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WO2025184747A1 - Processus électrolytiques pour la production de carbonates et de composés alcalins - Google Patents

Processus électrolytiques pour la production de carbonates et de composés alcalins

Info

Publication number
WO2025184747A1
WO2025184747A1 PCT/CA2025/050318 CA2025050318W WO2025184747A1 WO 2025184747 A1 WO2025184747 A1 WO 2025184747A1 CA 2025050318 W CA2025050318 W CA 2025050318W WO 2025184747 A1 WO2025184747 A1 WO 2025184747A1
Authority
WO
WIPO (PCT)
Prior art keywords
compartment
cathode
electrolysis cell
salt
anode
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.)
Pending
Application number
PCT/CA2025/050318
Other languages
English (en)
Other versions
WO2025184747A8 (fr
Inventor
Mohammad Saad DARA
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.)
Mangrove Water Technologies Ltd
Original Assignee
Mangrove Water Technologies Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Mangrove Water Technologies Ltd filed Critical Mangrove Water Technologies Ltd
Publication of WO2025184747A1 publication Critical patent/WO2025184747A1/fr
Publication of WO2025184747A8 publication Critical patent/WO2025184747A8/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • C25B1/14—Alkali metal compounds
    • C25B1/16—Hydroxides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D61/00—Processes of separation using semi-permeable membranes, e.g. dialysis, osmosis or ultrafiltration; Apparatus, accessories or auxiliary operations specially adapted therefor
    • B01D61/42—Electrodialysis; Electro-osmosis ; Electro-ultrafiltration; Membrane capacitive deionization
    • B01D61/44—Ion-selective electrodialysis
    • B01D61/445—Ion-selective electrodialysis with bipolar membranes; Water splitting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D61/00—Processes of separation using semi-permeable membranes, e.g. dialysis, osmosis or ultrafiltration; Apparatus, accessories or auxiliary operations specially adapted therefor
    • B01D61/42—Electrodialysis; Electro-osmosis ; Electro-ultrafiltration; Membrane capacitive deionization
    • B01D61/44—Ion-selective electrodialysis
    • B01D61/46—Apparatus therefor
    • B01D61/465—Apparatus therefor comprising the membrane sequence AB or BA, where B is a bipolar membrane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D61/00—Processes of separation using semi-permeable membranes, e.g. dialysis, osmosis or ultrafiltration; Apparatus, accessories or auxiliary operations specially adapted therefor
    • B01D61/42—Electrodialysis; Electro-osmosis ; Electro-ultrafiltration; Membrane capacitive deionization
    • B01D61/44—Ion-selective electrodialysis
    • B01D61/46—Apparatus therefor
    • B01D61/466—Apparatus therefor comprising the membrane sequence BC or CB
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B32/00—Carbon; Compounds thereof
    • C01B32/50—Carbon dioxide
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01D—COMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
    • C01D15/00—Lithium compounds
    • C01D15/08—Carbonates; Bicarbonates
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01D—COMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
    • C01D7/00—Carbonates of sodium, potassium or alkali metals in general
    • C01D7/07—Preparation from the hydroxides
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/46—Treatment of water, waste water, or sewage by electrochemical methods
    • C02F1/469—Treatment of water, waste water, or sewage by electrochemical methods by electrochemical separation, e.g. by electro-osmosis, electrodialysis, electrophoresis
    • C02F1/4693—Treatment of water, waste water, or sewage by electrochemical methods by electrochemical separation, e.g. by electro-osmosis, electrodialysis, electrophoresis electrodialysis
    • 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
    • C25B15/00—Operating or servicing cells
    • C25B15/08—Supplying or removing reactants or electrolytes; Regeneration of electrolytes
    • C25B15/081—Supplying products to non-electrochemical reactors that are combined with the electrochemical cell, e.g. Sabatier reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2311/00—Details relating to membrane separation process operations and control
    • B01D2311/26—Further operations combined with membrane separation processes
    • B01D2311/2642—Aggregation, sedimentation, flocculation, precipitation or coagulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2311/00—Details relating to membrane separation process operations and control
    • B01D2311/26—Further operations combined with membrane separation processes
    • B01D2311/2661—Addition of gas
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/66—Treatment of water, waste water, or sewage by neutralisation; pH adjustment
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/46—Treatment of water, waste water, or sewage by electrochemical methods
    • C02F1/461—Treatment of water, waste water, or sewage by electrochemical methods by electrolysis
    • C02F1/46104—Devices therefor; Their operating or servicing
    • C02F1/46109—Electrodes
    • C02F2001/46152—Electrodes characterised by the shape or form
    • C02F2001/46157—Perforated or foraminous electrodes
    • C02F2001/46161—Porous electrodes
    • C02F2001/46166—Gas diffusion electrodes

Definitions

  • the present disclosure generally relates to carbon reduction processes and systems employing an electrolysis cell, and in particular as they relate to the preparation or use of materials from the lithium-ion battery industry.
  • the present disclosure provides carbon reduction processes and systems employing an electrolysis cell, and in particular as they relate to the preparation or use of materials from the lithium-ion battery industry and ocean alkalinity enhancement.
  • the present disclosure relates to a process for producing lithium carbonate with carbon capture, comprising: receiving a Li salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising LiOH; and delivering the product comprising LiOH and CO2 to a carbonate production reactor to produce lithium carbonate.
  • the Li salt-containing solution comprises LiCI, U2SO4, Li3PO4, LiNCh, Lil, or LiBr.
  • the carbonate production reactor is fluidly coupled to a device or apparatus for providing CO2.
  • the device or apparatus for providing CO2 is a direct air capture system.
  • the present disclosure relates to a system for lithium carbonate production with carbon capture, the system comprising: an electrolysis cell comprising a cathode and an anode; and a carbonate production reactor configured to receive a product comprising LiOH from the electrolysis cell and CO2 to generate lithium carbonate.
  • the system for lithium carbonate production further comprises a device or apparatus for providing the CO2 to the carbonate production reactor.
  • the device or apparatus for providing the CO2 is a direct air capture system.
  • the present disclosure relates to a process of producing cathode active material with reduced carbon emissions, comprising: receiving a Li salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising LiOH; delivering the product comprising LiOH and CO2 to a carbonate production reactor to produce lithium carbonate; and mixing the lithium carbonate with precursor cathode active material to produce cathode active material.
  • the present disclosure relates to a process for producing sodium carbonate with carbon capture, comprising: receiving a Na salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising NaOH; and delivering the product comprising NaOH and CO2 to a carbonate production reactor to produce sodium carbonate.
  • the Na salt-containing solution comprises NaCI, Na2SC>4, NagPC ⁇ , NaNOg, Nal, or NaBr.
  • the carbonate production reactor is fluidly coupled to a device or apparatus for providing the CO2.
  • the device or apparatus for providing the CO2 is a direct air capture system.
  • the present disclosure relates to a system for sodium carbonate production with carbon capture, the system comprising: an electrolysis cell comprising a cathode and an anode; and a carbonate production reactor configured to receive a product comprising NaOH from the electrolysis cell and CO2 to generate sodium carbonate.
  • the system herein for sodium carbonate production further comprises a device or apparatus for providing the CO2 to the carbonate production reactor.
  • the device or apparatus for providing the CO2 is a direct air capture system.
  • the present disclosure relates to a process for enhancing ocean alkalinity, comprising: receiving a salt solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising an alkaline compound; and delivering the product comprising an alkaline compound to a body of seawater.
  • the salt solution comprises NaCI.
  • the NaCI is a by-product from a solar evaporation pond in a lithium brine extraction operation.
  • the salt solution comprises Na2SC>4.
  • the Na2SC>4 is a by-product from a lithium sulfate to lithium hydroxide or lithium carbonate conversion operation.
  • the alkaline compound comprises NaOH.
  • the product comprising an alkaline compound is flowed directly to or is shipped to a body of seawater.
  • the electrolysis cell is a chlor-alkali membrane electrolysis cell, a chlor-alkali diaphragm electrolysis cell, a bipolar membrane electrodialysis cell, or a membrane electrolysis cell.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a cation exchange membrane interposed between the anode compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions from the anode compartment to an opposed surface of the cation exchange membrane into the cathode compartment; an inlet through which the salt solution is received into an interior of the electrolysis cell; and at least one outlet through which the product is removed from an interior of the electrolysis cell.
  • the salt solution is received into the anode compartment and positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; water is reduced at the cathode to form OH-; and the positive salt ions and the OH- ions in the cathode compartment together form the alkaline compound.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a salt depletion compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; an anion exchange membrane interposed between the anode compartment and the salt depletion compartment, the anion exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the anion exchange membrane into the anode compartment; a cation exchange membrane interposed between the salt depletion compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the cation exchange membrane into the cathode compartment; an inlet through which the salt solution is received into the salt depletion compartment; and
  • the salt solution is received into the salt depletion compartment; positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; water is reduced at the cathode to form OH-; and the positive salt ions and the OH- ions in the cathode compartment together form the alkaline compound.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, a cation exchange membrane interposed between the salt depletion compartment and the base build
  • the salt solution is received into the salt depletion compartment; positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; water is dissociated in the first bipolar membrane and OH- migrates into the base build-up compartment; and the positive salt ions and the OH- ions in the base-build-up compartment together form the alkaline compound.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an acid build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the salt depletion compartment is interposed between the cathode compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the salt depletion compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, an anion exchange membrane interposed between the salt depletion compartment and the acid build-up compartment
  • the salt solution is received into the salt depletion compartment; water is dissociated in the first bipolar membrane and OH- migrates into the salt depletion compartment; and positive salt ions and the OH- ions in the salt depletion compartment together form the alkaline compound.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- i
  • the salt solution is received into the salt depletion compartment; positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; water is dissociated in the first bipolar membrane and OH- migrates into the base build-up compartment; and the positive salt ions and the OH- ions in the base-build-up compartment together form the alkaline compound.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a cation exchange membrane interposed between the anode compartment and the catalyst layer of the gas diffusion electrode, the cation exchange membrane being configured to exchange ions received from the anode to an opposed surface of the cation exchange membrane; an inlet through which the salt solution is received into the anode compartment; a gas inlet through which a gas comprising O2 is introduced into contact with the gas diffusion electrode;
  • the salt solution is received into the anode compartment; positive salt ions migrate through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; the gas comprising O2 is reduced at the cathode to form OH-; and the OH- ions and the positive salt ions in the cathode compartment together form the alkaline compound.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; an anion exchange membrane being disposed on the catalyst layer of the gas diffusion electrode and being configured to exchange ions received from the catalyst layer of the gas diffusion electrode to an opposed surface of the anion ion exchange membrane into the base build-up compartment; a cation exchange membrane interposed between the anode compartment and the base
  • the salt solution is received into the anode compartment; positive salt ions migrate through the cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; the gas comprising O2 is reduced at the cathode to form OH-; the OH- ions migrate through the anion exchange membrane to the opposed surface of the anion exchange membrane into the base build-up compartment; and the OH- ions and the positive salt ions in the base build-up compartment together form the alkaline compound.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a first anion exchange membrane being disposed on the catalyst layer of the
  • the salt solution is received into the salt depletion compartment; positive salt ions migrate through the first cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; the gas comprising O2 is reduced at the cathode to form OH-; the OH- ions migrate through the first anion exchange membrane to the opposed surface of the first anion exchange membrane into the base build-up compartment; and the OH- ions and the positive ions in the base build-up compartment together form the alkaline compound.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of
  • the salt solution is received into the salt depletion compartment; positive salt ions migrate through the first cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; the gas comprising O2 is reduced at the cathode to form OH-; the OH- ions migrate through the first anion exchange membrane to the opposed surface of the first anion exchange membrane into the base build-up compartment; and the OH- ions and the positive salt ions in the base build-up compartment together form the alkaline compound.
  • FIG. 1 shows process flow diagrams of exemplary processes of the present disclosure for producing lithium carbonate with carbon capture (panel (A)), including optional use of the lithium carbonate as a precursor material for producing cathode active materials (CAMs) (panel (B)).
  • panel (A) shows process flow diagrams of exemplary processes of the present disclosure for producing lithium carbonate with carbon capture
  • CAMs cathode active materials
  • FIG. 2 shows process flow diagrams of exemplary processes of the present disclosure for producing sodium carbonate with carbon capture (panel (A)), including optional lithium carbonate production via chemical precipitation of lithium salts with the sodium carbonate (panel (B)).
  • FIG. 3 is a process flow diagram of an exemplary process of the present disclosure for enhancing ocean alkalinity.
  • FIG. 4 is a schematic diagram of an exemplary chlor-alkali membrane electrolysis cell showing exemplary feed and product streams.
  • FIG. 5 is a schematic diagram of an exemplary chlor-alkali diaphragm electrolysis cell showing exemplary feed and product streams.
  • FIG. 6 is a schematic diagram of an exemplary 3-compartment electrolysis cell comprising a cation exchange membrane (GEM) and an anion exchange membrane (AEM), showing exemplary feed and product streams.
  • GEM cation exchange membrane
  • AEM anion exchange membrane
  • FIG. 7 is a schematic diagram of an exemplary multi-compartment cell comprising an optionally repeating unit consisting of a bipolar membrane and a GEM, showing exemplary feed and product streams.
  • a 2-compartment embodiment is shown in FIG. 7, but the cell may comprise additional compartments in view of the optionally repeating unit.
  • FIG. 8 is a schematic diagram of an exemplary multi-compartment cell comprising an optionally repeating unit consisting of a bipolar membrane and an AEM, showing exemplary feed and product streams.
  • a 2-compartment embodiment is shown in FIG. 8, but the cell may comprise additional compartments in view of the optionally repeating unit.
  • FIG. 9 is a schematic diagram of an exemplary multi-compartment cell comprising an optionally repeating unit consisting of a bipolar membrane, an AEM and a GEM, showing exemplary feed and product streams.
  • a 3-compartment embodiment is shown in FIG. 8, but the cell may comprise additional compartments in view of the optionally repeating unit.
  • FIG. 10 is a structural diagram of eight exemplary gas diffusion electrodes of the present disclosure (GDE-1 ) comprising at least a catalyst layer (CL) and a gas diffusion layer (GDL) (panel (a)), and in some exemplary embodiments of the GDE-1 further comprising: a microporous layer (MPL); a mesh; an anion exchange membrane (AEM); or a combination thereof (panels (b), (c), (d), (e), (f), (g) and (h)).
  • GDE-1 gas diffusion electrodes of the present disclosure
  • MPL microporous layer
  • AEM anion exchange membrane
  • FIG. 11 is a structural diagram of four exemplary gas diffusion electrodes of the present disclosure (GDE-2) comprising at least a gas diffusion layer and a catalyst coated membrane (CCM) (panel (a)), and in some exemplary embodiments of the GDE-2 further comprising: a microporous layer (MPL); a mesh; or a combination thereof (panels (b), (c) and (d))-
  • GDE-2 gas diffusion electrodes of the present disclosure
  • CCM catalyst coated membrane
  • FIG. 12 is a structural diagram of two 3-D exemplary gas diffusion electrodes of the present disclosure (GDE-3) comprising at least a gas diffusion layer (GDL) and a catalyst layer (CL) with a thickness (T) configured to consume a liquid reactant diffusing towards the GDL (panel (a)), and in another exemplary embodiment further comprising a mesh (panel (b)).
  • GDE-3 3-D exemplary gas diffusion electrodes of the present disclosure
  • FIG. 13 is a structural diagram of four exemplary gas diffusion electrodes of the present disclosure (GDE-4) comprising at least a first gas diffusion layer (1 st GDL) and a catalyst layer (CL), an ionomer layer (IL) and an anion exchange membrane (AEM), and a second gas diffusion layer (2 nd GDL) there between (panel (a)), and in some exemplary embodiments of the GDE-4 further comprising: a microporous layer (MPL); a mesh; or a combination thereof (panels (b), (c) and (d)).
  • GDE-4 a structural diagram of four exemplary gas diffusion electrodes of the present disclosure
  • FIG. 14 is a schematic diagram of an exemplary 5-compartment membrane electrolysis cell with a gas diffusion electrode (“GDE”) in the cathode compartment, showing feed and product streams.
  • GDE gas diffusion electrode
  • FIG. 15 is a schematic diagram of an exemplary 4-compartment membrane electrolysis cell with a GDE in the cathode compartment, showing feed and product streams.
  • FIG. 16 is a schematic diagram of an exemplary 3-compartment membrane electrolysis cell with a GDE in the cathode compartment, showing feed and product streams.
  • FIG. 17 is a schematic diagram of an exemplary 2-compartment membrane electrolysis cell with a GDE in the cathode compartment, showing feed and product streams.
  • LIBs Lithium-ion batteries
  • LIBs are a popular power source for clean technologies, like electric vehicles. LIBs can store a significant amount of energy in a small space, have desirable charging capabilities, and have the ability to remain effective after repeated charge cycles. LIBs are a crucial part of current efforts to replace gas-powered cars that emit CO2 and other greenhouse gases. However, conventional manufacturing processes for producing LIBs and their components also emit CO2, and thus have negative impacts on the environment.
  • one source of CO2 emission in LIB production comes from cathode production.
  • the cathode active materials such as the cathode active materials (CAMs)
  • significant amounts of heat are needed (e.g. between 800-1000°C) that can only cost-effectively be generated by burning fossil fuels, which emits CO 2 .
  • many LIBs are made using lithium carbonate (U2CO3) as a precursor material for producing the CAMs (e.g. lithium cobalt oxide, lithium manganese oxide, lithium iron phosphate, lithium nickel cobalt oxide, etc.).
  • U2CO3 lithium carbonate
  • PCAMs precursor cathode active materials
  • embodiments of the processes and systems disclosed herein enable the production of “carbon-negative” lithium carbonate.
  • the LiOH produced via electrolysis can be mixed with CO2 to produce lithium carbonate in a manner that removes or captures CO2 from a desired source (e.g. the air, exhaust gases, etc.).
  • a desired source e.g. the air, exhaust gases, etc.
  • the carbon-negative lithium carbonate may be used as a precursor material in the production of CAMs to offset the CO2 emissions of CAM manufacturing processes.
  • a CAM manufacturer could purchase the carbon-negative lithium carbonate to obtain a carbon credit against its CO2 emissions.
  • the CO2 emissions from the CAM manufacturing processes could even be captured and recycled back to be used in reaction with the LiOH produced via electrolysis to form more lithium carbonate.
  • FIG. 1 reference is made to an exemplary carbon reduction process of the present disclosure for preparing lithium carbonate with carbon capture.
  • the present disclosure relates to a process for producing lithium carbonate with carbon capture, comprising: receiving a Li salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising LiOH; and delivering the product comprising LiOH and CO2 to a carbonate production reactor to produce lithium carbonate.
  • salt solution refers to any aqueous solution of salts.
  • the salt solution may be a naturally occurring solution, a synthetic solution, or a semi-synthetic solution.
  • synthetic it is intended to mean that the salt solution was formed by combining individual ingredients (e.g. compounds, molecules, ions, etc.) to form the salt solution.
  • si-synthetic it is intended to mean that the salt solution is formed by adding one or more ingredients (e.g. compounds, molecules, ions, etc.) to a naturally occurring solution.
  • the naturally occurring solution may already be a salt solution that is desired to be modified with other ingredients.
  • the salt solution may be a produced water or brine that is extracted from an underground reservoir.
  • produced water it is intended to mean a salt solution that is formed by delivering an aqueous fluid downhole to capture desirable components within the underground formation (e.g. lithium).
  • brine it is intended to mean an existing underground aqueous solution containing desirable alkali metals.
  • the salt solution is a salar brine.
  • the salt solution may comprise LiCI, IJ2SO4, U3PO4, UNO3, Lil, LiBr, NaCI, Na2SC>4, NasPO4, NaNCh, Nal, NBr, KCI, K2SO4, K3PO4, KNO3, KI, KBr, or a combination thereof.
  • the salt solution is a Li salt-containing solution, such as a salt solution comprising LiCI, U2SO4, U3PO4, LiNOs, Lil, or LiBr.
  • the Li salt-containing solution is a produced water or a brine.
  • the processes herein comprise a step of receiving the Li salt-containing solution in an electrolysis cell comprising a cathode and an anode.
  • the electrolysis cell may be any of any shape or form, such as any electrolysis cell as described herein.
  • the electrolysis cell is a membrane electrolysis cell.
  • the electrolysis cell is a membrane electrolysis cell comprising a gas diffusion electrode as described herein.
  • the Li salt-containing solution may be received into the electrolysis cell in any suitable manner.
  • the electrolysis cell comprises an inlet through which the salt solution is delivered into an interior space or compartment of the electrolysis cell.
  • the inlet may be formed of a canal, a tubing, a conduit, a hole, an opening, or any combination thereof.
  • the inlet may be capable of being opened and closed, fully or partially, to control the flow of salt solution into the electrolysis cell, such as for example in accordance with flow rates as described herein.
  • the processes herein comprise a step of applying an electric potential between the cathode and anode.
  • the electrical potential is provided by delivering electrical power (i.e. electricity) to the electrolysis cell.
  • the electrical power that is delivered to the electrolysis cell to apply the electrical potential between the cathode and the anode is from a power grid, a localized power generation unit (e.g. a turbine), a renewable energy source, or any other source of electrical power.
  • the electrical power may be exclusively from any one of these or other sources.
  • the electrical power may be from any combination or these and other sources.
  • Electrolysis within the electrolysis cell results in the formation of a base.
  • base is intended to have interchangeably meaning with “alkali metal compound” or “alkaline compound”, each referring to any chemical compound that comprises an alkali metal (e.g. Li, Na, K, Rb, Cs, or Fr) in combination or association with one or more negatively charged molecules or anions (e.g. OFT, CO3 2 ).
  • alkali metal compound e.g. Li, Na, K, Rb, Cs, or Fr
  • the base is or comprises LiOH.
  • positive salt ions (Li + ) of the salt solution move through the electrolysis cell and associate with OH- ions from a water or gas source, to form the base.
  • the base may be removed from the electrolysis cell in any suitable manner.
  • the electrolysis cell comprises an outlet through which the base able to pass through to exit the electrolysis cell.
  • the outlet may be formed of a canal, a tubing, a conduit, a hole, an opening, or any combination thereof.
  • the outlet may be capable of being opened and closed, fully or partially, to control the flow of the base out of the electrolysis cell.
  • a by-product of the electrolysis process is a dilute salt solution.
  • dilute salt solution it is intended to mean a salt solution that has a lower concentration of a particular alkali metal (e.g. lithium) than the input salt solution to the electrolysis cell.
  • the dilute salt solution may be discarded or may be used for another purpose.
  • the dilute salt solution is returned to an underground reservoir.
  • the dilute salt solution is added to the Li salt-containing solution to re-concentrate the Li salt-containing solution with any lithium that was not removed from the salt solution, to form base, in the prior pass through the electrolysis cell.
  • the LiOH produced by the electrolysis cell is delivered and mixed with CO2.
  • the LiOH produced by the electrolysis cell is delivered and mixed with CO2.
  • lithium carbonate is formed with water as the by-product:
  • the carbonation step may be performed in any suitable vessel, container or apparatus under any suitable conditions.
  • the LiOH and CO2 are mixed or combined in a carbonate production reactor.
  • Reactors used to the production of carbonates are known, particularly in relation to the production of precipitated calcium carbonate (PCC).
  • the reactor employs a stirred tank reactor with a gas distributor.
  • gaseous CO2 is delivered to liquid base.
  • the stirred tank reactor can be operated in batch or continuous mode.
  • the carbonate production reactor herein is a continuous mode reactor.
  • Various types of mixers may be used to create a homogenous mixture of the LiOH suspension, lithium carbonate suspension, and gas bubbles created in the reaction system.
  • Vertical baffles may be included in the tank to prevent vortex formation. Temperature can be controlled, for example, by use of a tank jacket in which circulating water at a constant temperature is pumped. The water used may be the by-product water produced during the carbonation reaction.
  • Other types of carbonate production reactors include the Couette-Taylor reactor, spinning disc reactors (SDRs), rotating disc reactors (RDRs), microbubble systems (MBS), mineral carbonation reactors, and reactors with a microfiltration membrane.
  • the LiOH may be delivered from the electrolysis cell to the carbonate production reactor by any suitable means.
  • the carbonate production reactor is fluidly coupled to the electrolysis device, for example via an outlet on the electrolysis device.
  • fluidly coupled to it is meant to refer to any configuration or arrangement of components that allow a liquid or gas to pass from one device or apparatus (e.g. electrolysis cell) to another device or apparatus (e.g. carbonate production reactor).
  • the LiOH is stored in a vessel or container and transported to the carbonate production reactor. In an embodiment, the transport is a short or long distance.
  • the carbonate production reactor is fluidly coupled to a device or apparatus for providing CO2.
  • the device or apparatus for providing CO2 is a direct air capture system that is capable of removing CO2 from another substance (e.g. air, exhaust gas, etc.).
  • direct air capture systems include, without limitation, those manufactured and sold by AirCapture, Capture6, CarbonCapture Inc., Carbon Collect Limited, Carbyon, Climeworks, CO2Rrail, Fervo Energy, Global Thermostat, Heirloom, Mission Zero Technologies, Noya, Orca, Removr, RepAir Carbon Capture, Skytree, Soletair Power, Sustaera, Valiidun, and Verdox.
  • the carbonate production reactor itself comprises a CO2 sequestration apparatus or device.
  • the CO2 sequestration apparatus or device may be any carbon capture technology or equipment.
  • a system comprising an electrolysis cell comprising a cathode and an anode; and a carbonate production reactor configured to receive a product comprising LiOH from the electrolysis cell and CO2 to generate lithium carbonate.
  • the electrolysis cell may be any of any shape or form, such as any electrolysis cell as described herein.
  • the electrolysis cell is a membrane electrolysis cell.
  • the electrolysis cell is a membrane electrolysis cell comprising a gas diffusion electrode as described herein.
  • the carbonate production reactor may be any such device or apparatus as described herein, or otherwise known.
  • the system for lithium carbonate production further comprises a device or apparatus for providing the CO2 to the carbonate production reactor.
  • the device or apparatus for providing the CO2 is a direct air capture system, such as described herein.
  • the carbonate production reactor itself comprises a CO2 sequestration apparatus or device.
  • the processes herein for producing lithium carbonate include an additional step to produce cathode active materials.
  • the present disclosure relates to a process of producing cathode active material with reduced carbon emissions, comprising: receiving a Li salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising LiOH; delivering the product comprising LiOH and CO2 to a carbonate production reactor to produce lithium carbonate; and mixing the lithium carbonate with precursor cathode active material to produce cathode active material.
  • the production of CAMs using the lithium carbonate produced by the processes herein is more environmentally-friendly than using other sources of lithium carbonate for producing CAMs.
  • the production of CAMs emits CO2.
  • a producer can balance or offset their carbon emissions by using a starting material (Li2COa) that removed or captured CO2 from the air during its production.
  • the CO2 produced during the production of CAMs could be delivered to the carbonate production reactor to make more carbon-negative lithium carbonate.
  • PCAMs cathode active materials
  • NMC Lithium Nickel Cobalt Manganese Oxide
  • LFO Lithium Iron Phosphate
  • LMNO Lithium Nickel Manganese Spinel
  • NCA Lithium Nickel Cobalt Aluminum Oxide
  • LMO Lithium Manganese Oxide
  • LEO Lithium Cobalt Oxide
  • both of the starting materials are often sourced from rocky deposits or from brines that are rich in the compounds.
  • an important source of sodium carbonate used in these conventional processes is natural minerals, such as thermonatrite (sodium carbonate monohydrate; Na 2 CO 3 H 2 O) or natron (or natrite; sodium carbonate decahydrate; Na 2 CO 3 - 10H 2 O).
  • the present disclosure provides such a process whereby sodium carbonate may be produced from a different source.
  • a desired source e.g. the air, exhaust gases, etc.
  • the carbon dioxide may be supplied by a direct air capture method.
  • FIG. 2 reference is made to an exemplary carbon reduction process of the present disclosure for preparing sodium carbonate with carbon capture.
  • panel (A) the present disclosure relates to a process for producing sodium carbonate with carbon capture, comprising: receiving a Na salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising NaOH; and delivering the product comprising NaOH and CO2 to a carbonate production reactor to produce sodium carbonate.
  • salt solution has the meaning described elsewhere herein.
  • the salt solution is a Na salt-containing solution, such as a salt solution comprising NaCI, Na2SC>4, NaaPO ⁇ NaNOa, Nal, or NaBr.
  • the Na salt-containing solution may be sourced from a waste by-product generated during the production of lithium hydroxide or lithium carbonate by conventional methods.
  • the processes herein comprise a step of receiving the Na salt-containing solution in an electrolysis cell comprising a cathode and an anode.
  • the electrolysis cell may be any of any shape or form, such as any electrolysis cell as described herein.
  • the electrolysis cell is a membrane electrolysis cell.
  • the electrolysis cell is a membrane electrolysis cell comprising a gas diffusion electrode as described herein.
  • the Na salt-containing solution may be received into the electrolysis cell in any suitable manner, such as for example those described herein for receiving a Li salt-containing solution.
  • the processes herein comprise a step of applying an electric potential between the cathode and anode.
  • the electrical potential is provided by delivering electrical power (i.e. electricity) to the electrolysis cell, such as described elsewhere herein.
  • Electrolysis within the electrolysis cell results in the formation of a base, as described elsewhere herein.
  • the base is or comprises NaOH.
  • the configuration and operation of the electrolysis cell to provide the base is described elsewhere herein.
  • positive salt ions (Na + ) of the salt solution move through the electrolysis cell and associate with OH- ions from a water or gas source, to form the base.
  • the base may be removed from the electrolysis cell in any suitable manner, such as for example those described elsewhere herein for removing LiOH.
  • a by-product of the electrolysis process is a dilute salt solution.
  • the dilute salt solution is returned to an underground reservoir or a body of water (e.g. ocean).
  • the dilute salt solution is added to the Na salt-containing solution to re-concentrate the Na salt-containing solution with any sodium that was not removed from the salt solution, to form base, in the prior pass through the electrolysis cell.
  • the carbonation step may be performed in any suitable vessel, container or apparatus under any suitable conditions.
  • the NaOH and CO2 are mixed or combined in a carbonate production reactor, such as those described elsewhere herein.
  • the NaOH may be delivered from the electrolysis cell to the carbonate production reactor by any suitable means.
  • the carbonate production reactor is fluidly coupled to the electrolysis device, for example via an outlet on the electrolysis device.
  • the NaOH is stored in a vessel or container and transported to the carbonate production reactor. In an embodiment, the transport is a short or long distance.
  • the carbonate production reactor is fluidly coupled to a device or apparatus for providing CO2, such as for example in any manner and to any device or apparatus as described elsewhere herein.
  • the carbonate production reactor itself comprises a CO2 sequestration apparatus or device.
  • the CO2 sequestration apparatus or device may be any carbon capture technology or equipment.
  • the system for sodium carbonate production further comprises a device or apparatus for providing the CO2 to the carbonate production reactor.
  • the device or apparatus for providing the CO2 is a direct air capture system, such as described herein.
  • the carbonate production reactor itself comprises a CO2 sequestration apparatus or device.
  • the processes herein for producing sodium carbonate include an additional step to produce lithium carbonate.
  • the present disclosure relates to a process for producing lithium carbonate with carbon capture, comprising: receiving a Na salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising NaOH; delivering the product comprising NaOH and CO2 to a carbonate production reactor to produce sodium carbonate; and mixing the sodium carbonate with a Li salt-containing solution to produce lithium carbonate by way of a precipitation reaction.
  • the Li salt-containing solution is LiCI or Li2SO4.
  • the lithium carbonate produced by the processes herein involving chemical precipitation of lithium salts with carbon-negative sodium carbonate can be used as a precursor material for the production of CAMs as described herein, thus again providing a carbon-negative source of lithium carbonate via a carbon-negative source of sodium carbonate.
  • panel (B) in embodiments herein the byproduct of producing lithium carbonate from carbon-negative sodium carbonate is NaCI or Na2SO4.
  • these by-products can be recycled and used as the feedstock Na salt-containing solution in preparing the carbon-negative sodium carbonate in accordance with the processes herein.
  • This feedback loop further improves the carbon reduction potential of the processes of the present disclosure.
  • Na salt-containing solutions including those produced by the processes herein involving the precipitation of carbon-negative sodium carbonate to lithium carbonate.
  • Na salt-containing solutions including those produced in accordance with FIG. 2, panel (B) may be used in processes disclosed herein (e.g. FIG. 3) for ocean alkalinity enhancement (OAE) or increasing the alkalinity of any body of water, to thereby improve carbon dioxide removal (CDR) from the air.
  • OAE ocean alkalinity enhancement
  • CDR carbon dioxide removal
  • the ocean is one of Earth's largest natural carbon sinks. It naturally absorbs roughly one-third of fossil fuel emissions humans produce each year, making it a natural medium for CDR.
  • Carbon dioxide dissolves in ocean water and may form H2CO3, HCOa", and CO 3 2 ' as depicted in the following equilibrium reactions:
  • the equilibria of the above species may be shifted by adjusting the pH of the water. For example, lower pH will cause the equilibria to shift towards the left resulting in higher concentrations of CO2 which may be emitted from the water. Conversely, increasing pH (i.e. alkalinity enhancement) will cause the equilibria to shift to the right resulting in higher concentrations of bicarbonate and carbonate while increasing the water’s capacity to absorb CO2.
  • the NaCI or Na2SC>4 by-products may be used as feedstock for a process using an electrolysis cell for conversion to NaOH.
  • the resulting NaOH would be added to seawater for OAE.
  • the present disclosure relates to a process for enhancing ocean alkalinity, comprising: receiving a salt solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising an alkaline compound; and delivering the product comprising an alkaline compound to a body of seawater.
  • the salt solution has the meaning described elsewhere herein.
  • the salt solution is preferably a Na salt-containing solution, such as a salt solution comprising NaCI, Na2SC>4, Na3PO4, NaNOa, Nal, or NaBr.
  • the Na salt-containing solution is sourced from a waste by-product generated during the production of lithium hydroxide or lithium carbonate by conventional methods (e.g. NaCI or Na2SC>4 to NaOH).
  • the salt solution is sourced from by-products of the processes herein for producing lithium carbonate from carbon-negative sodium carbonate.
  • the salt solution comprises NaCI.
  • the NaCI is a by-product from a solar evaporation pond in a lithium brine extraction operation.
  • the NaCI is a by-product of the processes herein for producing lithium carbonate from carbon-negative sodium carbonate (FIG. 2, panel (B)).
  • the salt solution comprises Na2SO4.
  • the Na2SO4 is a by-product from a lithium sulfate to lithium hydroxide or lithium carbonate conversion operation.
  • the Na2SC>4 is a by-product of the processes herein for producing lithium carbonate from carbon-negative sodium carbonate (FIG. 2, panel (B)).
  • the processes herein comprise a step of receiving the salt-containing solution in an electrolysis cell comprising a cathode and an anode.
  • the electrolysis cell may be any of any shape or form, such as any electrolysis cell as described herein.
  • the electrolysis cell is a membrane electrolysis cell.
  • the electrolysis cell is a membrane electrolysis cell comprising a gas diffusion electrode as described herein.
  • the electrolysis cell is a 5-compartment electrolysis cell as described herein.
  • the salt-containing solution may be received into the electrolysis cell in any suitable manner, such as for example those described herein for receiving Li salt-containing solutions and Na salt-containing solutions.
  • the processes herein for enhancing ocean alkalinity comprise a step of applying an electric potential between the cathode and anode.
  • the electrical potential is provided by delivering electrical power (i.e. electricity) to the electrolysis cell, such as described elsewhere herein.
  • Electrolysis within the electrolysis cell results in the formation of a base, as described elsewhere herein.
  • the base is or comprises NaOH.
  • the configuration and operation of the electrolysis cell to provide the base is described elsewhere herein.
  • positive salt ions (Na + ) of the salt solution move through the electrolysis cell and associate with OH- ions from a water or gas source, to form the base.
  • positive ions of the salt solution (Na + ) and negative ions of the water or gas (OH ) migrate to the same compartment (e.g. the base build-up compartment) and together form the base / alkaline compound (NaOH).
  • the base may be removed from the electrolysis cell in any suitable manner, such as for example those described elsewhere herein for removing.
  • the resulting NaOH would be delivered and added to seawater or any other body of water for OAE.
  • the resulting base e.g. NaOH
  • the resulting base may be delivered to an ocean or other body of water by any suitable means.
  • the base / alkaline compound is flowed directly to or is shipped to a body of water (e.g. ocean seawater).
  • a by-product of the electrolysis process is a dilute salt solution.
  • the dilute salt solution is added to the Na salt-containing solution to re-concentrate the Na salt-containing solution with any sodium that was not removed from the salt solution, to form base, in the prior pass through the electrolysis cell.
  • a system comprising an electrolysis cell comprising a cathode and an anode.
  • the electrolysis cell may be any of any shape or form, such as any electrolysis cell as described herein.
  • the electrolysis cell is a membrane electrolysis cell.
  • the electrolysis cell is a membrane electrolysis cell comprising a gas diffusion electrode as described herein.
  • the electrolysis cell is a 5-compartment electrolysis cell as described herein.
  • electrolysis cell refers to any device comprising an anode and a cathode, whereby electrons move in response to an electrical energy or current being supplied to facilitate chemical reactions within the electrolysis cell.
  • An electrolysis cell is a type of electrochemical cell that generates a chemical reaction via electrolysis.
  • the electrolysis cell is an electrodialysis cell or a membrane electrolysis cell, these terms used interchangeably herein.
  • an electrodialysis cell is a form of an electrolysis cell that can be used to transport salts from one solution or compartment to another.
  • An electrodialysis cell comprises one or more membranes separating different compartments of the electrodialysis cell. Using an electrodialysis cell, electrolysis is used to transport salt ions from one solution or compartment through ion-exchange membranes to another solution or compartment under the influence of an applied electric potential difference.
  • the membrane electrolysis cell may comprise one compartment, two compartments, three compartments, four compartments, five compartments, or more.
  • the compartments may, for example be separated by membranes and/or diaphragms.
  • one or more compartments of the membrane electrolysis cell comprise an anode compartment, an acid build-up compartment, a salt depletion compartment, a base build-up compartment, a cathode compartment, or any combination thereof.
  • the “anode compartment” is the compartment comprising an anode.
  • the “cathode compartment” is the compartment comprising the cathode.
  • the “salt-depletion compartment” is a compartment from which salts from the salt solution are removed.
  • the “acid build-up compartment” is a compartment in which acidic species or solutions reside and can be obtained upon operation.
  • the “base build-up compartment” is a compartment in which basic species or solutions reside and can be obtained upon operation.
  • the base build-up compartment may comprise the desired alkali metal compounds of the present disclosure.
  • the membrane electrolysis cell comprises four compartments or five compartments.
  • the electrolysis cell may be a chlor-alkali membrane electrolysis cell (see FIG. 4) or a chlor-alkali diaphragm electrolysis cell (see FIG. 5).
  • a chlor-alkali membrane electrolysis cell comprises a cation exchange membrane (GEM).
  • GEM cation exchange membrane
  • the GEM permits the passage of cations, such as Li + , Na + , etc., through the membrane while preventing passage of other substances, including the salt solution.
  • a chlor-alkali diaphragm comprises a membrane or diaphragm that is semi-permeable and allows both the cations and the salt solution to pass through.
  • both of these electrolysis cells allow for the formation of LiOH, but with the chlor-alkali membrane cell the base (e.g. LiOH) is in aqueous solution whereas with the chlor-alkali diaphragm the base (e.g. LiOH) is in dilute salt solution.
  • Both of these types of electrolysis cells produce hydrogen (H2) as a by-product.
  • the electrolysis cell may be an electrodialysis cell that comprises both a GEM and an anion exchange membrane (AEM), such as for example shown in FIG. 6.
  • AEM anion exchange membrane
  • FIG. 6 is an electrolysis cell having three compartments, each compartment separated by a membrane.
  • the electrolysis cell may have four compartments, five compartments, or more. Different configurations may be used to obtain different outputs and/or utilize different inputs/feedstocks.
  • the electrolysis cell may be an electrodialysis cell that comprises at least one bipolar membrane (BPM), also referred to herein as a bipolar membrane electrodialysis cell.
  • BPM bipolar membrane
  • FIG. 7 An exemplary embodiment is shown in FIG. 7.
  • BPM bipolar membrane
  • the BPM is a sandwich of a GEM and an AEM to form a single BPM. Since a BPM allows both anions and cations to pass, these membranes are not typically considered to split the electrodialysis cell into different compartments.
  • the electrolysis cell may comprise a single BPM separating one or more OEMs and/or AEMs on either side.
  • the electrolysis cell may comprise the following arrangement of membranes: AEM-CEM-BPM- AEM-CEM.
  • the electrolysis cell may comprise two BPMs separated by a GEM (e.g. BPM-CEM-BPM; see FIG. 7).
  • the electrolysis cell may comprise two bipolar membranes separated by an AEM (e.g. BPM-AEM-BPM; see FIG. 8).
  • the electrolysis cell may comprise two bipolar membranes separated by an AEM and a GEM (e.g. BPM-AEM-CEM-BPM; see FIG. 9). Repeating units of any of these configurations within an electrolysis cell is contemplated and encompassed herein, such as for example BPM-CEM-BPM-CEM-BPM.
  • the electrolysis cell is a membrane electrolysis cell that comprises a gas diffusion electrode (“GDE”) in the cathode compartment.
  • GDE gas diffusion electrode
  • the membrane electrolysis cell comprises the GDE as the cathode in the cathode compartment.
  • the GDE comprises a porous catalyst layer which is disposed on a carrier material.
  • the catalyst layer which conducts electrons, catalyses an electrochemical reaction between a liquid and a gas.
  • the electrochemical reaction occurs at a so-called three-phase boundary where gas, liquid and solid ( .e. catalyst) are contacted.
  • the gas may comprise oxygen and the liquid may comprise water resulting in the cathodic reaction:
  • the GDE allows for a membrane electrolysis cell to operate using air as the oxygen source at the cathode. This may be a significant economic and safety advance in the ability to incorporate these cells into a process for producing a base (e.g. alkali metal compounds such as alkali metal hydroxides).
  • a base e.g. alkali metal compounds such as alkali metal hydroxides.
  • the gas may comprise oxygen admixed with carbon dioxide resulting in the following cathodic reactions:
  • GDE-1 Various embodiments of GDEs in accordance with the present disclosure are described below by reference to “GDE-1”, “GDE-2” and “GDE-3”. Non-limiting configurations of these GDE embodiments are shown in FIG. 10 (GDE-1), FIG. 11 (GDE-2 , FIG. 12 (GDE-3) and FIG. 13 (GDE-4).
  • the GDEs may be prepared by any of the numerous methods known in the art for applying a catalyst layer to a substrate (e.g. GDL or membrane).
  • the form of the catalyst layer preparation will influence the choice of method.
  • solid/powder e.g. dry powder spraying, decal method
  • suspension e.g. Doctor Blade, screen printing, inkjet printing, scrape method
  • aerosol e.g. sonicated spray, irradiation spray, hand brush air spray
  • vapour/plasma e.g. magnetron sputtering, decal sputtering, helican RF sputtering, chemical vapour deposition
  • electrode assisted deposition e.g. electrode spraying, electrodeposition, or electrophoretic deposition
  • the catalyst layer is a suspension and may be applied by way of, for example and without limitation, Doctor Blade, screen printing, inkjet printing, or scrape method.
  • a gas diffusion electrode comprising a gas diffusion layer (GDL) and a catalyst layer (CL).
  • the CL is disposed on a surface of the GDL. See, for example, FIG. 10(a).
  • the GDL of GDE-1 may be modified with a hydrophobic polymer treatment and/or application of a microporous layer (MPL).
  • MPL microporous layer
  • the GDE further comprises the MPL disposed on a surface of the GDL, wherein the CL is disposed on a surface of the microporous layer opposite the GDL. See, for example, FIG. 10(b).
  • GDE-1 may include a mesh in contact with a surface of the GDL opposite from the CL (see, for example, FIG. 10(c)) or opposite from the MPL (see, for example, FIG. 10(d)).
  • the mesh is bonded to the GDL by teflonization, hot-pressing, or lamination.
  • GDE-1 includes an anion exchange membrane (AEM) which may assist in the prevention of GDE flooding by the liquid reactant in an electrolysis cell.
  • AEM anion exchange membrane
  • the AEM may be disposed on a surface of the CL, the AEM being configured to exchange ions from the catalyst layer to an opposed surface of the AEM. See, for example, FIGs. 10(e)-1 (h).
  • the AEM may be held in direct contact with the CL through a mechanical means or the AEM is bonded to the CL, for example, by teflonization, hot-pressing, ionomer, or lamination.
  • a gas diffusion electrode comprising a gas diffusion layer (GDL) and a catalyst coated membrane (CCM).
  • the CL is disposed on a surface of a membrane to form the CCM. See, for example, see FIG. 1 1 (a).
  • the CCM refers to the anion exchange membrane having one surface coated with the CL.
  • the CCM may allow for better ion transport through the contact interface between the CL and membrane.
  • the GDL is in contact with the CL of the CCM.
  • the GDL of GDE-2 may be modified with a hydrophobic polymer treatment and/or application of a microporous layer (MPL).
  • MPL microporous layer
  • the GDE further comprises the MPL disposed on a surface of the GDL, wherein the MPL is in contact with the CL of the CCM. See, for example, FIG. 11 (b).
  • GDE-2 may include a mesh in contact with a surface of the GDL opposite from the CL (see, for example, FIG. 1 1 (c)) or opposite from the MPL (see, for example, FIG. 1 1 (d)).
  • the mesh is bonded to the GDL by teflonization, hot-pressing, or lamination.
  • a gas diffusion electrode comprising a gas diffusion layer (GDL) and a catalyst layer (CL) disposed on the GDL, wherein the catalyst layer has a thickness (T) optimized to substantially or completely consume a liquid reactant diffusing across the CL before reaching the GDL. See, for example, see FIG. 12(a).
  • the final concentration of the liquid reactant may be zero or near zero at the interface between the CL and GDL.
  • near zero it is meant a moisture content at the interface between the CL and the GDL that is of an amount insufficient to adversely affect the electrochemical reaction of the GDE.
  • the moisture content at the surface of the CL at the interface between the CL and GDL is an amount less than 5%, less than 4%, less than 3%, less than 2%, less than 1 % of the liquid reactant.
  • the thickness, and optionally the hydrophobicity and/or porosity of the CL By controlling the thickness, and optionally the hydrophobicity and/or porosity of the CL, one may control the concentration gradient to ensure more complete utilization of the reactant. With sufficient reaction of the liquid reactant in the CL, use of an ion exchange membrane with GDE-3 may be rendered unnecessary in an electrolysis cell.
  • GDE-3 may include a mesh in contact with a surface of the GDL opposite from the CL (see, for example, FIG. 12(b)).
  • the mesh is bonded to the GDL by teflonization, hot-pressing, or lamination.
  • a gas diffusion electrode comprising a first gas diffusion layer (1 st GDL), a catalyst layer (CL), a second gas diffusion layer (2 nd GDL), an ionomer layer (IL), and an anion exchange membrane (AEM).
  • the CL is disposed on a surface of the 1 st GDL.
  • a surface of the 2 nd GDL is in contact with the CL.
  • the IL is bonded to the AEM.
  • the IL is in contact with a surface of the 2 nd GDL opposite from the CL. See, for example, FIG. 13(a).
  • the 2 nd GDL of GDE-4 may be modified with a hydrophobic polymer treatment and/or application of a microporous layer (MPL).
  • MPL microporous layer
  • the GDE further comprises the MPL disposed on a surface of the 2 nd GDL.
  • the MPL is in contact with the CL. See, for example, FIG. 13(b).
  • GDE-4 may include a mesh in contact with a surface of the 1 st GDL opposite from the CL (see, for example, FIG. 13(c) or (d)).
  • the GDE-4 comprises a 1 st GDL and a 2 nd GDL.
  • the 1 st GDL and 2 nd GDL in the GDE-4 are the same.
  • the 1 st GDL and 2 nd GDL in the GDE-4 are different from each other.
  • the 1 st GDL and 2 nd GDL may have the same or different pore configurations, have the same or different porosity, be the same or different thickness, be made of the same or different materials (e.g.
  • the surfaces of any of the GDEs described herein may have an embossed/debossed pattern to effectively increase the active surface area.
  • the pattern may be applied to the GDEs by any known method including carving, molding and stamping.
  • the pattern may be any suitable pattern that increases the surface area of the substrate or material.
  • GDL Gas Diffusion Layer
  • the GDL is a porous structure that may act as a gas diffuser and/or a current collector.
  • the GDL may have relatively uniform pore size through its thickness.
  • the GDL may have a random pore size through its thickness.
  • the GDL may have a pore size gradient through its thickness.
  • the GDL may have a gradient of large to small pore size through its thickness in the direction of gas flow.
  • the GDL may have a gradient of small to large pore size through its thickness in the direction of gas flow.
  • the GDL may have a thickness of between 50 pm and 1000 pm, between 50 pm and 950 pm, between 50 pm and 900 pm, between 50 pm and 850 pm, between
  • the GDL may have an average pore diameter of between 1 pm and 100 pm, between 1 pm and 90 pm, between 1 pm and 80 pm, between 1 pm and 70 pm, between 1 pm and 60 pm, between 1 pm and 50 pm, between 1 pm and 40 pm, between 1 pm and 30 pm, between 1 pm and 20 pm, or between 1 pm and 10 pm.
  • the GDL may have a porosity of between 50% and 95%, between 50% and 90%, between 50% and 85%, between 50% and 80%, between 50% and 75%, between 50% and 70%, between 50% and 65%, between 50% and 60%, between 50% and 55%, between 55% and 95%, between 60% and 95%, between 65% and 95%, between 70% and 95%, between 75% and 95%, between 80% and 95%, between 85% and 95%, between 90% and 95%. between 55% and 90%, between 60% and 85%, between 65% and 80%, or between 70% and 75%.
  • the GDL may comprise carbon-fibre paper, carbon cloth, carbon felt, carbon foam, metal mesh, metal foam, or any combination thereof.
  • the GDL may be modified with a hydrophobic polymer treatment and/or application of a microporous layer (MPL).
  • MPL microporous layer
  • Non-limiting examples of carbon-fibre paper include:
  • Toray TGP-H carbon-fibre paper e.g. TGP-H-030, TGP-H-060, TGP-H-090, TGP-H-120
  • AvCarb® carbon-fibre paper e.g. MGL190, MGL280, MGL370, MGL190T, MGL280T, MGL370T, EP40, EP40T, EP55, EP55T, GDS1 120, GDS2120, GDS22100, GDS2230, GDS2240, GDS3215, GDS3250, GDS3260, GDS5130, MB30, P50, P50T, P75, P75T),
  • Sigracet® carbon-fibre paper e.g. 22 BB, 25 BA, 25 BC, 28 AA, 28 BC, 29 AA, 29 BC, 36 AA, 36BB, 39 AA, 39 BB
  • CeTech carbon-fibre paper e.g. GDS180S, GDS210, GDS230, GDS 250, GDS310, GDL240, GDL280, GDL340, GDS090S, GDS180HT, GDL120, GDL210SHT
  • JNT carbon-fibre paper series e.g. JNT15B, JNT17B, JNT18B, JNT20, JNT21 , JNT30
  • LINQCELL carbon-fibre paper e.g. GDP180, GDP210, GDP210-MP, GDP-210MPS, GDP 240, GDP340
  • Non-limiting examples of carbon cloth include:
  • AvCarb® carbon cloth e.g. 1071 , 1698, 1209, 1185, 1186, 7497, T1819, T1820, T1824
  • E-TEK carbon cloth e.g. CC4, CC4 Wet Proofed, CC6, CC6 Wet Proofed, ELAT plain cloth, ELAT LT1400, ELAT LT2400W
  • E-TEK carbon cloth e.g. CC4, CC4 Wet Proofed, CC6, CC6 Wet Proofed, ELAT plain cloth, ELAT LT1400, ELAT LT2400W
  • CeTech carbon cloth e.g. W0S1009, W0S1011, W0S1011 , W1S1011)
  • LINQCELL carbon cloth e.g. CF350, CF400-MP
  • Non-limiting examples of carbon felt include:
  • AvCarb® felt e.g. C100, C200, C280, G100, G200, G300A, G475A, G600A
  • CeTech felt e.g. CF120, GF20, GF100
  • JNT felt e.g. GF051 BH, GF061 AH.
  • Non-limiting examples of the metal foam include:
  • Non-limiting examples of the metal mesh include:
  • the GDL may be modified with a hydrophobic polymer.
  • a GDL modified with a hydrophobic polymer treatment involves the application of a hydrophobic additive to the GDL to control the wettability of the GDL.
  • Non-limiting examples of such hydrophobic additives include polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), fluorinated ethylene propylene (FEP), perfluoropolyether (PFPE), and polydimethylsiloxane (PDMS).
  • PTFE polytetrafluoroethylene
  • PVDF polyvinylidene fluoride
  • FEP fluorinated ethylene propylene
  • PFPE perfluoropolyether
  • PDMS polydimethylsiloxane
  • the GDL may be modified with any one or any combination of hydrophobic additives.
  • the GDL may comprise no hydrophobic addition or between 0.01 wt% and 50 wt%, between 0.01 wt% and 45 wt%, between 0.01 wt% and 40 wt%, between 0.01 wt% and 35 wt%, between 0.01 wt% and 30 wt%, between 0.01 wt% and 25 wt%, between 0.01 wt% and 20 wt%, between 0.01 wt% and 15 wt%, between 0.01 wt% and 10 wt%, between 0.01 wt% and 5 wt%, between 5 wt% and 50 wt%, between 10 wt% and 50 wt%, between 15 wt% and 50 wt%, between 20 wt% and 50 wt%, between 25 wt% and 50 wt%, between 30 wt% and 50 wt%, between 35 wt% and 50 wt%, between 40 wt% and 50 wt%
  • MPL Microporous Layer
  • the MPL is disposed on the GDL and may aid with electrical conductivity and/or water management.
  • the MPL comprises a particulate material coated on a planar face of the GDL. Any suitable particular material may be used.
  • the particulate material may be a mixture of carbon black and a hydrophobic polymer such as polytetrafluoroethylene (PTFE).
  • the MPL may comprise between 50 wt% and 95 wt%, between 55 wt% and 95 wt%, between 60 wt% and 95 wt%, between 65 wt% and 95 wt%, between 70 wt% and
  • 70 wt% between 60 wt% and 65 wt%, between 65 wt% and 90 wt%, between 70 wt% and
  • the MPL may comprise between 5 wt% and 50 wt%, between 5 wt% and 45 wt%, between 5 wt% and 40 wt%, between 5 wt% and 35 wt%, between 5 wt% and
  • the MPL may have a thickness of between 10 pm and 100 pm, between 10 pm and 90 pm, between 10 pm and 80 pm, between 10 pm and 70 pm, between 10 pm and 60 pm, between 10 pm and 50 pm, between 10 pm and 40 pm, between 10 pm and 30 pm, between 10 pm and 20 pm, between 20 pm and 100 pm, between 30 pm and 100 pm, between 40 pm and 100 pm, between 50 pm and 100 pm, between 60 pm and 100 pm, between 70 pm and 100 pm, between 80 pm and 100 pm, between 90 pm and 100 pm, between 20 pm and 90 pm, between 30 pm and 80 pm, between 40 pm and 70 pm, or between 50 pm and 60 pm.
  • the MPL may have an average pore diameter of between 0 pm and 10 pm, between 0 pm and 9 pm, between 0 pm and 8 pm, between 0 pm and 7 pm, between 0 pm and 6 pm, between 0 pm and 5 pm, between 0 pm and 4 pm, between 0 pm and 3 pm, between 0 pm and 2 pm, between 0 pm and 1 pm, between 0 pm and 0.9 pm, between 0 pm and 0.8 pm, between 0 pm and 0.7 pm, between 0 pm and 0.6 pm, between 0 pm and 0.5 pm, between 0 pm and 0.4 pm, between 0 pm and 0.3 pm, between 0 pm and 0.2 pm, or between 0 pm and 0.1 pm.
  • the MPL may have a porosity of between 30% to 75%, between 30% to 70%, between 30% to 65%, between 30% to 60%, between 30% to 55%, between 30% to 50%, between 30% to 55%, between 30% to 50%, between 30% to 45%, between 30% to 40%, between 30% to 35%, between 35% to 75%, between 40% to 75%, between 45% to 75%, between 50% to 75%, between 55% to 75%, between 60% to 75%, between 65% to 75%, or between 70% to 75%.
  • the catalyst layer may comprise a catalyst, and optionally an ionomer and/or a binder.
  • the catalyst layer may comprise a catalyst and an ionomer.
  • the catalyst layer may comprise a catalyst and a binder.
  • the catalyst layer may comprise a catalyst, an ionomer, and a binder.
  • the GDE has only a single catalyst layer. In other embodiments, the GDE may comprise more than one catalyst layer.
  • the catalyst layer may be hydrophilic or hydrophobic, for example depending on the desired operation of the CL.
  • the GDE comprises two CL
  • the first CL is hydrophilic and the second CL is hydrophobic.
  • both CLs may be hydrophobic or hydrophilic.
  • the catalyst layer may have a thickness of between 1 pm and 100 pm, between 1 pm and 95 pm, between 1 pm and 90 pm, between 1 pm and 85 pm, between
  • 1 pm and 80 pm between 1 pm and 75 pm, between 1 pm and 70 pm, between 1 pm and 65 pm, between 1 pm and 60 pm, between 1 pm and 55 pm, between 1 pm and 50 pm, between 1 pm and 45 pm, between 1 pm and 40 pm, between 1 pm and 35 pm, between
  • 1 pm and 30 pm between 1 pm and 25 pm, between 1 pm and 20 pm, between 1 pm and 15 pm, between 1 pm and 10 pm, between 1 pm and 9 pm, between 1 pm and 8 pm, between 1 pm and 7 pm, between 1 pm and 6 pm, between 1 pm and 5 pm, between 1 pm and 4 pm, between 1 pm and 3 pm, or between 1 pm and 2 pm.
  • the catalyst layer may have a porosity of between 30% to 75%, between 30% to 70%, between 30% to 65%, between 30% to 60%, between 30% to 55%, between 30% to
  • the ionomencatalyst ratio may be between 1:1 to 1:20, between 1:1 to 1:19, between 1:1 to 1:18, between 1:1 to 1:17, between 1:1 to 1:16, between 1:1 to 1:15, between 1:1 to 1:14, between 1:1 to 1:13, between 1:1 to 1:12, between 1:1 to 1:11, between 1:1 to 1:10, between 1:1 to 1:9, between 1:1 to 1:8, between 1:1 to 1:7, between 1:1 to 1:6, between 1:1 to 1:5, between 1:1 to 1:4, between 1:1 to 1:3, between 1:1 to 1:2, between 1:2 to 1:20, between 1 :3 to 1 :20, between 1 :4 to 1 :20, between 1 :5 to 1 :20, between 1 :6 to 1 :20, between 1:7 to 1:20, between 1:8 to 1:20, between 1:9 to 1:20, between 1:10 to 1:20, between 1:11 to 1:20, between 1:12 to 1:20, between 1:13 to 1:20, between 1:14 to 1:20, between 1:15 to 1:20, between 1:15 to 1
  • the catalyst may include (6) a metal, (7) a non-metal, or a combination thereof.
  • the metal may be (6a) a transition metal, (6b) a post-transition metal, (6c) a metalloid, or a combination thereof, or an alloy thereof.
  • the catalyst including a transition metal may include:
  • the catalyst including a post-transition metal may include:
  • the catalyst including a metalloid may include: (6c-a) silicon (Si), (6c-b) germanium (Ge), (6c-c) antimony (Sb), (6c-d) telelium (Te), or a combination thereof.
  • the catalyst including a non-metal may include (7a) carbon, (7b) a conductive polymer, or a combination thereof.
  • the carbon refers to a material whose main component is composed of carbon atoms.
  • the carbon may be a carbon fiber, graphite, a carbon nanomaterial, or a combination thereof.
  • the carbon nanomaterial may include a carbon nanotube, graphene, carbon nanoplate, or fullerene. Further, the material may optionally be doped with non-metallic elements (e.g. B, N, P, O or S).
  • the catalyst loading on the GDL may be between 0.1 and 10 mg cm -2 , between 0.1 and 9.0 mg cm' 2 , between 0.1 and 8.0 mg cm -2 , between 0.1 and 7.0 mg cm' 2 , between 0.1 and 6.0 mg cm' 2 , between 0.1 and 5.0 mg cm -2 , between 0.1 and 4.0 mg cm' 2 , between 0.1 and 3.9 mg cm' 2 , between 0.1 and 3.8 mg cm -2 , between 0.1 and 3.7 mg cm' 2 , between 0.1 and 3.6 mg cm' 2 , between 0.1 and 3.5 mg cm -2 , between 0.1 and 3.4 mg cm' 2 , between 0.1 and 3.3 mg cm' 2 , between 0.1 and 3.2 mg cm -2 , between 0.1 and 3.1 mg cm' 2 , between 0.1 and 3.0 mg cm' 2 , between 0.1 and 2.9 mg cm' 2 , between 0.1 and 2.8 mg cm -2 , between 0.1 and 2.7 mg cm' 2 , between 0.1 and 2.8
  • the ionomer includes a polymer wherein at least a portion of the repeating units of the polymer comprise ionic groups (e.g., wherein the polymer is a copolymer comprising electrically neutral units and units comprising an ionic group).
  • the ionomer comprises an anion exchange ionomer.
  • the anion exchange ionomer includes ionomers where the ionic groups are preferably cationic groups, which promote conduction of anions via electrostatic interaction between the anions and cationic groups.
  • Non-limiting examples of the anion exchange ionomer include (8a) FumionTM FAA-3 AEI, (8b) lonomrTM AEI (e.g. AF1 , AF2, AF3, AP1 , AP3), (8c) Sustainion® AEI (e.g. XA-9, XB-7, XC-1 , XC-2), (8d) Orion AEI (e.g. TM1 , AM, CMX), (8e) PentionTM AEI (e.g. D18, D35, D72), and (8f) PiperlON AEI.
  • 8a) FumionTM FAA-3 AEI e.g. AF1 , AF2, AF3, AP1 , AP3
  • Sustainion® AEI e.g. XA-9, XB-7, XC-1 , XC-2
  • Orion AEI e.g. TM1
  • the ionomer comprises a cation exchange ionomer.
  • the cation exchange ionomer includes ionomers where the ionic groups are preferably anionic groups, which promote conduction of cations via electrostatic interaction between the anions and cationic groups.
  • Non-limiting examples of the cation exchange ionomer include Aquivion® CEI (e.g. D72-25BS, D79-25BS, D83-24B, D98-25BS), FORBLUETM i-SERIES CEI (e.g. IC100, IC154), FumionTM CEI (e.g. E-600, FSLA-102, FSLA-725), lonomrTM CEI (e.g. PP1 ), and NationTM CEI (e.g. D520CS, D521CS, D2020CS, D2021CS).
  • Aquivion® CEI e.g. D72-25BS, D79-25BS, D83-24B, D98-25BS
  • FORBLUETM i-SERIES CEI e.g. IC100, IC154
  • FumionTM CEI e.g. E-600, FSLA-102, FSLA-725
  • lonomrTM CEI e.g. PP1
  • NationalTM CEI
  • the CL may comprise between 5 wt% and 45 wt%, between 5 wt% and 40 wt%, between 5 wt% and 35 wt%, between 5 wt% and 30 wt%, between 5 wt% and
  • the CL comprises a binder.
  • the binder may, for example, be a polymer that is hydrophilic or hydrophobic.
  • Non-limiting examples of the binder include (9a) PTFE.
  • the CL may comprise no binder or, if present, between 0.01 wt% and 40 wt%, between 0.01 wt% and 35 wt%, between 0.01 wt% and 30 wt%, between 0.01 wt% and 25 wt%, between 0.01 wt% and 20 wt%, between 0.01 wt% and 15 wt%, between 0.01 wt% and 10 wt%, between 0.01 wt% and 5 wt%, between 5 wt% and 40 wt%, between 10 wt% and 40 wt%, between 15 wt% and 40 wt%, between 20 wt% and 40 wt%, between 25 wt% and 40 wt%, between 30 wt% and 40 wt%, between 35 wt% and 40 wt%, between 5 wt% and 35 wt%, between 10 wt% and 30 wt%, or between 15 wt% and 25
  • GDEs of the present disclosure include GDEs described herein as GDE-1, GDE-2, GDE-3 or GDE-4, each having components as defined in the following rows, wherein each entry is a group number as defined above:
  • any of Embodiments 1-768 for these GDEs may further comprise an AEM as described herein, for example as shown in FIGs. 10(e)-(h).
  • any of Embodiments 1-768 for these GDEs may further comprise an MPL as described herein, for example as shown in FIGs. 10(b), (d), (f) and (h), FIGs. 1 1 (b) and (d), and FIGs. 13(b) and 13(d) .
  • any of Embodiments 1-768 for these GDEs may further comprise a mesh as described herein, for example as shown in FIGs. 10(c)-(h), 11 (c)-(d), 12(b) and 13(c) and 13(d).
  • the GDE-4 comprises a 1 st GDL and a 2 nd GDL, each of which may be the same or different.
  • at least one of the 1 st GDL and the 2 nd GDL is the GDL as defined for the respective embodiment of Embodiments 1-768.
  • the 1 st GDL and the 2 nd GDL are the same, and both of the GDLs in GDE-4 are as defined for the respective embodiment of Embodiments 1-768.
  • the 1 st GDL and the 2 nd GDL are different and only one of the GDLs is as defined for the respective embodiment of Embodiments 1-768.
  • the GDLs in the GDE-4 are different, it is the 1 st GDL that is as defined for the respective embodiment of Embodiments 1-768. In an embodiment where the GDLs in the GDE-4 are different, it is the 2 nd GDL that is as defined for the respective embodiment of Embodiments 1-768.
  • the GDE-1, GDE-2 or GDE-4 of the present disclosure may comprise an AEM.
  • Embodiments of AEMs are described elsewhere herein and that disclosure is equally applicable to AEMs that are a component of the GDE.
  • the AEM of the GDE comprises a polymer having at least one positively charged cationic group bound to at least a portion of a polymeric backbone.
  • the polymer comprises polyalkylene, a polyfluorene, a poly(arylene ether), a polysulfone, a poly(arylene ether sulfone), a polyetherketone, a polyetherimide, a poly(ether oxadiazole), a poly(phenylene oxide), a poly(vinyl benzyl), a polyphenylene, a perfluoro, a polybenzimidazole, a polystyrene, or a polyphosphazene.
  • the positively charged cationic group is a primary, secondary, tertiary or quaternary ammonium, a heterocyclic cation, a guanidinium, a phosphonium, a sulfonium, or a metal cation.
  • the AEM of the GDE is a FumasepTM, a NeoseptaTM, an OrionTM, a Xergy Xion PentionTM, a PiperlONTM, a RalexTM, a SustanionTM, or an lonomrTM anion exchange membrane.
  • the electrolysis cell is one that comprises a GDE.
  • the GDE may be any of those as described herein.
  • one or more ion exchange membranes are stacked in an order specific to the components of the salt solution being processed as well as the desired outputs.
  • the membranes are designed to allow specific charged ionic species permeate through.
  • Cation exchange membranes transfer cationic species while anion exchange membrane only allow anions transport through the membrane structure.
  • the movement of ions is enabled by applying an external voltage using a cathode and anode electrode. Under applied voltage, anions travel toward the positively charged anode while cations travel towards the negatively charged cathode.
  • desired chemicals such acids, bases, and salts can be produced.
  • multi-compartment electrolysis cells comprising GDEs
  • GDEs Various different types of multi-compartment electrolysis cells comprising GDEs may be used, such as those described herein.
  • the electrolysis cell is a 5-compartment membrane electrolysis cell.
  • the 5-compartment membrane electrolysis cell comprises an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment, and an acid build-up compartment.
  • Each compartment may be separated by, for example, an AEM, a CEM or a BPM, such as described herein without limitation.
  • the 5-compartment membrane electrolysis cell comprises: an anode compartment (AC) and a cathode compartment (CC); and each of a base build-up compartment (BBC), a salt depletion compartment (SDC) and an acid build-up compartment (ABC) interposed between the CC and the AC.
  • the BBC is interposed between the CC and the SDC
  • the SDC is interposed between the BBC and the ABC
  • the ABC is interposed between the SDC and the AC (e.g. AC-ABC-SDC-BBC-CC).
  • AC-ABC-SDC-BBC-CC AC-ABC-SDC-BBC-CC
  • the 5-compartment membrane electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite
  • positioned to extend within the interior it is intended to refer to a configuration where all or a portion of the anode or cathode extends into the interior of the membrane electrolysis cell to thereby position all or a portion of the anode or cathode in the anode compartment or the cathode compartment, respectively.
  • a salt solution is received into the salt depletion compartment; positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; water is dissociated in the first bipolar membrane and OH- migrates into the base build-up compartment; and the positive salt ions and the OH- ions in the base-build-up compartment together form a base / alkaline compound.
  • the cathode comprises a gas diffusion electrode, such as for example and without limitation, any gas diffusion electrode described herein.
  • the gas diffusion electrode comprises a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions.
  • the 5-compartment membrane electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and
  • a salt solution is received into the salt depletion compartment; positive salt ions migrate through the first cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; a gas comprising O2 is reduced at the cathode to form OH-; the OH- ions migrate through the first anion exchange membrane to the opposed surface of the first anion exchange membrane into the base build-up compartment; and the OH- ions and the positive salt ions in the base build-up compartment together form a base / alkaline compound.
  • the 5-compartment membrane electrolysis cell further comprises an inlet through which a salt solution is received into an interior of the electrolysis cell (e.g. into the salt depletion compartment). In an embodiment, the 5-compartment membrane electrolysis cell further comprises at least one outlet through which a product is removed from an interior of the electrolysis cell. In an embodiment of the 5-compartment membrane electrolysis cell comprising a gas diffusion electrode, there may further be a gas inlet (e.g. positioned in the cathode compartment) through which a gas comprising O2 is introduced into contact with the gas diffusion electrode. [00222] In an embodiment, the membrane electrolysis cell comprises five compartments as depicted in FIG. 14.
  • the membrane electrolysis cell comprises a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between a cathode compartment and an anode compartment.
  • the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment
  • the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment
  • the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment.
  • An anode is housed in the anode compartment.
  • a cathode comprising a gas diffusion electrode (GDE) is housed in the cathode compartment, wherein:
  • the CL of the GDEs shown in FIGs. 10(a)-(d) is in direct contact with the 1 st AEM shown in FIG. 14. Otherwise, the AEM of the GDEs shown in FIGs. 10(e)-(h) is the 1 st AEM shown in FIG. 14.
  • the 1 st AEM defines a boundary between the cathode compartment and the base build-up compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the 1 st AEM.
  • the base build-up compartment is defined by the 1 st AEM and a 1 st CEM.
  • the CCM of the GDEs shown in FIGs. 11(a)-(d) is in place of the 1 st AEM shown in FIG. 14.
  • the CCM defines a boundary between the cathode compartment and the base build-up compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the CCM.
  • the base build-up compartment is defined by the CCM and the 1 st CEM.
  • the GDE is GDE-3 described herein
  • the 1 st AEM shown in FIG. 14 is omitted resulting in the cathode compartment and the base build-up compartment becoming a single compartment. Therefore, use of GDE-3 without the 1 st AEM effectively renders the cell to a 4-compartment membrane electrolysis cell.
  • the GDE is GDE-4 described herein
  • the AEM of the GDEs shown in FIGs. 13(a)-(d) is the 1 st AEM shown in FIG. 14.
  • the 1 st AEM defines a boundary between the cathode compartment and the base build-up compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the 1 st AEM.
  • the base build-up compartment is defined by the 1 st AEM and a 1 st GEM.
  • the 1 st GEM defines a boundary between the base build-up compartment and the salt depletion compartment.
  • the base build-up compartment is in fluid communication with the salt depletion compartment via the 1 st GEM.
  • the salt depletion compartment is defined by the 1 st GEM and a 2 nd AEM.
  • the 2 nd AEM defines a boundary between the salt depletion compartment and the acid build-up compartment.
  • the salt depletion compartment is in fluid communication with the acid build-up compartment via the 2 nd AEM.
  • the acid build-up compartment is defined by the 2 nd AEM and a 2 nd GEM.
  • the 2 nd GEM defines a boundary between the acid build-up compartment and the anode compartment.
  • the acid build-up compartment is in fluid communication with the anode compartment via the 2 nd GEM.
  • the 1 st and 2 nd AEMs are as described herein and may be the same or different.
  • the 1 st and 2 nd CEMs are as described herein and may be the same or different.
  • a salt solution comprising positive ions and negative ions is fed or received into the salt depletion compartment.
  • a gas comprising oxygen is fed or received into the GDE in the cathode compartment.
  • the positive ions from the salt solution migrate towards the negatively charged cathode compartment through the 1 st GEM and remain in the base build-up compartment, since they cannot pass through the 1 st AEM (GDE-1 and GDE-4), the CCM (GDE-2), or the catalyst layer (GDE-3).
  • Gas comprising O2 is reduced at the GDE/cathode to form OFT.
  • the OH- anions produced at the GDE build up in the base build-up compartment since they will migrate away from the negatively charged cathode towards the positively charged anode through the 1 st AEM (GDE-1 and GDE-4), the CCM (GDE-2), or the catalyst layer (GDE-3).
  • the OH- ions remain in the base build-up compartment because they cannot pass through the 1 st GEM. Therefore, a base/alkaline compound is formed in the base build-up compartment.
  • the negative ions from the salt solution migrate towards the positively charged anode compartment through the 2 nd AEM and remain in the acid build-up compartment, since they cannot pass through the 2 nd GEM.
  • the anodic reaction results in the formation of protons which are then transported through the 2 nd CEM into the acid build-up compartment. The protons combine with the negative ions to form an acid.
  • the salt solution comprises LiCI, IJ2SO4, U3PO4, UNO3, or Lil
  • LiOH will be produced in the base build-up compartment and HCI, H2SO4, H3PO4, HNO3, HI, respectively, will be produced simultaneously in the acid build-up compartment.
  • the salt solution comprises NaCI, Na2SC>4, NasPCL, NaNOs, or Nal
  • NaOH will be produced in the base build-up compartment and HCI, H2SO4, H3PO4, HNO3, HI, respectively, will be produced simultaneously in the acid build-up compartment.
  • the salt solution comprises KCI, K2SO4, K3PO4, KNO3, or KI
  • KOH will be produced in the base build-up compartment and HCI, H2SO4, H3PO4, HNO3, HI, respectively, will be produced simultaneously in the acid build-up compartment.
  • the electrolysis cell is a 4-compartment membrane electrolysis cell.
  • the 4-compartment membrane electrolysis cell comprises an anode compartment; a cathode compartment; and two additional compartments selected from any combination of a base build-up compartment, a salt depletion compartment, and an acid build-up compartment.
  • the 4-compartment membrane electrolysis cell comprises an anode compartment; a cathode compartment; a base build-up compartment, and a salt depletion compartment.
  • Each compartment may be separated by, for example, an AEM, a CEM or a BPM, such as described herein without limitation.
  • the 4-compartment membrane electrolysis cell comprises: an anode compartment (AC) and a cathode compartment (CC); and each of a base build-up compartment (BBC) and a salt depletion compartment (SDC) interposed between the CC and the AC.
  • the BBC is interposed between the CC and the SDC
  • the SDC is interposed between the BBC and the AC (e.g. AC-SDC-BBC-CC).
  • the 4-compartment membrane electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, a cation exchange membrane interposed between the salt depletion compartment and the base build-up compartment, the
  • a salt solution is received into the salt depletion compartment; positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; water is dissociated in the first bipolar membrane and OH- migrates into the base build-up compartment; and the positive salt ions and the OH- ions in the base-build-up compartment together form a base / alkaline compound.
  • the cathode comprises a gas diffusion electrode, such as for example and without limitation, any gas diffusion electrode described herein.
  • the gas diffusion electrode comprises a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions.
  • the 4-compartment membrane electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a first anion exchange membrane being disposed on the catalyst layer of the gas diffusion electrode and being
  • a salt solution is received into the salt depletion compartment; positive salt ions migrate through the first cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; a gas comprising O2 is reduced at the cathode to form OH-; the OH- ions migrate through the first anion exchange membrane to the opposed surface of the first anion exchange membrane into the base buildup compartment; and the OH- ions and the positive ions in the base build-up compartment together form a base / alkaline compound.
  • the 4-compartment membrane electrolysis cell further comprises an inlet through which a salt solution is received into an interior of the electrolysis cell (e.g. into the salt depletion compartment). In an embodiment, the 4-compartment membrane electrolysis cell further comprises at least one outlet through which a product is removed from an interior of the electrolysis cell. In an embodiment of the 4-compartment membrane electrolysis cell comprising a gas diffusion electrode, there may further be a gas inlet (e.g. positioned in the cathode compartment) through which a gas comprising O2 is introduced into contact with the gas diffusion electrode. [00238] In an embodiment, the membrane electrolysis cell comprises four compartments as depicted in FIG. 15.
  • the membrane electrolysis cell comprises a base build-up compartment and a salt depletion compartment interposed between a cathode compartment and an anode compartment.
  • the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment.
  • An anode is housed in the anode compartment.
  • a cathode comprising a gas diffusion electrode (GDE) is housed in the cathode compartment, wherein:
  • the CL of the GDEs shown in FIGs. 10(a)-(d) is in direct contact with a 1 st AEM shown in FIG. 15. Otherwise, the AEM of the GDEs shown in FIGs. 10(e)-(h) is the 1 st AEM shown in FIG. 15.
  • the 1 st AEM defines a boundary between the cathode compartment and the base build-up compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the 1 st AEM.
  • the base build-up compartment is defined by the 1 st AEM and a CEM.
  • the CCM of the GDEs shown in FIGs. 11 (a)-(d) is in place of the 1 st AEM shown in FIG. 15.
  • the CCM defines a boundary between the cathode compartment and the base buildup compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the CCM.
  • the base build-up compartment is defined by the CCM and the CEM.
  • the GDE is GDE-3 described herein
  • the 1 st AEM shown in FIG. 15 is omitted resulting in the cathode compartment and the base build-up compartment becoming a single compartment. Therefore, use of GDE-3 without the 1 st AEM effectively renders the cell to a 3-compartment membrane electrolysis cell.
  • the GDE is GDE-4 described herein
  • the AEM of the GDEs shown in FIGs. 13(a)-(d) is the 1 st AEM shown in FIG. 15.
  • the 1 st AEM defines a boundary between the cathode compartment and the base build-up compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the 1 st AEM.
  • the base build-up compartment is defined by the 1 st AEM and a GEM.
  • the 1 st and 2 nd AEMs are as described herein and may be the same or different.
  • the GEM is as described herein.
  • a salt solution comprising positive ions and negative ions is fed or received into the salt depletion compartment.
  • a gas comprising oxygen is fed or received into the GDE in the cathode compartment.
  • the positive ions from the salt solution migrate towards the negatively charged cathode compartment through the GEM and remain in the base build-up compartment, since they cannot pass through the 1 st AEM (GDE-1 and GDE-4), the CCM (GDE-2), or the catalyst layer (GDE-3). Gas comprising O2 is reduced at the GDE/cathode to form OFT.
  • the OFT anions produced at the GDE build up in the base build-up compartment since they will migrate away from the negatively charged cathode towards the positively charged anode through the 1 st AEM (GDE-1 and GDE-4), the CCM (GDE-2), or the catalyst layer (GDE-3).
  • GDE-1 and GDE-4 the 1 st AEM
  • GDE-2 the CCM
  • GDE-3 the catalyst layer
  • the OH- ions remain in the base build-up compartment because they cannot pass through the GEM. Therefore, a base/alkaline compound is formed in the base build-up compartment.
  • the negative ions from the salt solution migrate towards the positively charged anode compartment through the 2 nd AEM into the anode compartment.
  • the salt solution comprises (a) LiCI, LiBr, or Lil, (b) NaCI, NaBr, or Nal, or (c) KCI, KBr, or KI, then (a) LiOH, (b) NaOH, or (c) KOH, respectively, will be produced in the base build-up compartment. Simultaneously, HCI, HBr or HI will be produced in the anode compartment (dependent of the input salt solution) with the possibility of production of CI2, Br2 or I2, respectively.
  • the salt solution comprises IJ2SO4, IJ3PO4, or IJNO3, then LiOH will be produced in the base build-up compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • the salt solution comprises Na2SC>4, NasPO4, or NaNOs, then NaOH will be produced in the base build-up compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • the salt solution comprises K2SO4, K3PO4, or KNO3, then KOH will be produced in the base build-up compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • the electrolysis cell is a 3-compartment membrane electrolysis cell.
  • the 3-compartment membrane electrolysis cell comprises an anode compartment; a cathode compartment; and one additional compartment selected from any of a base build-up compartment, a salt depletion compartment, and an acid build-up compartment.
  • the 3-compartment membrane electrolysis cell comprises an anode compartment; a cathode compartment; and a base build-up compartment.
  • the 3-compartment membrane electrolysis cell comprises an anode compartment; a cathode compartment; and a salt depletion compartment.
  • Each compartment may be separated by, for example, an AEM, a CEM or a BPM, such as described herein without limitation.
  • the 3-compartment membrane electrolysis cell comprises: an anode compartment; a cathode compartment; and a salt depletion compartment interposed between the cathode compartment and the anode compartment.
  • the 3-compartment membrane electrolysis cell comprises: an anode compartment; a cathode compartment; and a base build-up compartment interposed between the cathode compartment and the anode compartment.
  • the 3-compartment membrane electrolysis cell comprises: an anode compartment; a cathode compartment; a salt depletion compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; an anion exchange membrane interposed between the anode compartment and the salt depletion compartment, the anion exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the anion exchange membrane into the anode compartment; and a cation exchange membrane interposed between the salt depletion compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the cation exchange membrane into the cathode compartment.
  • a salt solution is received into the salt depletion compartment; positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; water is reduced at the cathode to form OH-; and the positive salt ions and the OH- ions in the cathode compartment together form a base / alkaline compound.
  • the cathode comprises a gas diffusion electrode, such as for example and without limitation, any gas diffusion electrode described herein.
  • the gas diffusion electrode comprises a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions.
  • the 3-compartment membrane electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; an anion exchange membrane being disposed on the catalyst layer of the gas diffusion electrode and being configured to exchange ions received from the catalyst layer of the gas diffusion electrode to an opposed surface of the anion ion exchange membrane into the base build-up compartment; and a cation exchange membrane interposed between the anode compartment and the base build-up
  • a salt solution is received into the anode compartment; positive salt ions migrate through the cation exchange membrane to the opposed surface of the cation exchange membrane into the base build-up compartment; a gas comprising O2 is reduced at the cathode to form OH-; the OH- ions migrate through the anion exchange membrane to the opposed surface of the anion exchange membrane into the base build-up compartment; and the OH- ions and the positive salt ions in the base build-up compartment together form a base / alkaline compound.
  • the 3-compartment membrane electrolysis cell further comprises an inlet through which a salt solution is received into an interior of the electrolysis cell (e.g. into the salt depletion compartment, into the anode compartment, etc.). In an embodiment, the 3-compartment membrane electrolysis cell further comprises at least one outlet through which a product is removed from an interior of the electrolysis cell. In an embodiment of the 3-compartment membrane electrolysis cell comprising a gas diffusion electrode, there may further be a gas inlet (e.g. positioned in the cathode compartment) through which a gas comprising O2 is introduced into contact with the gas diffusion electrode.
  • a gas inlet e.g. positioned in the cathode compartment
  • the membrane electrolysis cell comprises three compartments as depicted in FIG. 16.
  • the membrane electrolysis cell comprises a base build-up compartment interposed between a cathode compartment and an anode compartment.
  • An anode is housed in the anode compartment.
  • a cathode comprising a gas diffusion electrode (GDE) is housed in the cathode compartment, wherein:
  • the CL of the GDEs shown in FIGs. 10(a)-(d) is in direct contact with an AEM shown in FIG. 16. Otherwise, the AEM of the GDEs shown in FIGs. 10(e)-(h) is the AEM shown in FIG. 16.
  • the AEM defines a boundary between the cathode compartment and the base build-up compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the AEM.
  • the base build-up compartment is defined by the AEM and a GEM.
  • the COM of the GDEs shown in FIGs. 11 (a)-(d) is in place of the AEM shown in FIG. 16.
  • the COM defines a boundary between the cathode compartment and the base buildup compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the COM.
  • the base build-up compartment is defined by the COM and the GEM.
  • the AEM of the GDEs shown in FIGs. 13(a)-(d) is the AEM shown in FIG. 16.
  • the AEM defines a boundary between the cathode compartment and the base build-up compartment.
  • the cathode compartment is in fluid communication with the base build-up compartment via the AEM.
  • the base build-up compartment is defined by the AEM and a GEM.
  • the GEM defines a boundary between the base build-up compartment and the anode compartment.
  • the base build-up compartment is in fluid communication with the anode compartment via the GEM.
  • a salt solution comprising positive ions and negative ions is fed or received into the anode compartment.
  • a gas comprising oxygen is fed or received into the GDE in the cathode compartment.
  • the positive ions from the salt solution migrate towards the negatively charged cathode compartment through the CEM and remain in the base build-up compartment, since they cannot pass through the AEM (GDE-1 and GDE-4), the CCM (GDE-2), or the catalyst layer (GDE-3).
  • Gas comprising O2 is reduced at the GDE/cathode to form OH-.
  • the OH- anions produced at the GDE build up in the base build-up compartment since they will migrate away from the negatively charged cathode towards the positively charged anode through the AEM (GDE-1 and GDE-4), the CCM (GDE-2), or the catalyst layer (GDE-3). Like the positive ions, the OH- ions remain in the base build-up compartment because they cannot pass through the CEM. Therefore, a base/alkaline compound is formed in the base build-up compartment.
  • the salt solution comprises (a) LiCI, LiBr, or Lil, (b) NaCI, NaBr, or Nal, or (c) KCI, KBr, or KI, then (a) LiOH, (b) NaOH, or (c) KOH, respectively, will be produced in the base build-up compartment. Simultaneously, HCI, HBr or HI will be produced in the anode compartment (dependent of the input salt solution) with the possibility of production of CI2, Br2 or I2, respectively.
  • the salt solution comprises Li2SO4, Li 3 PO 4 , or LiNO 3
  • LiOH will be produced in the base build-up compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • the salt solution comprises Na2SO 4 , Na 3 PO4, or NaNO 3
  • NaOH will be produced in the base build-up compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • the salt solution comprises K2SO4, K3PO4, or KNO3, then KOH will be produced in the base build-up compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • the electrolysis cell is a 2-compartment membrane electrolysis cell.
  • the 2-compartment membrane electrolysis cell comprises an anode compartment; a cathode compartment; and an AEM, a CEM or a BPM interposed between the anode compartment and the cathode compartment.
  • the 2-comparment membrane electrolysis cell comprises an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; and a cation exchange membrane interposed between the anode compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions from the anode compartment to an opposed surface of the cation exchange membrane into the cathode compartment.
  • a salt solution is received into the anode compartment and positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; water is reduced at the cathode to form OH-; and the positive salt ions and the OH- ions in the cathode compartment together form a base / alkaline compound.
  • the cathode comprises a gas diffusion electrode, such as for example and without limitation, any gas diffusion electrode described herein.
  • the gas diffusion electrode comprises a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions.
  • the 2-comparment membrane electrolysis cell comprises an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; and a cation exchange membrane interposed between the anode compartment and the catalyst layer of the gas diffusion electrode, the cation exchange membrane being configured to exchange ions received from the anode to an opposed surface of the cation exchange membrane.
  • a salt solution is received into the anode compartment; positive salt ions migrate through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; a gas comprising O2 is reduced at the cathode to form OH-; and the OH- ions and the positive salt ions in the cathode compartment together form a base / alkaline compound.
  • the 2-compartment membrane electrolysis cell further comprises an inlet through which a salt solution is received into an interior of the electrolysis cell (e.g. into the anode compartment). In an embodiment, the 2-compartment membrane electrolysis cell further comprises at least one outlet through which a product is removed from an interior of the electrolysis cell. In an embodiment of the 2-compartment membrane electrolysis cell comprising a gas diffusion electrode, there may further be a gas inlet through which a gas comprising 02 is introduced into contact with the gas diffusion electrode.
  • the membrane electrolysis cell comprises two compartments as depicted in FIG. 17.
  • the membrane electrolysis cell comprises a cathode compartment and an anode compartment.
  • the cathode and anode compartments are in fluid communication via a GEM.
  • the GEM is as described herein.
  • An anode is housed in the anode compartment.
  • a cathode comprising a GDE as shown in FIGs. 10(a)-(d) is housed in the cathode compartment.
  • the cathode compartment also acts as a base build-up compartment in the region between the GEM and the CL of the GDE.
  • a salt solution comprising positive ions and negative ions is fed or received into the anode compartment.
  • a gas comprising oxygen is fed to the GDE in the cathode compartment.
  • the positive ions migrate towards the negatively charged cathode compartment through the GEM.
  • the OH- anions produced at the GDE remain in the cathode compartment because they cannot pass through the GEM. Therefore, a base/alkaline compound is formed in the cathode compartment.
  • the salt solution comprises (a) LiCI, LiBr, or Lil, (b) NaCI, NaBr, or Nal, or (c) KOI, KBr, or KI, then (a) LiOH, (b) NaOH, or (c) KOH, respectively, will be produced in the cathode compartment. Simultaneously, HOI, HBr or HI will be produced in the anode compartment (dependent of the input salt solution) with the possibility of production of CI2, Br2 or I2, respectively.
  • the salt solution comprises IJ2SO4, IJ3PO4, or IJNO3, then LiOH will be produced in the cathode compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • the salt solution comprises Na2SC>4, NasPO4, or NaNOs, then NaOH will be produced in the cathode compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • the salt solution comprises K2SO4, K3PO4, or KNO3, then KOH will be produced in the cathode compartment and H2SO4, H3PO4, or HNO3, respectively, will be produced simultaneously in the anode compartment.
  • An AEM refers to a membrane permeable to anions.
  • the AEM comprises a polymer having multiple positively charged cationic groups bound to at least a portion of a polymeric backbone.
  • the cationic functional groups may be bound via an extended side chain or directly onto the backbone.
  • Non-limiting examples of a polymer backbone of the anion exchange membrane include a polyalkylene such as a polyethylene (PE); a polyfluorene (PFN), a poly(arylene ether) (PAE); a polysulfone, poly(arylene ether sulfone) (PAES), a polyetherketone (PEK), a polyetherimide (PEI), a poly(ether oxadiazole), a poly(phenylene oxide) (PPO); a poly(vinyl benzyl) (PVB); a polyphenylene (PPN); a perfluoro (PF); a polybenzimidazole (PBI); a polystyrene (PS); or a polyphosphazene.
  • PE polyethylene
  • PBE polyfluorene
  • PAES poly(arylene ether ether)
  • PAES polyetherketone
  • PEI polyetherimide
  • PPO poly(phenylene oxide)
  • PVB poly(
  • Non-limiting examples of the cationic functional group include a primary, secondary, tertiary or quaternary ammonium; a heterocyclic cation such as an imidazolium or a pyridinium; a guanidinium; a phosphonium; a sulfonium; and a metal cation.
  • FumasepTM FAB AEMs e.g. FAB-PK-75, FAB-PK-130
  • FumasepTM FAM AEMs e.g. FAM
  • FumasepTM FAAM AEMs e.g. FAAM-10, FAAM-15, FAAM-20, FAAM-40
  • FumasepTM FAP AEMs e.g. FAP-330, FAP-450, FAP-330-PE, FAP-330-PE, FAP-420-PE
  • FumasepTM FAPQ AEMs e.g. FAPQ-330, FAPQ-375-PP
  • FumasepTM FAS AEMs e.g. FAS-50, FAS-30, FAS-PET-75, FAS-PE-130
  • NeoseptaTM AEMs e.g. ACN, ACS, AFN, AFX, AHA, AMX, ASE, AXP-D
  • PentionTM AEMs e.g. Pention-AEM-18-05, Pention-AEM-18-10, Pention-AEM-18-20, Pention-AEM-18-30, Pention-AEM-35-05, Pention-AEM- 35-10, Pention-AEM-35-20, Pention-AEM-35-30, Pention-AEM-72-05, Pention-AEM-72-10, Pention-AEM-72-20, Pention-AEM-72-30
  • Pention-AEM-18-05, Pention-AEM-18-10, Pention-AEM-18-20, Pention-AEM-18-30 Pention-AEM-35-05, Pention-AEM- 35-10, Pention-AEM-35-20, Pention-AEM-35-30
  • Pention-AEM-72-05, Pention-AEM-72-10, Pention-AEM-72-20, Pention-AEM-72-30 e.g. Pention-AEM-18-05, Pention-AEM-18-10, Pention-AEM-18-20
  • PiperlONTM AEMs e.g. PiperlON Anion Exchange Membrane - 15 microns, PiperlON Anion Exchange Membrane - 20 microns, PiperlON Anion Exchange Membrane - 40 microns, PiperlON Anion Exchange Membrane - 60 microns, PiperlON Anion Exchange Membrane - 80 microns
  • PiperlONTM AEMs e.g. PiperlON Anion Exchange Membrane - 15 microns, PiperlON Anion Exchange Membrane - 20 microns, PiperlON Anion Exchange Membrane - 40 microns, PiperlON Anion Exchange Membrane - 60 microns, PiperlON Anion Exchange Membrane - 80 microns
  • RALEXTM AEMs e.g. AMHPES, AMHPP
  • SELEMIONTM AEMs e.g. AAV, AAVN, AHO, AMT, AMV, AMVN, ASV, ASVN, DSV, DSVN
  • Sustainion® AEMs e.g. B22-50, E28-50, E30-50, X37-50, X37-60, X37-FA, X37-T, X37-TZ), and
  • lonomr AEMs e.g. Aemion
  • CEM Cation Exchange Membranes
  • a CEM refers to a membrane permeable to cations.
  • the CEM may be a monovalent cation selective membrane.
  • the CEM may be a lithium selective membrane.
  • the CEM may comprise a polymer having multiple negatively charged anionic groups bound to at least a portion of a polymeric backbone. The anionic functional groups may be bound via an extended side chain or directly onto the backbone.
  • Non-limiting examples of a polymer backbone of the cation exchange membrane include a polyalkylene such as a polyethylene (PE) or a polypropylene; a polyfluorene (PFN), a poly(arylene ether) (PAE); a polysulfone, poly(arylene ether sulfone) (PAES), a polyetherketone (PEK), a polyetherimide (PEI), a poly(ether oxadiazole), a poly(phenylene oxide) (PPO); a poly(vinyl benzyl) (PVB); a polyphenylene (PPN); a perfluoro (PF); a polybenzimidazole (PBI); a polystyrene (PS); or a polyphosphazene.
  • a polyalkylene such as a polyethylene (PE) or a polypropylene
  • PEP polyfluorene
  • PAE poly(arylene ether)
  • PAES poly(ary
  • Non-limiting examples of the anionic functional group include a sulfonate such as a perfluorosulfonate; a carboxylate; a phosphonate; and a phenolate anion.
  • Non-limiting examples of the cation exchange membrane include:
  • (l lb) FumasepTM CEMs e.g. F-930-RFD, F-1075-PK, F-1850, F-10120, F-10120- PK, F-10150-PF, F-10270-PTFE-e, FS-720, FS-950, FS-990-PK, FS-9100- PK, FKB, FKB-PK-130, FKD-PK-75, FKE-50, FKL-PK-130, FKM, FKS-30, FKS-50, FKS-PET-75, FKS-PET-130),
  • F-930-RFD F-1075-PK, F-1850, F-10120, F-10120- PK, F-10150-PF, F-10270-PTFE-e, FS-720, FS-950, FS-990-PK, FS-9100- PK, FKB, FKB-PK-130, FKD-PK-75, FKE-50, FKL-PK-130, FKM, FKS-30, FKS-50,
  • NeoseptaTM CEMs e.g. CMB, CMX, CSE, CXP-S
  • SELEMIONTM CEMs e.g. CMD, CMF, CMTE, CMV, CMVN, CSC
  • lonomrTM OEMs e.g. Permion
  • electrolysis cells of the present disclosure include membrane electrolysis cells (MEC), each as defined in the following rows, wherein each entry is a group number as defined above:
  • the flow rate of the salt solution in any of the electrolysis cells described herein may be between 0.5 and 5 Litres/min, between 0.5 and 4.8 Litres/min, between 0.5 and 4.6 Litres/min, between 0.5 and 4.4 Litres/min, between 0.5 and 4.2 Litres/min, between 0.5 and 4.0 Litres/min, between 0.5 and 3.8 Litres/min, between 0.5 and
  • the flow rate of the gas comprising oxygen in the electrolysis cells described herein may be between 5 and 25 Litres/min, between 5 and 23 Litres/min, between 5 and 21 Litres/min, between 5 and 19 Litres/min, between 5 and 17 Litres/min, between 5 and 15 Litres/min, between 5 and 13 Litres/min, between 5 and 11 Litres/min, between 5 and 9 Litres/min, between 5 and 7 Litres/min, between 7 and 25 Litres/min, between 9 and 25 Litres/min, between 11 and 25 Litres/min, between 13 and 25 Litres/min, between 15 and 25 Litres/min, between 17 and 25 Litres/min, between 19 and 25 Litres/min, between 21 and 25 Litres/min, between 23 and 25 Litres/min, between 7 and 23 Litres/min, between 9 and 21 Litres/min, between 11 and 19 Litres/min, or between 13 and 17 Litres/min.
  • the temperature of the salt solution in the electrolysis cells described herein may be between 40 and 70°C, between 40 and 65°C, between 40 and 60°C, between 40 and 55°C, between 40 and 50°C, between 40 and 45°C, between 45 and 70°C, between 50 and 70°C, between 55 and 70°C, between 60 and 70°C, between 65 and 70°C, between 45 and 65°C, or between 50 and 60°C.
  • a process for producing lithium carbonate with carbon capture comprising: receiving a Li salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising LiOH; and delivering the product comprising LiOH and CO2 to a carbonate production reactor to produce lithium carbonate.
  • Li 2 SO 4 Li 3 PO 4 , LiNO 3 , Lil, or LiBr.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a cation exchange membrane interposed between the anode compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions from the anode compartment to an opposed surface of the cation exchange membrane into the cathode compartment; an inlet through which the Li salt-containing solution is received into an interior of the electrolysis cell; and at least one outlet through which the product is removed from an interior of the electrolysis cell, wherein in performing the process: the Li salt-containing solution is received into the anode compartment and Li + ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; water is reduced at the
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a salt depletion compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; an anion exchange membrane interposed between the anode compartment and the salt depletion compartment, the anion exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the anion exchange membrane into the anode compartment; a cation exchange membrane interposed between the salt depletion compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the cation exchange membrane into the cathode compartment; an inlet through which the Li salt-containing solution is received into the salt de
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, a cation exchange membrane interposed between the salt depletion compartment and the
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an acid build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the salt depletion compartment is interposed between the cathode compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the salt depletion compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, an anion exchange membrane interposed between the salt depletion compartment and the acid build-up
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a cation exchange membrane interposed between the anode compartment and the catalyst layer of the gas diffusion electrode, the cation exchange membrane being configured to exchange ions received from the anode to an opposed surface of the cation exchange membrane; an inlet through which the Li salt-containing solution is received into the anode compartment; a gas inlet through which a gas comprising O2 is
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; an anion exchange membrane being disposed on the catalyst layer of the gas diffusion electrode and being configured to exchange ions received from the catalyst layer of the gas diffusion electrode to an opposed surface of the anion ion exchange membrane into the base build-up compartment; a cation exchange membrane interposed between the anode compartment
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a first anion exchange membrane being disposed on the catalyst
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater
  • a system for lithium carbonate production with carbon capture comprising: an electrolysis cell comprising a cathode and an anode; and a carbonate production reactor configured to receive a product comprising LiOH from the electrolysis cell and CO 2 to generate lithium carbonate.
  • CO2 is a direct air capture system.
  • a process of producing cathode active material with reduced carbon emissions comprising: receiving a Li salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising LiOH; delivering the product comprising LiOH and CO2 to a carbonate production reactor to produce lithium carbonate; and mixing the lithium carbonate with precursor cathode active material to produce cathode active material.
  • a process for producing sodium carbonate with carbon capture comprising: receiving a Na salt-containing solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising NaOH; and delivering the product comprising NaOH and CO2 to a carbonate production reactor to produce sodium carbonate.
  • CO2 is a direct air capture system.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a cation exchange membrane interposed between the anode compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions from the anode compartment to an opposed surface of the cation exchange membrane into the cathode compartment; an inlet through which the Na salt-containing solution is received into an interior of the electrolysis cell; and at least one outlet through which the product is removed from an interior of the electrolysis cell, wherein in performing the process: the Na salt-containing solution is received into the anode compartment and Na + ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; water is reduced at the
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a salt depletion compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; an anion exchange membrane interposed between the anode compartment and the salt depletion compartment, the anion exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the anion exchange membrane into the anode compartment; a cation exchange membrane interposed between the salt depletion compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the cation exchange membrane into the cathode compartment; an inlet through which the Na salt-containing solution is received into the salt
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, a cation exchange membrane interposed between the salt depletion compartment and
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an acid build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the salt depletion compartment is interposed between the cathode compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the salt depletion compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, an anion exchange membrane interposed between the salt depletion compartment and the acid build
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH-
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a cation exchange membrane interposed between the anode compartment and the catalyst layer of the gas diffusion electrode, the cation exchange membrane being configured to exchange ions received from the anode to an opposed surface of the cation exchange membrane; an inlet through which the Na salt-containing solution is received into the anode compartment; a gas inlet through which a gas comprising O2 is introduced into contact
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; an anion exchange membrane being disposed on the catalyst layer of the gas diffusion electrode and being configured to exchange ions received from the catalyst layer of the gas diffusion electrode to an opposed surface of the anion ion exchange membrane into the base build-up compartment; a cation exchange membrane interposed between the ano
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a first anion exchange membrane being disposed on the catalyst
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater
  • a system for sodium carbonate production with carbon capture comprising: an electrolysis cell comprising a cathode and an anode; and a carbonate production reactor configured to receive a product comprising NaOH from the electrolysis cell and CO2 to generate sodium carbonate.
  • electrolysis cell is a chlor-alkali membrane electrolysis cell, a chlor-alkali diaphragm electrolysis cell, a bipolar membrane electrodialysis cell, or a membrane electrolysis cell.
  • CO2 is a direct air capture system.
  • a process for enhancing ocean alkalinity comprising: receiving a salt solution in an electrolysis cell comprising a cathode and an anode; applying an electric potential between the cathode and anode; producing from the electrolysis cell a product comprising an alkaline compound; and delivering the product comprising an alkaline compound to a body of seawater.
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a cation exchange membrane interposed between the anode compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions from the anode compartment to an opposed surface of the cation exchange membrane into the cathode compartment; an inlet through which the salt solution is received into an interior of the electrolysis cell; and at least one outlet through which the product is removed from an interior of the electrolysis cell, wherein in performing the process: the salt solution is received into the anode compartment and positive salt ions move through the cation exchange membrane to the opposed surface of the cation exchange membrane into the cathode compartment; water is reduced at the cathode to form OH-;
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a salt depletion compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; an anion exchange membrane interposed between the anode compartment and the salt depletion compartment, the anion exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the anion exchange membrane into the anode compartment; a cation exchange membrane interposed between the salt depletion compartment and the cathode compartment, the cation exchange membrane being configured to exchange ions received from the salt depletion compartment to an opposed surface of the cation exchange membrane into the cathode compartment; an inlet through which the salt solution is received into the salt depletion compartment; and at
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, a cation exchange membrane interposed between the salt depletion compartment and the base build-up compartment,
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an acid build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the salt depletion compartment is interposed between the cathode compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the salt depletion compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the opposite surface of the bipolar membrane, an anion exchange membrane interposed between the salt depletion compartment and the acid build-up compartment, the ani
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment; a first bipolar exchange membrane interposed between the cathode compartment and the base build-up compartment and being configured to dissociate water with transport of H + ions through one surface of the bipolar membrane and OH- ion from the
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a cation exchange membrane interposed between the anode compartment and the catalyst layer of the gas diffusion electrode, the cation exchange membrane being configured to exchange ions received from the anode to an opposed surface of the cation exchange membrane; an inlet through which the salt solution is received into the anode compartment; a gas inlet through which a gas comprising O2 is introduced into contact with the gas diffusion electrode; and at
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment interposed between the cathode compartment and the anode compartment; an anode positioned to extend within the interior of the electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; an anion exchange membrane being disposed on the catalyst layer of the gas diffusion electrode and being configured to exchange ions received from the catalyst layer of the gas diffusion electrode to an opposed surface of the anion ion exchange membrane into the base build-up compartment; a cation exchange membrane interposed between the anode compartment and the base build-up
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment and a salt depletion compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, and the salt depletion compartment is interposed between the base build-up compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion layer and the catalyst layer being configured to transport negative ions; a first anion exchange membrane being disposed on the catalyst layer of the gas diffusion electrode
  • the electrolysis cell comprises: an anode compartment; a cathode compartment; a base build-up compartment, a salt depletion compartment and an acid build-up compartment interposed between the cathode compartment and the anode compartment, the base build-up compartment is interposed between the cathode compartment and the salt depletion compartment, the salt depletion compartment is interposed between the base build-up compartment and the acid build-up compartment, and the acid build-up compartment is interposed between the salt depletion compartment and the anode compartment; an anode positioned to extend within the interior of the membrane electrolysis cell and positioned in the anode compartment; a cathode comprising a gas diffusion electrode positioned to extend within the interior of the electrolysis cell and positioned in the cathode compartment, the gas diffusion electrode comprising a diffusion layer configured to diffuse gas and a catalyst layer disposed on a surface of the diffusion layer, the catalyst layer having a hydrophilicity greater than that of the diffusion
  • the term “about” refers to an approximately +/-10 % variation from a given value. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.
  • ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited, as well as, ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited, in the same way, ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited.
  • any numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed.
  • every range of values (of the form, "from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited.
  • every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited.

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Abstract

L'invention propose des processus et des systèmes de réduction de carbone pour mettre en œuvre de tels processus utilisant une cellule d'électrolyse, comprenant des processus et des systèmes pour produire du carbonate de lithium avec capture de carbone, des processus et des systèmes pour produire un matériau actif de cathode avec des émissions de carbone réduites, des processus et des systèmes pour produire du carbonate de sodium avec capture de carbone, et des processus et des systèmes pour améliorer l'alcalinité de l'océan.
PCT/CA2025/050318 2024-03-08 2025-03-07 Processus électrolytiques pour la production de carbonates et de composés alcalins Pending WO2025184747A1 (fr)

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5618640A (en) * 1993-10-22 1997-04-08 Fuji Photo Film Co., Ltd. Nonaqueous secondary battery
WO2008018928A2 (fr) * 2006-04-27 2008-02-14 President And Fellows Of Harvard College Capture de dioxyde de carbone et procédés associés
WO2013177680A1 (fr) * 2012-05-30 2013-12-05 Nemaska Lithium Inc. Procédés de préparation de carbonate de lithium
CA3230515A1 (fr) * 2021-09-30 2023-04-06 Asaka Riken Co., Ltd. Procede de recuperation de lithium a partir de batteries lithium-ion usagees
WO2023114474A2 (fr) * 2021-12-16 2023-06-22 Capture6 Corp Systèmes et procédés de capture directe de dioxyde de carbone dans l'air
WO2024064916A2 (fr) * 2022-09-22 2024-03-28 Redwood Materials, Inc. Production électrochimique d'hydroxydes de métal alcalin et d'acide sulfurique à partir de flux de sortie de fabrication et de recyclage de batteries
WO2024127687A1 (fr) * 2022-12-14 2024-06-20 環境工学株式会社 Dispositif de récupération de dioxyde de carbone et procédé de récupération de dioxyde de carbone
WO2024151422A1 (fr) * 2023-01-13 2024-07-18 Nuscale Power, Llc Systèmes à énergie intégrée de réacteur nucléaire modulaire de petite dimension destinés à capturer du dioxyde de carbone atmosphérique à l'aide d'hydroxyde de sodium

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5618640A (en) * 1993-10-22 1997-04-08 Fuji Photo Film Co., Ltd. Nonaqueous secondary battery
WO2008018928A2 (fr) * 2006-04-27 2008-02-14 President And Fellows Of Harvard College Capture de dioxyde de carbone et procédés associés
WO2013177680A1 (fr) * 2012-05-30 2013-12-05 Nemaska Lithium Inc. Procédés de préparation de carbonate de lithium
CA3230515A1 (fr) * 2021-09-30 2023-04-06 Asaka Riken Co., Ltd. Procede de recuperation de lithium a partir de batteries lithium-ion usagees
WO2023114474A2 (fr) * 2021-12-16 2023-06-22 Capture6 Corp Systèmes et procédés de capture directe de dioxyde de carbone dans l'air
WO2024064916A2 (fr) * 2022-09-22 2024-03-28 Redwood Materials, Inc. Production électrochimique d'hydroxydes de métal alcalin et d'acide sulfurique à partir de flux de sortie de fabrication et de recyclage de batteries
WO2024127687A1 (fr) * 2022-12-14 2024-06-20 環境工学株式会社 Dispositif de récupération de dioxyde de carbone et procédé de récupération de dioxyde de carbone
WO2024151422A1 (fr) * 2023-01-13 2024-07-18 Nuscale Power, Llc Systèmes à énergie intégrée de réacteur nucléaire modulaire de petite dimension destinés à capturer du dioxyde de carbone atmosphérique à l'aide d'hydroxyde de sodium

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