Abstract: A system for producing metal particles using a discrete particle electrolyzer cathode, a discrete particle electrolyzer cathode, and methods for manufacturing the cathode. The cathode has a plurality of active zones on a surface thereof at least partially immersed in a reaction solution. The active zones are spaced from one another by between about 0.1 mm and about 10 mm, and each has a surface area no less than about 0.02 square mm. The cathode is spaced from an anode also at least partially immersed in the reaction solution. A voltage potential is applied between the anode and cathode. Metal particles form on the active zones of the cathode. The particles may be dislodged from the cathode after they have achieved a desired size. The geometry and composition of the active zones are specified to promote the growth of high quality particles suitable for use in metal/air fuel cells. Cathodes may be formed from bundled wire, machined metal, chemical etching, or chemical vapor deposition techniques.

Abstract: A method of extracting zinc from a sulphidic ore is provided which comprises bioleaching the ore in a heap with acidophilic microorganisms to produce a pregnant leach solution which is recovered from the bottom of the heap. An integrated process which comprises subjecting the pregnant leach solution to neutralization and solvent extraction to produce a concentrated zinc solution is also provided. Zinc may be recovered from the concentrated solution by means of electrowinning, either in the absence or presence of manganese. Alternatively zinc may be recovered in the form of a zinc compound.

Abstract: This invention relates to novel designs of high power batteries, electrochemical cells, energy storage materials and electrode materials, and processes for manufacturing same.

Abstract: A method and apparatus for continuous, high-speed production of punched strip having an array of high-tolerance closely-spaced holes with positive ejection of waste punch-out material. A first pair of opposed rotary dies, one a female die and the other a male/female die, punches a first set of holes in a strip fed continuously between the dies, and a second pair of opposed rotary dies, one the male/female die and the other a male die, punches a second set of holes in the strip between the first set of holes, the strip being wrapped about the common male/female die during punching of the first and second sets of holes to continuously index the strip with the two opposed pairs of rotary dies to ensure production of the high-tolerance closely-spaced holes.

Abstract: A solid porous zinc electrode for use in alkaline-zinc batteries, zinc-air batteries and fuel cells is provided which comprises specific zinc filaments, fibers, threads or strands compressed into a physically-stable wooly mass to form the electrode with a controlled geometrical shape and porosity distribution. Differential densification incorporates ribs, borders, grids or tabs for good structural integrity, mechanical strength, electrochemical behavior, and electrical conductivity. Pressing in a mold or rolling of a compressed sheet can also provide an anode with a large anode/cathode interface area and a complex geometry. The filaments of controlled dimension and composition are preferably made by spin forming from molten zinc alloys. Such anodes are not susceptible to breakage, have a long storage life and can be used in high rate discharge applications.

Abstract: Improved fuel cell systems comprise a fuel delivery system having a fluidization apparatus and a fluidization pump for creating an electrolyte flow suitable for fluidizing at least a portion of the fuel particles located within the fluidization apparatus. Due to the presence of the fluidization pump and the fuel delivery pump, the degree of fluidization of the fuel particles can be controlled independently of the overall electrolyte flow rate provided to the cell stacks. In other words, the mass flow rate of fuel particles through the fuel cell can be varied independently from the total flow rate through the fuel cell system. The fluidization of fuel particles can facilitate suitable mixing of fuel particles and electrolyte and can prevent fuel particle agglomeration, which can clog the fuel cell piping system.

Abstract: A method of producing metal particles through electrolysis. A cathode having a plurality of active zones on a surface thereof is at least partially immersed in a reaction solution. The cathode is spaced from an anode also at least partially immersed in the reaction solution. A voltage potential is applied between the anode and cathode. Metal particles form on the active zones of the cathode. In order to promote the formation of good quality particles, a turbulent flow of the solution is maintained past one or more the active zones, and the current density in the active zones is maintained greater than about 5 kA/m2. The particles may be dislodged from the cathode after they have achieved a desired size.

Abstract: A system for maintaining a concentration range of an electroreducible metal species undergoing electrolysis within a predetermined concentration range comprises a first container containing a body of an electrolyte solution in which a metal is partially dissolved, a second container in fluid communication with the first container, the second container containing a second body of the solution, and a means for exchanging solution between the containers. The second container is configured with a means for electrolyzing, and a means for sensing the concentration of, the dissolved metal in the second body. During electrolysis, if the sensed concentration is within a predetermined range, the second body is circulated through the electrolyzing means; if the sensed concentration is outside or nearly outside the range, the solution is exchanged to maintain the concentration within the range.

Abstract: This invention relates to new multi-component catalyst systems for the polycondensation of polyesters. More particularly, this invention pertains to novel multi-component, germanium based catalyst systems for the polycondensation of PET (polyethylene terephthalate) used in the manufacture of bottles, fibre or film. A multi-component catalyst system for the polycondensation of a polyester comprising the element germanium and one or more catalyst enhancers selected from the group of elements consisting of aluminium, silicon, molybdenum, manganese, lithium and combinations thereof, said elements being in the form of compounds, acids, bases, salts, compositions, oxides or organic complexes.

Abstract: A method and apparatus for continuous, high-speed production of punched strip having an array of high-tolerance closely-spaced holes with positive ejection of waste punch-out material. A first pair of opposed rotary dies, one a female die and the other a male/female die, punches a first set of holes in a strip fed continuously between the dies, and a second pair of opposed rotary dies, one the male/female die and the other a male die, punches a second set of holes in the strip between the first set of holes, the strip being wrapped about the common male/female die during punching of the first and second sets of holes to continuously index the strip with the two opposed pairs of rotary dies to ensure production of the high-tolerance closely-spaced holes.

Abstract: A solid porous zinc electrode for use in alkaline-zinc batteries, zinc-air batteries and fuel cells is provided which comprises specific zinc filaments, fibers, threads or strands compressed into a physically-stable wooly mass to form the electrode with a controlled geometrical shape and porosity distribution. Differential densification incorporates ribs, borders, grids or tabs for good structural integrity, mechanical strength, electrochemical behavior, and electrical conductivity. Pressing in a mold or rolling of a compressed sheet can also provide an anode with a large anode/cathode interface area and a complex geometry. The filaments of controlled dimension and composition are preferably made by spin forming from molten zinc alloys. Such anodes are not susceptible to breakage, have a long storage life and can be used in high rate discharge applications.

Abstract: A method of extracting a halide and sulphate from an aqueous sulphate solution, such as a zinc sulphate solution, comprises subjecting the solution to solvent extraction to extract halide and sulphate from the solution and controlling the amount of sulphate extracted by selective adjustment of the acidity of the aqueous solution.

Abstract: A method and apparatus for continuously producing pasted positive and negative electrode plates from pasted lead or lead alloy expanded, punched or cast metal mesh strip for use in lead-acid batteries without the use of paper barriers. The heating of cutting devices such as roll-mounted die-cutters to a predetermined temperature range of at least about 150° C., preferably about 160 to 300° C., and more preferably about 180 to 210° C., eliminates sticking of the paste on the pasted metal mesh strip to the cutting devices and obviates the need for the paper barriers.

Abstract: This invention relates to new multi-component catalyst systems for the polycondensation of polyesters. More particularly, this invention pertains to novel multi-component, germanium based catalyst systems for the polycondensation of PET (polyethylene terephthalate) used in the manufacture of bottles, fiber or film. A multi-component catalyst system for the polycondensation of a polyester comprising the element germanium and one or more catalyst enhancers selected from the group of elements consisting of aluminium, silicon, molybdenum, manganese, lithium and combinations thereof, said elements being in the form of compounds, salts, compositions, oxides or organic complexes.

Abstract: A single step method and apparatus for the production of expanded metal mesh from deformable metal strip such as lead or lead-alloy strip for use in lead-acid battery manufacture. The apparatus comprises a pair of opposed rolls each having a plurality of spaced discs having opposite side walls and circumferential, equally spaced, convexly shaped tool surfaces alternating with substantially flat surfaces, said discs having radial notches formed in the opposite sidewalls of alternate circumferential flat surfaces, whereby peripheral surfaces of opposing rolls are adapted to interact on deformable strip passing therebetween to concurrently slit and form convex wire segments and alternate nodes in said strip by intermeshing of said shaped tool surfaces.

Abstract: A method and apparatus for continuously producing pasted positive and negative electrode plates from pasted lead or lead alloy expanded, punched or cast metal mesh strip for use in lead-acid batteries without the use of paper barriers. The heating of cutting devices such as roll-mounted die-cutters to a predetermined temperature range of at least about 150° C., preferably about 160 to 300° C., and more preferably about 180 to 210° C., eliminates sticking of the paste on the pasted metal mesh strip to the cutting devices and obviates the need for the paper barriers.

Abstract: A process and an alloy for galvanizing non-reactive steel and mixed or moderately reactive steel for providing a decorative spangle to the galvanized coating. The alloy contains 0.1 to less than 0.8 wt % tin, 0.05 to 0.2 wt % bismuth, 0.001 to 0.008 wt % aluminum, and optionally 0 to 0.1 wt % nickel, the balance zinc of commercial purity.

Abstract: A method of producing lead alloy strip for fabrication of positive and negative electrodes of a lead-acid battery by extruding a lead alloy at elevated temperature to produce a lead alloy strip having a desired profile and rapidly cooling the extruded strip to acquire a desired microstructure. Battery grids produced from the lead alloy strip have reduced vertical growth and enhanced resistance to corrosion.

Abstract: A method of extracting a halide and sulphate from an aqueous sulphate solution, such as a zinc sulphate solution, comprises subjecting the solution to solvent extraction to extract halide and sulphate from the solution and controlling the amount of sulphate extracted by selective adjustment of the acidity of the aqueous solution.