from this disclosure.
  • Spatially relative terms such as “inner”, “outer”, “beneath”, “below”, “lower”, “above”, and “upper,” may be used for ease of description to describe one element or feature’s relationship to another element or feature as illustrated in the figures.
  • Spatially relative terms may be intended to encompass different orientations of the device in use or operation besides the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below.
  • the device may be otherwise oriented (rotated 90 degrees or at other orientations), and the spatially relative descriptors interpreted.
  • FIG. 5 is a diagram showing an improved process for producing green hydrogen.
  • the figure depicts the same process as disclosed in FIG. 4 but with the components of the prior art that the current process makes extraneous crossed out.
  • the current processes disclosed in this document do not use these components in some embodiments, DC/AC inverter 21 , step-up transformer 22, grid 24, intermediate voltage connection 23, optional second step-up transformer (not shown), step-down transformer 25, and rectifier 26.
  • the embodiment depicted in FIG. 5 has the equipment for separating the hydrogen gas from the oxygen gas, gas separator 28.
  • FIG. 6 depicts a flowchart illustrating process 601 .
  • Step 600 encompasses producing a mixture of hydrox (oxyhydrogen, HHO) by any known method. This hydrox is used in step 610 for generating heat to heat an industrial process.
  • hydrox oxyhydrogen, HHO
  • FIG. 7 depicts a diagram showing a process 701 operated with Earth Mount PV array 720 feeding DC electricity directly into hydrox generator or electrolyzer 700.
  • electrolyzer 700 has been changed as described below to have the functionality to adjust its power requirements to match the variable DC output of Earth Mount PV array 720.
  • electrolyzer 700 produces hydrox, which through connections between electrolyzer 700 and either boiler 705 or a furnace 710, delivers the fuel for combustion to boiler 705 or furnace 710.
  • electrolyzer 700 does not have the functionality to adjust its power requirements to match the variable DC output of Earth Mount PV array 720.
  • electrolyzer 700 generates hydrox that directly passes to a hydrox or hydrogen boiler 705.
  • FIG. 8 illustrates process 801 .
  • Step 810 comprises exposing Earth Mount PV array 720 to sunlight. This step produces electricity in step 820.
  • step 830 the electricity produced in step 820 is supplied to electrolyzer 700 to form hydrox. Hydrox feeds boiler 705 in step 840, which produces heat or steam in step 850.
  • step 850 the generated heat or steam is supplied to an industrial process in step 860.
  • electrolyzer 700 generates hydrox that directly passes to a furnace 710.
  • FIG. 9 illustrates process 901 , in which PV sunlight is used to provide industrial heating to furnace 710.
  • Step 910 comprises exposing Earth Mount PV array 720 to sunlight. This step produces electricity in step 920.
  • step 930 the electricity produced in step 920 is supplied to electrolyzer 700 to form hydrox.
  • step 950 heat is generated in furnace 710 using hydrox as fuel. The heat is supplied to substrate 715 when substrate 715 is within furnace 710 in step 960.
  • a similar embodiment takes the generated hydrox gas and separates it into oxygen gas and hydrogen gas.
  • a diagram 1001 of this is depicted in FIG. 10.
  • Earth Mount PV array 720 produces electricity, which is supplied to electrolyzer 700 to form hydrox.
  • Hydrox is separated into hydrogen and oxygen gas either within the electrolyzer 700 or a prior art electrolyzer or within gas separator 28.
  • Gas compressor 29 compresses the oxygen and hydrogen gas into tank 11 for storage.
  • the flowchart in FIG. 11 illustrates process 1101.
  • Step 1110 comprises exposing Earth Mount PV array 720 to sunlight. This step produces electricity in step 1120.
  • step 1130 the electricity produced in step 1120 is supplied to electrolyzer 700 to form hydrox or partially separated oxygen and hydrogen depending on the design of electrolyzer 700 or of a prior art electrolyzer.
  • step 11 0 the hydrox is separated into oxygen and hydrogen in gas separator 28, or the oxygen and hydrogen are further separated in gas separator 28, as needed. For example, in embodiments that do not need highly pure hydrogen and oxygen, separation within an electrolyzer is sometimes enough without sending the gases through gas separator 28.
  • step 1150 the oxygen and hydrogen are stored in separate tanks, such as tank 11 .
  • FIG. 12 illustrates the combustion of hydrox or a mixture of previously separated hydrogen and oxygen (depending on the embodiment) in a boiler.
  • the boiler produces steam, which can power a steam-powered process or device.
  • nitrogen when nitrogen is not present, the process does not produce combustion gases containing NOx compared to prior art processes using hydrogen as a fuel and air as the oxidant.
  • the situation is similar when hydrogen and oxygen are fed to a furnace. Again, the disclosed processes of producing heat with hydrogen and oxygen do not produce or do not produce appreciable amounts of NOx.
  • oxygen gas can be vented to the atmosphere instead of being consumed or stored.
  • the process would function despite the power-tracking electrolyzer being replaced with an electrolyzer that does not track power from the DC source.
  • Some embodiments of this disclosure do not change DC power from a DC power source into AC power and do not change AC power into DC power.
  • some embodiments of this disclosure do not use an external maximum power point tracker to match the DC power from the DC power source to the DC power needed by the electrolysis deck.
  • DC power from a DC power source such as one or more PV assemblies
  • systems and methods do not require equipment or components, such as one or more transformers, rectifiers, inverters, or IGBTs. Skipping now-extraneous components reduces equipment expense and maintenance and increases system efficiency.
  • variable current and voltage from the DC power generation apparatus are maintained relatively steady (steady-state operation) at the electrolysis stack by adjusting the stack’s resistance (which can be measured in ohms). Adjusting the resistance can be done in several ways, such as by, but not limited to, changing or adjusting: the depth of one or both of the negative or positive electrodes in the electrolytic fluid; the fluid level (e.g., the fluid height relative to one or more electrodes); the fluid temperature; the distance between the positive and negative electrodes; the number of electrode cells in series; the number of electrode panels in parallel; the fluid volume; the surface area of the electrodes exposed to the electrolyte; and the stack resistance using some other method.
  • the resistance is changed automatically by a controller (or control system) based on changes in the input voltage.
  • the control system can be an open- or closed-loop control circuit/system to provide the proper resistance to match the associated solar energy collected by the DC power source, whereby the maximum power point (MPP) or a desired power point other than the MPP may be achieved.
  • MPP maximum power point
  • the resultant gas discharge from the stack is proportional to the DC amperage conducted through the stack.
  • a system and method can provide a DC power source, such as one or more PV assemblies, that provides DC power directly to the stack, wherein the DC power has both a variable voltage and variable current.
  • a DC power source such as one or more PV assemblies
  • Such variable DC power benefits by using a variable resistance electrolysis stack.
  • the disclosed systems and methods eliminate the need for one or more energy transformation components, which convert DC power to AC power, change AC voltage, or convert AC power to DC power.
  • Wind turbines as known to ordinarily skilled artisans are variable voltage devices.
  • Standard PV installations are variable voltage devices.
  • Many other variable voltage devices exist, as known to ordinarily skilled artisans. Any of these types of devices function in various embodiments disclosed in this document.
  • Earth Mount systems Frat-On-Ground Systems (FOG)
  • Variations on utility-scale PV module electricity generating systems are disclosed. These systems are characterized by mounting some or all the modules substantially flat on the ground dispensing with tracker or racking structure (inclusively “racked” systems). Mounting modules flat on the ground results in the module orientation being directed by contact with the ground (earth). This orientation is fundamentally different than the custom or semicustom orientation that racking creates (sun-oriented).
  • FOG mounting establishes a topographical orientation of the modules, as distinguished from a sun orientation in which the sun’s direction dictates the modules’ direction.
  • the modules sit edge-to-edge, end-to-end, or both depending on the implementation.
  • FOG systems have a tiny exposure to air (wind) moving across their modules, letting them largely dispense with mounting hardware to hold system modules against the ground. But some embodiments use mounting hardware.
  • Various methods of attaching the modules to the ground or each other are contemplated for arrays that use such optional connections.
  • FOG mounting substantially reduces module wind loading, avoiding high wind forces. And FOG systems have low module elevations.
  • FOG mounting provides significant advantages when used with commercially available string- or micro-inverters. But FOG mounting does not prevent using industry-standard central inverters or alternate power conversion and transmission technologies.
  • FOG mounting eliminates the need for the steel structures required by racked systems.
  • Earth mounting eliminates structural corrosion and increases power plant life expectancy from 25 years to perhaps longer than 40 years while significantly reducing initial costs. Still, steel, coated or otherwise, can be used with the system.
  • FOG-mounted systems often include commercially available and compatible new module cleaning or dust removal techniques.
  • Earth mounting increases the power density per acre of land, which reduces the needed land area by over 50% of traditional utility-scale solar plant PV power plants sometimes.
  • FOG mounting lets the PV array follow the land’s existing contour, obviating the need for land preparation such as mass grading, plowing, tilling, cutting, and filling.
  • Earth mounting reduces wind loading and uplift forces, eliminates module-to-module shading, requires zero or minimal row spacing, and increases the ground coverage ratio. And it orients the modules parallel to existing topography, independent of a site’s azimuth angle.
  • Modules are typically flat rectangles (or any other convenient space-filling shape).
  • Various implementations modify module installation techniques to allow installation directly on the ground and are configured to take advantage of the ground’s cooling and heat-sinking effects.
  • Placing the modules sometimes includes using attachment brackets.
  • the modules snap into or otherwise secure the attachment brackets, retaining the array on or near the ground. Ground placement avoids mounting the modules on racks and avoids shadows. No shadows mean no need for substantial spacing between modules.
  • Earth-mounted systems can be constructed with little or no gaps between adjacent modules. Eliminating the gaps allows a two-dimensional array, when desired, of closely adjacent modules to extend row-wise and column-wise (from row to row). In other words, gaps between sequential modules from row to row can closely approximate gaps between sequential modules along the rows.
  • modules in an FOG-mounted arrangement use far less land area than racked systems. In some implementations, FOG-mounted arrays use less than 50%, 45%, 40%, 35%, or 30% of the land area used by racked systems. Some implementations dispense with module-to-module mechanical connections. Some inter-module connections do not control the spacing between modules.
  • FIG. 13 illustrates a schematic view of module 9 having photovoltaic substrate 1310, frames 1311 , edges 12, and module top face 14.
  • module 9 is frameless and does not have frames 1311.
  • FIG. 14 is a schematic view comprising modules 9 assembled into Earth Mount PV array 720 mounted flat on the ground 215 following the topography. Some or all modules 9 are mounted to contact the ground 215. Depending on the version, not all edges 12 or not a complete length of edge 12 touch the ground 215.
  • FIG. 15 shows some versions of FOG-mounted systems with structures 205 between modules 9 and ground (grade 215) but not tracker objects or angled racking objects.
  • the figure illustrates a cross-section view of module 9, which has a structure 205 between module bottom 210 and grade 215.
  • Structures 205 meet the definition of “structure” because they are either solid below the contact surface 240 or the volume beneath the contact surface 240 “constrains air movement”.
  • Prior art structure 235 is also shown.
  • the inconsequential () objects are called structures.
  • FIG. 16 is a schematic diagram showing an Earth Mount PV array 720 layout for a commercial solar power plant.
  • FIG. 16 shows eighteen of block 1710 in an implementation of a utility-scale plant. Some utility-scale solar power plant implementations have one or more of these arrangements.
  • Optional DC-AC inverter 1720 and robot bridges 1233 are shown, as well.
  • FOG-mounted systems disclosed in this document are mounted at a height, h, of less than 100, 75, 50, or 20 cm above grade on objects that extend into the ground less than one-half of the height.
  • FIG. 17 is a perspective diagram that shows a perspective view of module 9.
  • Mesh cable 70 is shown in the figure and extends along module 9.
  • FIG. 17 also shows the underside of PV substrate 21 .
  • FIG. 17 is a perspective view of the underside of module 9 showing a mesh cable device.
  • FIG. 18 is a side view of several modules from a row of modules. It shows mesh cable 70 interacting with module 9 through a hole or penetration 60 (see FIG. 19) in module 9.
  • FIG. 19 shows a magnified view of FIG. 18 having upper gap 440.
  • FIG. 18 depicts modules 9 sitting on a non-flat, earth or ground surface and illustrates the ability of mesh cables 70 to accommodate adjacent modules 9 sitting at different angles. As shown, despite adjacent panels sitting at different angles, mesh cable 70 retains the top edge 15 of each panel or the top surface of each panel at substantially the same height or position. In some exemplars, mesh cables 70 maintain the height of modules 9 close enough to each other to allow an autonomous robotic cleaning system to operate on the array. In some exemplars, mesh cables 70 maintain the height of adjacent modules within 0.25, 0.5, 1 , 2, or 3 inches of each other.
  • FIG. 20 shows a view of an edge block 80. These devices direct water and wind up and over the flat panels in an Earth Mount PV array 720.
  • the FOG-mounted system mounts the solar panels directly to the earth without an intermediate structure between the modules and the earth itself.
  • Earth Mount systems facilitate more economical module cleaning.
  • Robotic cleaning systems for operation on Earth Mount systems are much simpler than robotics systems for cleaning racked systems. Since FOG-mounted systems are substantially flat, cleaning FOG-mounted systems with autonomous robotics systems is far more economical than cleaning racked systems.
  • Earth Mount implementations used connectors to minimize module-to-module z-axis variability.
  • Another way to facilitate robotic cleaning is to provide bridges between separate module sections or separate module arrays. These bridges let the robot cross from one section or array to another.
  • FIG. 21 depicts an autonomous cleaning robot 1900.
  • Autonomous cleaning robot 1900 comprises rear cover 1910, front cover 1920, and wheels 1930.
  • robot 1900 uses two or more, three or more, for more, six or more, or eight or more wheels 1930.
  • This implementation shows the robot with two brush assemblies 1940, but the cleaning nature of robot 1900 can use one brush assembly 1940.
  • Brush assembly 1940 comprises brush 1950, brush motor 1960, and various other components that connect brush assembly 1940 to robot 1900.
  • Brush assembly 1940 connects to the chassis of robot 1900, and, in some implementations, the chassis of robot 1900 has two pieces.
  • Brush motor 1960 drives the rotation of brush 1950 through a transmission.
  • FIG. 22 depicts a diagram showing a process 2301 operated with Earth Mount PV array 720 feeding DC electricity directly into hydrox generator or electrolyzer 700.
  • Electrolyzer 700 has been modified as described below to have the functionality to adjust its power requirements to match the variable DC output of Earth Mount PV array 720.
  • electrolyzer 700 produces hydrox, which through connections between electrolyzer 700 and furnace 2310, delivers the hydrox fuel for combustion to furnace 2310.
  • electrolyzer 700 generates hydrox that directly passes to a furnace 2310.
  • FIG. 23 illustrates process 2301 , in which PV sunlight is used to provide industrial heating to furnace 2310.
  • Step 2310 comprises exposing Earth Mount PV array 720 to sunlight. This step produces electricity in step 2320.
  • step 2330 the electricity produced in step 2320 is supplied to electrolyzer 700 to form hydrox.
  • Hydrox feeds furnace 2310, which contains or can contain charge-heating compartment 2215 (containing charge 2220), in step 2340.
  • step 2350 heat is generated in furnace 2310 using hydrox as fuel. The heat is supplied to charge 2220 when charge 2220 is within charge-heating compartment 2215 in step 2360.
  • FIG. 25 is a schematic diagram of the silicon smelting process.
  • the figure shows a crucible 2540 that contains silicon dioxide and reductants such as carbon or hydrogen 2560.
  • molten silicon collects at pool 2565 that connects to tap 2550 for removing silicon.
  • Crucible 2540 also contains hydrox jet or burner 2520, which provides heat for the smelting reaction.
  • Crucible 2540 also contains a charge input port 2562 and flue 2563. The heat drives the reaction by impinging hydrox flame directly against charge 2541 . In addition to other reactants, the hydrox flame produces silicon (molten).
  • the molten silicon collects in pool 2565, which exits crucible 2540 through tap 2550.
  • Crucible 2540 can comprise silicon dioxide; Tungsten (W) 3,422 °C; Rhenium (Re) 3,180 °C; Osmium (Os) 3,033 °C; Molybdenum (Mo) 2,623 °C; Iridium (Ir) 2,467 °C; Hafnium (Hf) 2,220 °C; Niobium (Nb) 2,468 °C; Ruthenium (Ru) 2,334 °C; Tantalum (Ta) 3,020 °C; Alumina (Aluminum Oxide, AI2O3) 2,072 °C; Zirconia (Zirconium Dioxide, ZrO2) 2,715 °C; Silicon Carbide (SiC) 2,730 °C; Tungsten Carbide (WC) 2,870 °C; Titanium Diboride (T
  • FIG. 26 is another schematic diagram of the silicon smelting process.
  • the figure depicts a schematic view of a reverberatory furnace 2602 and shows a crucible 2640 that contains silicon dioxide and reductants such as carbon or hydrogen 2660.
  • molten silicon collects at pool 2665 that connects to a tap 2650 for removing silicon.
  • Crucible 2640 also contains hydrox jet or burner 2620 that provides heat for the smelting reaction.
  • Crucible 2640 also contains a charge input port 2662 and flue 2663.
  • hydrox jet 2620 heats the wall material of crucible 2640, which radiates heat to charge 2641 and drives the reaction.
  • the hydrox flame produces silicon (molten).
  • the molten silicon collects in pool 2665, which exits crucible 2640 through tap 2650. More material is added to charge 2641 through port 2662, as needed.
  • the addition of charge and periodic tapping of silicon allows the reaction to operate continuously or pseudo-continuously.
  • Crucible 2640 can comprise silicon dioxide; Tungsten (W) 3,422 °C; Rhenium (Re) 3,180 °C; Osmium (Os) 3,033 °C; Molybdenum (Mo) 2,623 °C; Iridium (Ir) 2,467 °C; Hafnium (Hf) 2,220 °C;
  • a material that contains oxide and a substance comprising boron, gallium, arsenic, silicon, indium, tellurium, germanium, tin lead antimony, bismuth, or selenium is reduced to a lower oxidation state by a chemical reaction with a hydrogen-containing gas, such as hydrox.
  • a hydrogen-containing gas such as hydrox.
  • the hydrogen-containing gas supplies the energy or heat energy that the reduction requires, supplies a reactant to the chemical reaction, or both.
  • hydrox is combusted to heat a charge in furnace 2310 to drive the reduction of some component of the charge, the oxidation of some component of the charge, or both. See flowchart in Fig. 24.
  • Process 2401 picks up after step 930 of process 901 .
  • an industrial process is any process that uses heat at a rate equivalent to greater than 2000, 5000, 10,000, 15,000, 20,000, 40,000, 80,000, 160,000, or 320,000 pounds of steam per hour equivalent, depending on the embodiment.
  • Industrial heat refers to many methods by which heat is used to transform materials into valuable products. For example, heat is used to remove moisture, separate chemicals, create steam, treat metals, melt plastics, Agricultural space and media heating, cooking, pressurization, sterilization, and bleaching, industrial distillation, concentrating, drying, or kilning, and chemical or other high-temperature processes, silicon, and other refining, including semiconductor production, and much more.
  • industrial heat can be broken down into low-, medium-, and high- temperature heat.
  • a hydrogen boiler is any boiler that has been specifically modified to use hydrogen as combustion fuel.
  • a hydrox boiler is any boiler that has been specifically modified to use a mixture of hydrogen and oxygen (such as hydrox) as the reactants in a boiler.
  • this definition includes a modified condensing boiler.
  • the mixture of hydrogen and oxygen is generated locally to the boiler by electrolysis and not separated before delivery to the boiler.
  • the mixture is prepared before entry into the boiler.
  • the mixture is prepared simultaneously with entry into the boiler or prepared shortly after entry into the boiler.
  • a hydrogen furnace is any furnace or industrial furnace that has been specifically modified to use hydrogen as combustion fuel.
  • a hydrox furnace is any furnace or industrial furnace that has been specifically modified to use hydrogen and oxygen (such as hydrox) as the reactants.
  • a hydrogen turbine is any turbine or industrial turbine that has been specifically modified to use hydrogen as combustion fuel.
  • a hydrox turbine is any turbine or industrial turbine that has been specifically modified to use hydrogen and oxygen (such as hydrox) as the reactants.
  • a hydrogen engine is an internal combustion engine that has been specifically modified to use hydrogen as a combustion fuel.
  • a hydrox engine is any internal combustion engine that has been specifically modified to use hydrogen and oxygen (such as hydrox) as the reactants.
  • a “module” is the photovoltaic media, PV wire connections to the media, and any support, such as frames, that the module manufacturer adds to the media.
  • Modules have a capacity greater than 100, 200, 300, 400, 500, 600, or 800 watts and less than 2000, 1500, 1000, or 900 watts and a size greater than 1 , 2, 3, 4, 5, 6, 7, 8, and 10 m 3
  • Array is a grouping of multiple modules, some of which are next to three separate modules. In some implementations, an array has greater than 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, or 100 columns of modules. In some implementations, an array has greater than 5, 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, or 100 rows of modules. In some implementations, an array has over 50, 100, 200, 400, 600, or 800 modules. Sometimes, rows or columns have two or more modules. Module-to-module spacing for site-oriented systems can be much, much closer. In some implementations, module-to-module spacing in an FOG- mounted system ranges from 0.1 300 mm, 10-200 mm, 1 -50 mm, or 1-25 mm.
  • Contiguous or “adjacent” modules, rows, or columns means modules, rows, or columns having a spacing of less than 30, 20, 10, or 5 cm “Conterminous” means that each member of a group or grouping is next to at least one other member.
  • No favored orientation means that the array is oriented with respect to a geographic feature on the site, e.g., river, stream bed, canyon, hill, etc. In some embodiments, the array is not oriented with respect to the sun’s direction.
  • Geographic feature includes legal property lines but does not include latitude, longitude, or the orientation of impinging sunlight. Systems with no favored orientation are sometimes called earth or topography oriented. Azimuth independent means independent of the orientation of the sun with respect to the module’s latitude.
  • “FOG-mounted” refers to a group of greater than 50, 100, 200, 400, 600, 800, 1000, or 1500 modules in which at least 80 percent of the modules have at least one contact point, as defined below, that rests on the ground or rests on a contact surface of one or more structures, provided that the portion or portions of the structure or structures encompassed by the volume of space beneath and perpendicular to the contact surface is solid or constrains air movement.
  • “FOG- mounted” means any flat mounting substantially parallel to the earth or ground that places the plane of the array within a short distance above the ground. This disclosure sometimes uses “ground-mounted” as a synonym for “earth-mounted”.
  • “flat” means horizontally flat and substantially parallel to the earth.
  • a “ground module” is an FOG-mounted module.
  • “contact points” are regions of a module that touch the ground or touch a contact surface. In some versions, “contact points” are regions of a module that touch the ground without intervening regular structure or are regions of a module that touch the ground without intervening manufactured structure.
  • Contact surfaces are portions of a structure that touch a contact point.
  • the volume perpendicular to the contact surface between the contact surface and the ground does not have free air.
  • an object that does not have “free air” is an object that does not contain constrained air.
  • a contact surface defines a starting point of a path that is continuous and ends at a point of the structure touching the ground and directly beneath the contact surface.
  • the volume perpendicular to the contact surface between the contact surface and the ground constrains air movement.
  • “constrains air movement” means constrains lateral air movement.
  • an object that “constrains air movement” bounds a volume of air on at least two lateral sides.
  • “constrained air” is air constrained on at least two lateral sides in addition to the top and bottom.
  • “utility-scale” means having one or more of the following characteristics: a total DC output of greater than 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, or 1800 V; or a total DC power output of greater than 100, 200, 500, 700, 1000, 2000 kW.
  • ground level is the level of the ground immediately before module installation.
  • “Ground” or “native topography” is the surface of the site and includes material naturally present at the site and material added to the site by human activity at any time before the first module is placed.
  • “Ground” or “native topography” is the surface of the site and includes material naturally present at the site and irregularly shaped material added to the site by human activity at any time before placing the first module.
  • “Ground” or “native topography” is the surface of the site and includes material naturally present at the site and material added to the site by human activity at any time before placing the first module, provided that the largest dimension of 80% of the material is less than 20 cm.
  • “Structure” is any material added to the site or brought onto the site that occupies any of the space between a module and the ground and does not include manufacturer support. “Structure” is support for the module not installed by the panel manufacturer during production.
  • Plane of the array is the average of the planes for each individual module in the array.
  • Robot cleaning device is an air-pressure-based, water-pressure- based, vacuum-based, brush-based, or wiper-based device for cleaning modules.
  • autonomous means performed without manual intervention or undertaken or carried out without any outside control.
  • an “autonomous robotic device” is a robotic cleaning device that operates to clean modules without real-time human control.
  • An “autonomous robotic device” is sometimes used synonymously with a “fully autonomous cleaning robot”.
  • An Al autonomous robotic device is an autonomous robotic device that contains hardware and software that observes its own cleaning performance and adjusts its performance algorithms based on those observations.
  • “operates to clean modules” includes initiating a cleaning cycle.
  • a “cleaning cycle” is a complete cleaning of a section of modules from start to finish.
  • a cleaning cycle includes the robotic device leaving its resting pad or structure, traveling to a section of modules, cleaning each module of the section, and traveling to another section or returning to the resting pad or structure.
  • “Cleaning period” is 6,12, 24, 36, 48, 60, 72, 84, 96, 108, 120, 132, or 144 hours.
  • “Module-to-module z-axis variability” or “module-to-module elevation difference” - is a measure of the largest elevation difference between the highest point at a module edge and the lowest point of an adjacent edge of an adjacent module. The “z-axis” extends from the module face and points substantially vertically.
  • “smooth”, “smoothed”, “flat”, or “flattened” means smooth or flat enough or made smooth or flat enough such that the height difference or the module-to-module z- axis variability between adjacent modules is small enough that a fully autonomous cleaning robot can move from one module onto another.
  • the maximum module-to-module z-axis variability in some implementations is less than 4, 3, 4, 1 , or 0.5 inches.
  • “smooth”, “smoothed”, “flat”, or “flattened” means smooth or flat enough or made smooth or flat enough such that the height difference or the module-to-module z-axis variability between adjacent modules in an array installed on the ground is small enough that a fully autonomous cleaning robot can move from one module onto another.
  • Low module elevation is defined as an elevation of a module that is low enough to prevent upward forces caused by air movement across the module from lifting a module from the array, whether the array comprises mechanical components to resist module lifting or not.
  • a low module elevation is defined as an elevation of a group of modules that is low enough that air-caused upward forces on the group are too small to lift the group.
  • low module elevation is an elevation of less than 100 cm, 0 to 90 cm, 0 to 80 cm, 0 to 70 cm, 0 to 60 cm, 0 to 50 cm, 0 to 40 cm, 0 to 30 cm, 0 to 20 centimeters, or 0 to 10 cm measured from the ground to a lower edge of the module or, in edge-less module systems, from the ground to the module surface.
  • “Intermediate distance” is defined as from 0-1 m, 0-70cm, 0-60cm, or 0-50 cm. “Short distance” is defined as 0-49.9cm, 0-30 cm, 0-20cm, or 0- 10cm. [00102] “Mechanical stow functionality” is functionality that changes the direction that a tracker-based system points the modules to minimize the effect of winds on the system. This minimizes the danger of high winds damaging the tracker or the installed modules.
  • Extreme dampening functionality is functionality that dampens mechanical oscillations in a tracker-based system caused by high winds to minimize the danger that those winds will damage the tracker or the installed modules.
  • Connectors are structures that connect modules.
  • connectors can be mechanical connectors, electrical connectors or electrical interconnects, or both.
  • Electrical interconnects are DC electrical connections between modules.
  • Flexible connections or “flexibly connected” are or describe connections made with rigid or non-rigid connectors that allow the angle between a plane of a module and of an adjacent module to vary without breaking the connection.
  • “Joints” are any permanent or semi-permanent connection between the joined components.
  • a “high DC: AC” voltage ratio is greater than 1.0-2, 1.1 -1.9, 1.2-1 .8, and 1.3-1.7.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Electrolytic Production Of Non-Metals, Compounds, Apparatuses Therefor (AREA)

Abstract

Un procédé comprenant la génération de chaleur de traitement à partir d'hydrox. Dans certaines versions, l'hydrox comprend au moins 10 %, 50 %, 60 %, 70 %, 90 % ou 99 % en volume ou en poids d'un matériau ayant un rapport stœchiométrique d'hydrogène gazeux et d'oxygène gazeux. Le procédé comprend en outre, dans certains cas, une étape de fourniture d'un générateur d'hydrox électrique (EOG), et certains EOG comprennent un électrolyseur pour produire de l'hydrox. Des versions de l'électrolyseur (générateur d'hydrox) ont deux cellules ou plus, dont certaines présentent parfois une fonction de résistance variable. Selon la version, la fonction de résistance variable est mesurée ou commandée électriquement, mécaniquement ou électro-mécaniquement. De même, dans ces versions ou dans d'autres versions, l'EOG fonctionne à l'aide d'électricité photovoltaïque, qui provient parfois d'un groupe de modules (tels que 100 modules ou plus) disposés à plat sur le sol. Dans certaines versions de l'EOG, le trajet de puissance ne contient pas de dispositif qui fonctionne pour ajuster la tension de l'électricité dans le trajet de puissance. Les procédés décrits peuvent brûler de l'hydrox de telle sorte que l'échappement de combustion présente moins de 1000 ppb de NOx. Dans diverses versions, l'hydrox alimente une chaudière, un four, une turbine, un moteur ou un autre dispositif à l'aide d'un combustible.
PCT/US2024/011548 2023-01-15 2024-01-15 Fusion et production de polysilicium alimentées par hydrox Ceased WO2024152036A1 (fr)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030000564A1 (en) * 2001-06-27 2003-01-02 Shingleton Jefferson G. High-concentration photovoltaic assembly for a utility-scale power generation system
CN101805811A (zh) * 2010-04-14 2010-08-18 钢铁研究总院 全氧富氢煤气炼铁方法及其装置
WO2011116141A2 (fr) * 2010-03-18 2011-09-22 Sun Hydrogen, Inc. Procédé propre de production d'acier faisant appel à une source d'énergie renouvelable sans carbone
CN207095287U (zh) * 2017-07-28 2018-03-13 洛阳万有力科技有限公司 一种氢氧机熔炼炉

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20030000564A1 (en) * 2001-06-27 2003-01-02 Shingleton Jefferson G. High-concentration photovoltaic assembly for a utility-scale power generation system
WO2011116141A2 (fr) * 2010-03-18 2011-09-22 Sun Hydrogen, Inc. Procédé propre de production d'acier faisant appel à une source d'énergie renouvelable sans carbone
CN101805811A (zh) * 2010-04-14 2010-08-18 钢铁研究总院 全氧富氢煤气炼铁方法及其装置
CN207095287U (zh) * 2017-07-28 2018-03-13 洛阳万有力科技有限公司 一种氢氧机熔炼炉

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