Disposable Electrolytic Cell having Bipolar Electrodes, and Method of Use Thereof

Abstract

An electrolytic cell that generates metal hydroxides from metallic anode material utilizing small metal particles or fines. Metal fines are impregnated in an open cell or reticulated foam material and rolled into a cylindrical shape having a fixed electrode in the center and on the outer surface of the cylinder. Basket cells with larger metal pieces disposed therein in a packed bed configuration may alternatively be utilized.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part application claiming priority to and the full benefit of U.S. Non-provisional application Ser. No. 13/291,131, entitled “Disposable Electrolytic Cell with Bi-polar Electrode, and Method of Use Thereof ”, filed Nov. 8, 2011, and priority to and the full benefit of U.S. Provisional Application Ser. No. 61/414,352, entitled “Disposable Electrolytic Cell Configurations and their Bi-polar Electrode Profiles”, filed Nov. 16, 2010. Applications 61/414,352 and 13/291,131 are incorporated herein by reference.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

None

PARTIES TO A JOINT RESEARCH AGREEMENT

None

REFERENCE TO A SEQUENCE LISTING

None

BACKGROUND OF THE INVENTION

1. Technical Field of the Invention

The present invention relates generally to electrolytic cells, and more specifically to a disposable electrolytic cell that utilizes metallic particles and fines, and which is utilized in treating wastewater.

2. Description of Related Art

The treatment of wastewater often requires the use of a polymer or metal hydroxide to coagulate the colloidal solids so that they can be filtered and/or removed from the system. Coagulants can be produced electrolytically by a process known as electro-coagulation.

Numerous types of wastewater treatment systems exist, some of which employ electro-coagulation. Electro-coagulation has been proven for many years to be an excellent method for the coagulation and oxidation of solids in wastewater versus the use of chemicals and biological means to do the job. However, one set of problems has been the cost and maintenance of the cells used, and this has kept electro-coagulation from extensive commercial use.

Historically, systems employing electrolytic technology have had other disadvantages, namely, an impermeable oxide film forms on the cathode leading to the loss of cell efficiency and requiring frequent maintenance which is time consuming and costly. Moreover, analyzing cell efficiency and maintaining efficiency is often not addressed. Electrolytic cells are generally utilized for the treatment of wastewater to produce polymer or metal hydroxide to coagulate the colloidal solids. Typically, the electrolytic cells are utilized to generate metal hydroxides from metallic anodes.

Electrolytic coagulation and oxidation take place in a cell where electrical current is passed between the anode and cathode. During the exchange of electrons, the anodes decompose to form a metal hydroxide while the cathode is coated with a non-conductive film. It is the decomposition of the anode that produces the metal hydroxide used to coagulate the suspended particles in the electrolyte (wastewater).

Conventional electrolytic cells consist of plates that are stacked or positioned so that the electrolyte passes between the plates. Other profiles may use anodes of ¼″ to ½″ in a packed bed electrolytic cell. However, current cell designs using plates are not energy efficient and require costly maintenance in order to keep the cell operating for long periods of time. Unfortunately, plate style electrodes (anodes) do not decompose completely before they need to be serviced or replaced.

While other methods have attempted to solve these problems, none have utilized or disclosed a system or method utilizing a disposable electro-coagulation cell and analytical system.

Therefore, it is readily apparent that there is a need for an electrolytic cell that will produce metal hydroxides in solution more efficiently than the use of chemical coagulants or other types of electrolytic cell equipment.

BRIEF SUMMARY OF THE INVENTION

Briefly described, in a preferred embodiment, the present invention overcomes the above-mentioned disadvantages and meets the recognized need for such a device by providing disposable electrolytic cells that are designed to utilize small metal pieces and fines as bipolar electrodes in a packed bed configuration, and to utilize scrap metal as anodes in a disposable basket or cartridge, thereby eliminating the high cost of maintenance and improving the energy efficiency associated with the decomposition of metal to its hydroxide form. The use of metal pieces or fines that decompose completely and do not need to be serviced before they are discarded, contrasts with the high cost of service needed to maintain a plate system.

According to its major aspects and broadly stated, the present invention in its preferred form is a disposable electrolytic cell that produces metal hydroxides in solution from metal fines more efficiently than the use of chemical coagulants or other types of electro-coagulation (EC) equipment. The metal fines are impregnated in an open cell or reticulated foam material and rolled into a cylindrical shape having a fixed electrode in the center and outer portions of the cylinder. An electrolytic sponge allows the use of metal fines that decompose completely. Basket cells with larger metal pieces disposed therein in a packed bed configuration may alternatively be utilized. Further, the electrolytic sponge or basket cells are disposable.

More specifically, the disposable electrolytic cell allows the use of metal fines that are more energy efficient in their decomposition than chemical coagulants or other types of EC equipment.

The open cell foam or sponge is fabricated from any materials that allow the metal fines to migrate throughout the cellular structure. Any sponge or open cell material is utilized that can be cut or fashioned into any shape and inserted into a housing that will accommodate the introduction of wastewater (electrolyte) and allow the bipolar electrodes to react upon application of an electric current.

The metal fines comprise any metal type, such as, for exemplary purposes only and without limitation, machining shavings or particles that are smaller than the pore size of the cell structure in the open cell material, and may also comprise non-metal materials, such as, for exemplary purposes only and without limitation, graphitic and other carbons. The cell structure holds the metal particles in place after the material is rolled into cylinder. The electrolytic sponge or basket cells hold the metal fines, non-metal material or blend of metal fines and non-metal material in the reactive range of the cell. Since the sponge has two sides, the interior is accessible from either side resulting in a bipolar electrode.

Disposable basket and cartridge cells hold the metal pieces and fines in the reactive zone of the cell. Bipolar electrodes have a greater surface area for the space they occupy and take less energy to decompose to a metal hydroxide than the most common plate cell configuration.

Electrolytic sponge may alternatively be utilized in a plate configured cell or in any shape to accommodate the movement of water through the sponge while introducing an electrical current through the cell.

As the anodes decompose, the cathode in the same cell is coated with a resistive film that prevents the passage of current and the decomposition of the anode over time. This coating of a resistive film takes place at a slower pace as the size of the anode decreases, resulting in complete decomposition before replacement becomes necessary.

Accordingly, disposable electrolytic cells lower fabrication and maintenance costs by using low cost expendable materials. The anodes used in the disposable cells are generally produced from scrap metal chips, turnings and fines generated from machining metal parts. Small pieces of metal can be decomposed more quickly with less energy than solid plates. Efficiency in energy to decompose metal in an electrolyte (water) is directly related to the profile of the electrodes (bipolar anodes) utilized in the electrolytic cell. The more surface area exposed to the exchange of electrons, the higher the efficiency achieved in decomposition (consumption) of the metal (anode) to the hydroxide state.

To make the disposable electrolytic cells of the preferred embodiment, the open cell foam or sponge like materials are impregnated with metal fines or any conductive materials. After the sponge or open cell material is impregnated with metal fines, the sponge or open cell material is cut and/or fashioned into a selected shape and inserted in the housing, wherein the housing accommodates the introduction of wastewater (electrolyte) and permits electrical connections to the fixed electrodes.

The impregnated sponge is rolled around a fixed electrode (bar or pipe) until it forms a cylinder of the desired size to fit into the housing, much like a filter cartridge. The outside of the cylinder is wrapped with a perforated metal screen and the cartridge is inserted into the housing. The inner and outer fixed electrodes are subsequently connected to a power source.

Accordingly, a feature and advantage of the present invention is its ability to be utilized in any industry where the production of a metal hydroxide, oxygen or hydrogen may be required.

Another feature and advantage of the present invention is its ability to eliminate the maintenance associated with electrodes in electrolytic cells.

Still another feature and advantage of the present invention is its ability to quickly replace disposable electrolytic cells.

Yet another feature and advantage of the present invention is that low cost electrolytic cells can be manufactured as disposable baskets or cartridges.

Yet still another feature and advantage of the present invention is that it automatically connects disposable electrolytic cells without hard wiring.

A further feature and advantage of the present invention is its ability to pass an electrolyte (wastewater) through a cell without restricting the flow.

Still a further feature and advantage of the present invention is that it can utilize inexpensive scrap anode materials.

These and other features and advantages of the present invention will become more apparent to one skilled in the art from the following description and claims when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The present invention will be better understood by reading the Detailed Description of the Preferred and Selected Alternate Embodiments with reference to the accompanying drawing figures, in which like reference numerals denote similar structure and refer to like elements throughout, and in which:

FIG. 1 depicts a cross-section of reticulated or open cell foam impregnated with metal particles and fines to form an anode, according to a preferred embodiment;

FIG. 2 is a top edge view of the impregnated foam or open cell material anode of FIG. 1, partially rolled around a tubular perforated electrode, according to a preferred embodiment;

FIG. 3 is a top view of an electrolytic sponge cartridge having a perforated tubular electrode at the center within the electrolytic sponge and a screen electrode surrounding the outer surface of the electrolytic sponge, according to a preferred embodiment;

FIG. 4A is a side perspective view of a cartridge (disposable electrolytic sponge) with wastewater flow passing through the cartridge from the center perforated influent tubular electrode to the outside via the electrolytic sponge and screen electrode, according to a preferred embodiment;

FIG. 4B depicts a side perspective view of the center perforated influent tubular electrode of FIG. 4A, according to a preferred embodiment;

FIG. 5 is a side perspective view of a pressurized housing with an electrolytic sponge cartridge and removable cap for changing the electrolytic sponge cartridge without major mechanical dismantling and without interrupting the process flow, according to a preferred embodiment;

FIG. 6 is a side perspective view of a low pressure housing with hinged cap for changing the electrolytic sponge cartridge and further shows the position of a flow restrictor to eliminate high flow, high pressure conditions, according to a preferred embodiment;

FIG. 7 is a cross-sectional side view of a high pressure housing utilized with a basket cell and having a hold down clamp to secure the cap, according to a preferred embodiment;

FIG. 8 is a side view of an air-operated cap removal tool utilized to quickly remove the cap of the high pressure housing of FIG. 7 in order to replace the basket cell, according to a preferred embodiment;

FIG. 9 is a cross-sectional side view of a disposable cell basket that is utilized to hold bipolar electrodes in a packed bed configuration according to a preferred embodiment;

FIG. 10A is a cross-sectional side view of a metallic fabric basket resting on electrical contacts, thereby eliminating hard wired connections, according to a preferred embodiment;

FIG. 10B is a bottom view of the metallic fabric basket of FIG. 10A, according to a preferred embodiment;

FIG. 11 is a cross-sectional side view of conductive/consumable metal anode particles and non-conductive/non-consumable materials within a packed bed electrolytic cell, according to a preferred embodiment;

FIG. 12 is a chart showing consumption and energy efficiency of various electrode profiles, including plate electrodes, electrodes formed from chipped materials, electrodes formed from spherical particles and electrodes formed from fine materials, according to a preferred embodiment;

FIG. 13 depicts a partially-exploded side view of a removable basket, according to a preferred embodiment;

FIG. 14 is a cross-sectional side view of a disposable electrolytic cell with twist-off cap, quick connector and flow restrictor, according to an alternate embodiment;

FIG. 15A depicts a cross-sectional side view of a disposable electrolytic cell having a disposable basket liner, according to an alternate embodiment;

FIG. 15B depicts a cross-sectional side view of a disposable basket liner for the disposable electrolytic cell of FIG. 15A, according to an alternate embodiment;

FIG. 15C depicts a bottom view of a disposable basket liner of FIG. 15B, according to an alternate embodiment;

FIG. 16 depicts an anode mix/blend configuration for a packed bed electrolytic cell;

FIG. 17 is a cross-sectional side view of an electro-coagulation cell efficiency analyzer; and

FIG. 18 is a top view of an electrical contact component of the pressurized housing of FIG. 5 and the low pressure housing of FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED AND SELECTED ALTERNATE EMBODIMENTS OF THE INVENTION

In describing the preferred and selected alternate embodiments of the present invention, as illustrated in FIGS. 1-18, specific terminology is employed for the sake of clarity. The invention, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish similar functions.

Referring now to FIGS. 1-4B, the present invention in a preferred embodiment is a disposable electrolytic sponge cartridge comprising an anode formed from an electrolytic sponge, such as, for exemplary purposes only, a reticulated or open cell foam impregnated with metal particles, such as, for exemplary purposes only, metal fines. The electrolytic sponge is rolled around, and is in electrical communication with, a perforated tubular electrode, thereby forming the anode. The anode is subsequently inserted into a perforated tubular cathode.

The anode and cathode are in electrical communication with a power source, wherein the anode is connected to the negative terminal of the power source and the cathode is connected to the positive terminal of the power source.

Turning now more particularly to FIG. 1, depicted therein is a cross-section of reticulated or open cell foam impregnated with metal fines to form an anode according to a preferred embodiment. Impregnated electrolytic sponge 20 comprises electrolytic sponge 22, metallic particles/fines 24, left edge 23, right edge 25, top edge 27 and bottom edge 29, wherein electrolytic sponge 22 is impregnated with metallic particles 24 therewithin, and wherein electrolytic sponge 22 is selectively reticulated or open cell foam.

Turning now more particularly to FIG. 2, depicted therein is a top edge view of the impregnated foam or open cell material anode partially rolled around a perforated cathode to form a cartridge cell according to a preferred embodiment. Impregnated electrolytic sponge 20 is wound around perforated tubular fixed electrode 30 in a jellyroll fashion, wherein left edge 23 is disposed proximate perforated tubular fixed electrode 30 and right edge 25 is consequently at the exterior of impregnated electrolytic sponge 20.

Turning now more particularly to FIG. 3, depicted therein is a top view of an electrolytic sponge cartridge having a tubular cathode at the center within the anode and a perforated metal cathode at the outer surface of the anode according to a preferred embodiment. Once impregnated, electrolytic sponge 20 is wound around perforated tubular fixed electrode 30, the roll is inserted into a cylindrical sleeve comprising metal screen fixed electrode 70 to form disposable electrolytic sponge cartridge 10.

Turning now more particularly to FIGS. 4A and 4B, depicted therein is a cartridge (disposable electrolytic sponge) with wastewater flow passing through the cartridge from the center perforated influent tubular electrode to outside according to a preferred embodiment. The power connections are made at the bottom of the cartridge so that the connections are made when the cartridge is placed in the housing, eliminating the need for “hard wired connections”. Particularly, perforated tubular fixed electrode 30 comprises first end 50, second end 60 and perforations 40. Disposable electrolytic sponge cartridge is inserted into a suitable housing and electrical connection is made (best shown in FIGS. 5-6).

Influent 450 enters disposable electrolytic sponge cartridge 10 via first end 50. A portion of influent passes out of disposable electrolytic sponge cartridge 10 via second end 60 while another portion passes through impregnated electrolytic sponge 20 exiting disposable electrolytic sponge cartridge 10 via metal screen 70 as effluent 460.

Turning now to FIGS. 5-15 and 18, to assist in replacement of active components, the cap on the housing is removably secured in order to make access quick and easy, allowing the entire operation of changing the cartridge to take no more than 1 minute per cell, as depicted in FIGS. 5, 6, 7 and 14.

Turning now more particularly to FIGS. 5 and 18, depicted therein is a pressurized housing with an electrolytic sponge cartridge and means to change the electrolytic sponge cartridge without major mechanical dismantling and without interrupting the process flow according to a preferred embodiment; FIG. 5 further shows quick electrical connections that are made automatically when the cartridge is replaced. Particularly, bottom fed pressurized electrolytic cell 100 comprises disposable electrolytic sponge cartridge 10, housing wall 130, o-ring 140, top cap 150 and bottom cap 160, wherein bottom cap 160 comprises positive contact 110, negative contact 120 and flow restrictor 170. Top cap 150 is removable and is sealed to housing wall 130 via o-ring 140. Bottom cap 160 is fixedly secured to housing wall 130.

Disposable electrolytic sponge cartridge 10 has tab 75 affixed thereto, wherein upon insertion of disposable electrolytic sponge cartridge 10 into housing wall 130 and bottom cap 160, tab 75 becomes wedged into positive contact 110 and second end 60 (best shown in FIG. 4B) of perforated tubular fixed electrode 30 contacts and rests upon negative contact 120. Perforated tubular fixed electrode 30 comprises closure 145 that seals perforated tubular fixed electrode 30, thereby preventing wastewater effluent 460 from exiting first end 50 (best shown in FIG. 4B) and forcing wastewater effluent 460 to flow through impregnated electrolytic sponge 20. Subsequent to insertion of disposable electrolytic sponge cartridge 10 into housing wall 130 and bottom cap 160, top cap 150 is disposed over o-ring 140 and secured to housing wall 130 via any means known in the art, thereby sealing bottom fed pressurized electrolytic cell 100. Top cap 150 comprises top outlet 180.

In use, contacts 110, 120 are connected to a suitable source of electric power and wastewater influent 450 flows into bottom fed pressurized electrolytic cell 100 at bottom cap 160 thereof via flow restrictor 170, and subsequently enters second end 60 (best shown in FIG. 4B) of perforated tubular fixed electrode via negative contact 120, wherein negative contact 120 comprises a hollow cone having side-opening vanes 225 or perforations to permit fluid flow thereinto (best shown in FIG. 18). Flow of wastewater influent 450 continues through perforated tube 30 through impregnated electrolytic sponge 20 to the outside thereof, and as the liquid passes through impregnated electrolytic sponge 20 electrolytic reaction with metallic particles/fines 24 (best shown in FIG. 1) causes metallic particles/fines 24 to decompose to form a metal hydroxide. Wastewater effluent 460 exits bottom fed pressurized electrolytic cell 100 via top outlet 180.

Turning now more particularly to FIG. 6, depicted therein is a low pressure housing for a quick change of the electrolytic sponge cartridge and further shows the position of a flow restrictor to eliminate high flow, high pressure conditions according to a preferred embodiment; FIG. 6 further shows the power connections at the bottom of the housing to eliminate hard wired connections.

Particularly, bottom fed low pressure housing 200 comprises disposable electrolytic sponge cartridge 10, housing wall 230, o-ring 240, top cap 250 and bottom cap 260, wherein bottom cap 260 comprises positive contact 210, negative contact 220 and flow restrictor 270. Top cap 250 is removable and is sealed to housing wall 230 via o-ring 240. Bottom cap 260 is fixedly secured to housing wall 230. Housing wall 230 further comprises latch pin 280 thereon and top cap 250 comprises latch 290 thereon, wherein top cap 250 is secured to housing wall 230 via cooperative engagement of latch 290 with latch pin 280.

Disposable electrolytic sponge cartridge 10 has tab 75 affixed thereto, wherein upon insertion of disposable electrolytic sponge cartridge 10 into housing wall 230 and bottom cap 260, tab 75 becomes wedged into positive contact 210 and second end 60 (best shown in FIG. 4B) of perforated tubular fixed electrode 30 contacts and rests upon negative contact 220. Perforated tubular fixed electrode 30 comprises closure 245 that seals perforated tubular fixed electrode 30, thereby preventing wastewater effluent 460 from exiting first end 50 (best shown in FIG. 4B) and forcing wastewater effluent 460 to flow through impregnated electrolytic sponge 20 (best shown in FIG. 4B).

Subsequent to insertion of disposable electrolytic sponge cartridge 10 into housing wall 230 and bottom cap 260, top cap 250 is disposed over o-ring 240 and secured to housing wall 230 via cooperative engagement of latch 290 with latch pin 280, or similar means known in the art, thereby sealing bottom fed pressurized electrolytic cell 200. Housing wall 230 comprises side outlet 190.

In use, contacts 210, 220 are connected to a suitable source of electric power and wastewater influent 450 flows into bottom fed low pressure electrolytic cell 200 at bottom cap 260 thereof via flow restrictor 270, and subsequently enters second end 60 (best shown in FIG. 4B) of perforated tubular fixed electrode 30 via negative contact 220, wherein negative contact 220 comprises a hollow cone that permits fluid flow therethrough. Wastewater effluent 460 exits bottom fed pressurized electrolytic cell 200 via side outlet 190.

Turning now more particularly to FIGS. 7-9, depicted therein is the high pressure housing utilized with a basket cell having a hold down clamp to secure the cap and bottom power connections according to a preferred embodiment; FIG. 7 further shows quick connectors to remove the housing without disrupting the process flow. FIG. 9 depicts the disposable basket cell of FIG. 8, wherein disposable basket cell 400 is utilized to hold bipolar electrodes in a packed bed configuration according to a preferred embodiment; the basket cell of FIG. 9 is comprised of a fabric basket with a fixed electrode at the center of the basket and a perforated fixed electrode encasing the basket.

Particularly, bipolar anode disposable basket cell pressurized housing 300 comprises housing wall 330 having top cap 350 and bottom cap 360 disposed thereon, and disposable basket cell 400 disposed therewithin, wherein disposable basket cell 400 comprises perforated tubular fixed electrode 30, loose packed anode bed 320, and perforated cylindrical fixed electrode 370. Top cap 350 is secured to housing wall 330 via hold down clamp 390. Perforated tubular fixed electrode 30 is disposed within loose packed anode bed 320 and comprises handle 395 at first end 50 thereof, wherein handle 395 is secured to housing wall 330 via seal 340. Loose packed anode bed 320 is disposed within perforated cylindrical fixed electrode 370, wherein perforated cylindrical fixed electrode 370 comprises a container for loose packed anode bed 320.

Wastewater influent 450 enters perforated tubular fixed electrode 30 proximate bottom cap 360 and passes through loose packed anode bed 320, exiting bipolar anode disposable basket cell pressurized housing 300 as effluent 460 via top cap 350.

FIG. 8 depicts air-operated cap removal tool 410 comprising handle 409, air cylinder 405, upper arm 407, lower arm 408 and hinge 406 in hinged communication with upper arm 407. To separate top cap 350 from housing wall 330, air-operated cap removal tool 410 is inserted with upper arm 407 below top cap 350 and lower arm 408 above bottom cap 360, wherein air cylinder 405 pushes upper arm 407 upward, thereby forcing top cap 350 to separate from housing wall 330, and wherein air-operated cap removal tool 410 is utilized to quickly remove top cap 350 in order to replace disposable basket cell 400 according to a preferred embodiment.

Turning now more particularly to FIGS. 10A and 10B, depicted therein is electrolytic cell 500 comprising metallic fabric basket cell 540 sitting on electrical enclosure 550, wherein electrical enclosure 550 comprises positive electrical contact 510 and inert support 530. Metallic fabric basket cell 540 containing loose packed anode bed 320, is disposed in electrical communication with positive electrical contact 510 and perforated tubular fixed electrode 30 is disposed in electrical communication with negative contact 520, thereby eliminating hard wired connections.

Turning now more particularly to FIG. 11, depicted therein is packed bed electrolytic cell electrode 600 comprising conductive/consumable metal anode particles 610 and non-conductive/non-consumable materials 620 within packed bed 622.

Turning now more particularly to FIG. 12, depicted therein is a graph showing the energy efficiency percentage with regard to the decomposition of metal to the hydroxide form for various electrode profiles utilizing Plates, Chips, Spheres and/or Fines according to a preferred embodiment.

Turning now more particularly to FIG. 13, depicted therein is twist lock cell 650 with removable disposable basket cell 605 therein, wherein removable disposable basket cell 605 is preferably comprised of, for exemplary purposes only, titanium. Twist lock cell 650 comprises top ring 680, base 670, positive contacts 660, perforated tubular fixed electrode 30 having twist lock 690 and metal bushing 695 having locking pin 679 therein. When installed, twist lock 690 of disposable basket cell 605 cooperatively engages locking pin 679 on metal bushing 695 in electrical communication, wherein locking pin 679 comprises a negative contact, and base 670 cooperatively engages positive contacts 660 in electrical communication.

Turning now more particularly to FIGS. 14-15C, depicted therein is disposable quick connect electrolytic cell 700 according to an alternate embodiment, wherein quick connect electrolytic cell 700 comprises twist-off cap 750, quick connector 710, flow restrictor 720 and disposable basket liner 780 (best shown in FIG. 15B), and wherein disposable basket liner 780 comprises anode basket 760 with mixed anode material 770 therewithin. Quick connect 710 comprises flow restrictor 720, electrical contacts 730 and non-conductive bushing 740. Disposable quick connect electrolytic cell 700 twists to lock into electrical communication with electrical contacts 730 and flow restrictor 720 twists to lock into electrical communication with perforated tubular fixed electrode 30. Wastewater influent 450 enters quick connect electrolytic cell 700 via flow restrictor 720 and effluent 460 exits via sidewall 735.

Turning now to FIG. 16, depicted therein is an Anode Mix & Anode Blend Configuration of a Packed Bed Electrolytic Cell. In order to maintain maximum cell efficiency it is important to keep the anodes free by mixing non-conductive or resistive materials with the reactive or consumable (metal) materials within the packed bed. In this way there is a greater reaction within the packed bed which enhances the decomposition of the metal anodes to form metal hydroxides more evenly through the bed. This mixing also permits better utilization of the energy in doing its “work” of producing oxygen and hydroxyl ions within the cell.

In FIG. 16, packed bed electrolytic cell configuration 800 comprises type 1 consumable 810, type 2 consumable 820, non-conductive/resistive particles 830 and electrolytic sponge 840. Consumables 810, 820 and non-conductive/resistive particles 830 interact with each other via paths 805.

Turning now to FIG. 17 depicted therein is an EC Cell Efficiency Analyzer, wherein hydrogen gas concentration is an indicator of cell efficiency. When the concentration of hydrogen drops below 50% of its design production, the cell is flagged to be replaced. The cell is designed to produce 200% of its effective production and therefore a reduction of 50% ensures the cell will function at 100% Oxygen produced on the Anode is generally utilized to oxidize organic compounds in the water resulting in higher dissolved oxygen reading in the effluent. Oxidation may be further enhanced by the introduction of air or ozone through a diffuser at the bottom of the cell.

Particularly, electrocoagulation cell efficiency analyzer 900 comprises manifold 920, hydrogen collection chambers 930, hydrogen concentration analyzer 940, relief valves 950, diffuser 960 and air/ozone injector 970. Cell 910 is connected to manifold 920 and air/ozone is added via air/ozone injector 970 through diffuser 960. Hydrogen gas 980 generated by cell 910 that does not react with air/ozone enters manifold 920, passing to hydrogen collection chambers 930, wherein the concentration of hydrogen gas 980 is monitored by hydrogen concentration analyzer 940. Excess pressure of hydrogen gas 980 is vented via relief valves 950 should the need arise.

Returning again to FIGS. 1-15, the open cell foam or sponge is fabricated from any materials that allow the metal fines to migrate throughout the cellular structure. Any sponge or open cell material is utilized that can be cut or fashioned into any shape and inserted into a housing that will accommodate the introduction of wastewater (electrolyte) and allow the bipolar electrodes to react upon application of an electric current. After impregnating, the foam is rolled around a perforated cathode which serves as the water inlet to the cartridge cell.

The metal fines comprise any metal type or non-metal material, such as, for exemplary purposes only and without limitation, machining shavings or particles that are smaller than the pore size of the cell structure in the open cell material. The cell structure holds the metal particles in place after the material is rolled into cylinder. The electrolytic sponge or basket cells hold the metal fines or non-metal material in the reactive range of the cell. Since the sponge has two sides, the interior is accessible from either side resulting in a bipolar electrode.

Disposable basket and cartridge cells hold the metal pieces and fines in the reactive zone of the cell. Bipolar electrodes have a greater surface area for the space they occupy and take less energy to decompose to a metal hydroxide than the most common plate cell configuration.

Electrolytic sponge may alternatively be utilized in a plate configured cell or in any shape to accommodate the movement of water through the sponge while introducing an electrical current through the cell.

As the anodes decompose, the cathode in the same cell is coated with a resistive film that prevents the passage of current and the decomposition of the anode over time. This coating of a resistive film takes place at a slower pace as the size of the anode decreases, resulting in complete decomposition before replacement becomes necessary (best shown in FIG. 12).

Accordingly, disposable electrolytic cells lower fabrication and maintenance costs by using low cost expendable materials. The anodes used in the disposable cells are generally produced from scrap metal chips, turnings and fines generated from machining metal parts. Small pieces of metal can be decomposed more quickly with less energy than solid plates. Efficiency in energy to decompose metal in an electrolyte (water) is directly related to the profile of the electrodes (bipolar anodes) utilized in the electrolytic cell. The more surface area exposed to the exchange of electrons, the higher the efficiency achieved in decomposition (consumption) of the metal (anode) to the hydroxide state.

To make the disposable electrolytic cells of the preferred embodiment, the open cell foam or sponge like materials are impregnated with metal fines or any conductive materials. After the sponge or open cell material is impregnated with metal fines, the sponge or open cell material is cut and/or fashioned into a selected shape and inserted in the housing, wherein the housing accommodates the introduction of wastewater (electrolyte) and permits electrical connections to the fixed electrodes.

The impregnated sponge is rolled around a fixed electrode (bar or pipe) until it forms a cylinder of the desired size to fit into the housing, much like a filter cartridge. The outside of the cylinder is wrapped with a perforated metal screen and the cartridge is inserted into the housing. The inner and outer fixed electrodes are subsequently connected to a power source.

The foregoing description and drawings comprise illustrative embodiments of the present invention. Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims.

Claims

1. An electrolytic cell comprising:

a housing; and

a replaceable cartridge disposed within said housing,

wherein said replaceable cartridge comprises a cathode and an anode.

2. The electrolytic cell of claim 1, wherein said anode comprises a fixed tubular perforated electrode surrounded by an electrolytic sponge.

3. The electrolytic cell of claim 2, wherein said cathode comprises a metal mesh electrode.

4. The electrolytic cell of claim 2, wherein said electrolytic sponge comprises reticulated foam material with metal fines therein.

5. The electrolytic cell of claim 1, wherein said anode comprises a packed bed anode basket.

6. The electrolytic cell of claim 1, wherein said replaceable cartridge comprises a disposable basket.

7. The electrolytic cell of claim 1, further comprising a pressurized cell.

8. The electrolytic cell of claim 1, further comprising a low pressure cell.

9. The electrolytic cell of claim 3, wherein wastewater flows in through said fixed tubular perforated electrode and subsequently passes through said electrolytic sponge to and through said metal mesh electrode.

10. The electrolytic cell of claim 1, further comprising a flow restrictor.

11. The electrolytic cell of claim 1, further comprising a removable cap.

12. The electrolytic cell of claim 11, wherein said removable cap is sealed to said housing by an o-ring seal.

13. The electrolytic cell of claim 11, wherein said removable cap is secured to said housing by a cooperative latch pin and latch.

14. The electrolytic cell of claim 11, wherein said removable cap is secured to said housing by a hold down clamp.

15. The electrolytic cell of claim 3, wherein electrical contact is made between said fixed tubular perforated electrode and a negative contact and between said metal mesh electrode and a positive contact.

16. The electrolytic cell of claim 1, wherein said replaceable cartridge rests on and in electrical contact with an electrical enclosure having positive and negative contacts.

17. The electrolytic cell of claim 2, further comprising a twist lock mechanism between said fixed tubular perforated electrode and a metal bushing having a locking pin therein.

18. The electrolytic cell of claim 1, further comprising a quick disconnect mechanism.

19. The electrolytic cell of claim 1 in combination with a cell efficiency analyzer, wherein said cell efficiency analyzer monitors hydrogen gas.

20. A method of forming metal hydroxides, said method comprising the steps of:

impregnating a reticulated foam with metal fines;

forming said impregnated reticulated foam around a fixed tubular perforated electrode to create an anode;

disposing said anode within a metal mesh cathode;

applying an electric current to said anode and said cathode; and

passing wastewater sequentially into said fixed tubular perforated electrode, through said impregnated reticulated foam and through said metal mesh cathode.