Electrolysis systems

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OTHER PUBLICATIONS J. O’M. Bockris, On Methods For the Large-Scale Produc F.C. Jensen et al., Hydrogeneration Through Static Feed tion of Hydrogen From Water, Hydrogen Energy, Part A, Water Electrolysis, Hydrogen Energy, Part A, Hydrogen Hydrogen Economy Miami Energy Conference, 1974, pp. Economy Miami Energy Conference, 1974, pp. 425-439 (no 371-403 (no month).

R. Rautenbach et al., Membrane Processes, Gas Permeation, month). Chapter 13, 1989, pp. 422-432 (no month).

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ELECTROLYSIS SYSTEMS It is also not possible to produce high gas flow rates (of the order of 10,000 liters per hour) on demand from the prior

This is a Continuation of International Applin. No. PCT/ art apparatus without the use of expensive and complicated AU94/00532, filed Sep. 6, 1994, which designated the U.S. equipment, and even then the equipment Suffers from low efficiencies in the conversion of electrical energy to generate

TECHNICAL FIELD OF THE INVENTION the hydrogen and oxygen gases. Thus, the large Scale The present invention relates to the generation of hydro commercial implementation of Such apparatus is not eco nomically viable.

gen gas and oxygen gas from water, either as an admixture Admixed hydrogen and oxygen gases (or hydroxy gas) or as Separated gases, by the process of electrolysis, and are used as a thermal Source when burnt in a stream, for relates further to applications for the use of the liberated gas. example,

Embodiments of the invention particularly relate to an cutting andin often furnaces. Hydrogen alone is used for atomic for atomic welding, although the device apparatus for the efficient generation of these gases, and to described in the Brown patent performed atomic welding the use of the gases as a thermal Source in atomic welding with admixed hydrogen and oxygen. Recent industry prac or cutting, and in gaseous waste disposal. 15 tice clearly exemplifies that the presence of oxygen in a BACKGROUND ART plasma arc causes Severe oxidation of the tungsten elec trodes.

The technique of electrolysing water in the presence of an One of the problems experienced in implementing these electrolyte such as sodium hydroxide (NaOH) or potassium applications is the need to incorporate electrical Switchgear hydroxide (KOH) to liberate hydrogen and oxygen gas (H, to transform main Supply Voltages to a level Suitable for a O) is well known. The process involves applying a DC bank of electrolysis cells (i.e. by Step-down transformers). potential difference between two or more anode/cathode The resulting completed arrangement is electrically ineffi electrode pairs and delivering the minimum energy required cient and cumberSome, and also can be expensive if precise to break the H-O bonds (i.e. 68.3 kcal per mole (aSTP). voltage and current regulation (hence gas flow regulation) is The gases are produced in the Stoichiometric proportions for 25 required.

O:H of 1:2 liberated respectively from the anode (+) and Combusted hydrogen and oxygen gases mixed into a cathode (-). Single Stream burn at a very high temperature, typically of Reference can be made to the following texts: “Modern the order of 6000 C. Hydrogen/oxygen welding sets are Electrochemistry, Volume 2, by John O'M. Bockris and generally known to comprise of a welding tip or hand piece Amulya K. N. Reddy, (Plenum Publishing Corporation)”, connected by a dual gas hose to Separate Supplies of oxygen “Electro-Chemical Science,” by J. O’M. Bockris and D. M. and hydrogen.

Drazic, (Taylor and Francis Limited) and “Fuel Cells, Their There are four other common types of welding apparatus Electrochemistry,” by J. O’M. Bockris and S. Srinivasan, and techniques in use. These are oxy-acetylene welding, (McGraw-Hill Book Company). 35 electric arc welding, MIG (metal-inert-gas)/TIG (tungsten A discussion of experimental work in relation to elec inert-gas) Systems and plasma cutting.

trolysis processes can be obtained from "Hydrogen Energy, It is estimated that more than 100,000 oxy-acetylene sets Part A, Hydrogen Economy Miami Energy Conference.” are used in Australia. Of those, approximately 70% are used Miami Beach, Fla., 1974, edited by T. Nejat Veziroglu, primarily for cutting metals, with the remainder being used Plenum Press. The papers presented by J. O’M. Bockris on 40 as a heat Source, for fusion welding of sheet metal, brazing, pages 371 to 379, by F. C. Jensen and F. H. Schubert on Silver Soldering and the like. Typically, oxy-acetylene Sets pages 425 to 439 and by John B. Pangborn and John C. can weld thicknesses of metal between 0.5 mm to 2 mm. Sharer on pages 499 to 508 are of particular relevance. Further, thicknesses up to 140 mm can be cut, but only On a macro-Scale, the amount of gas produced depends where the Steel contains a high percentage of iron. The upon a number of variables, including the type and concen 45 reason for this is that the iron and the oxygen are required tration of the electrolytic Solution used, the anode/cathode to Support the oxidation process which induces the cutting electrode pair Surface area, the electrolytic resistance effect. The acetylene gas provides the initial temperature to (equating to ionic conductivity, which is a function of start the oxidation reaction, being typically 850 C. Oxy temperature), the achievable current density and anode/ acetylene Sets require a bottled Supply of both acetylene and cathode potential difference. The total energy delivered must 50 oxygen gas. Hence, the bottles must be bought or rented, be Sufficient to disasSociate the water ions to generate then continually maintained and refilled with use. hydrogen and oxygen gases, yet avoid plating (oxidation/ Electric arc welding is a method used for welding metals reduction) of the metallic or conductive non-metallic mate of greater than 1.5 mm in thickness. The principle of rials from which the electrodes are constructed. operation is that a hand piece is Supplied with a consumable Reference also is made to prior art Australian Patent No. 55 electrode, and the work piece forms the other electrode. An 487062 to Yul Brown, that discloses an electrolysis cell AC or DC potential difference is created between the arrangement to produce hydrogen and oxygen on demand, electrodes, thus causing an arc to be struck when the hand together with a Safety device preventing the generation of piece is brought into proximity of the work piece. The arc excess pressure of the liberated gases. FIG. 2 of the Brown can be used to fuse or Weld metal pieces together. patent shows a number of electrodes (20a,20b) in a series 60 MIG systems are based around a continuous wire feed electrical arrangement between two terminals (22), across System. In one known arrangement, the consumable wire is which a voltage is applied. The cell (20) produces a gas Shrouded by argon gas (or a plasma) which typically is Volumetric flow rate output, and if that output is insufficient provided from a bottled supply. TIG systems, on the other for a particular application, then a larger number of indi hand, require the filler wire to be hand-fed into the weld vidual cell units must be provided which are all electrically 65 pool. MIG/TIG systems can weld metals from between 1 connected in Series. mm to 20 mm in thickness. These metals, typically include The end result is a large Structure to be Supported. Stainless Steel, aluminium, mild Steel and the like. Reference

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can be made to a text “The Science and Practice of Welding, through which passes one or more common Second conduc Volume 2, A. C. Davies, Cambridge University Press” with tive interconnecting members, respect to a plasma MIG processes. and wherein the anode electrodes and the cathode elec Plasma cutting is a method of cutting by introducing trodes are interleaved.

compressed air (comprising predominantly nitrogen) to a 5 The invention further discloses a cell arrangement for the DC electric arc, thereby producing very high temperatures electrolysis of water to liberate hydrogen and oxygen gases, (about 15,000 C.) and so stripping electrons from the the arrangement comprising:

nitrogen nucleus to form a high temperature plasma. This a plurality of anode-forming electrodes interconnected by plasma can be utilized to cut ferrous and non-ferrous mate one or more first common conductive members to be elec rials. Such as mild Steel, StainleSS Steel, copper, brass and trically in parallel, the anode electrodes being interleaved aluminium. Available plasma cutters can cut up to a 25 mm thickneSS and have the advantage of not requiring bottled with nected a plurality of cathode forming electrodes intercon by one or more Second conductive members to be gas, but rather utilize free air. Reference can be made to the electrically in parallel, the anode electrodes and cathode text “Gas Shielded Arc Welding,” by N. J. Henthome and R. electrodes forming a cell unit; and a plurality of the cell units

W. Chadwick, (Newnes Technical Books.) with respect to being electrically connected in Series.

plasma cutting.

The invention further discloses a cell arrangement for the

AS can be seen from the discussion of the prior art, no one electrolysis of water to liberate Separated or admixed hydro unit or System has the capability of performing all welding gen and oxygen gases, the arrangement comprising: and cutting functions, and typically, one of the Systems a plurality of anode-forming electrodes arranged in a already described would be chosen over another for any particular job. This then requires that metal workers or other Stacked through relation, each anode electrode comprising a flat plate which passes one or more first conductive intercon metal trade industry manufacturers must purchase and main necting members, tain a number of different types of welding units in order to have the capability to handle any job on demand. The costs 25 a plurality of cathode-forming electrodes arranged in a asSociated with the purchase of replacement bottled gas also Spaced linear Stacked relation, each cathode electrode com are very high. prising a flat plate through which passes one or more Second conducting interconnecting members, wherein the anode

DISCLOSURE OF THE INVENTION electrodes and the cathode electrodes are interleaved; and a plurality of membranes, each membrane located

It is a preferred object of the present invention to provide between an arrangement whereby hydrogen and oxygen gases can be the membranes an adjacent anode electrode and cathode electrode, produced by electrolysis in a manner that avoids one or more between adjacent allowing the passage of ionic current of the foregoing disadvantages. In that Sense, the electrolysis tively blocking the flow of gascathode anode and electrodes, but Selec therethrough dependant upon apparatus is compact and offers greater efficiencies than the a pressure differential between opposite Sides of a mem prior art for comparative gas flow rates. 35 brane.

It is a further preferred object of the invention to provide The invention yet further discloses an electrolysis unit for an improved Structure for an electrolysis cell for use in the the liberation of oxygen and hydrogen gases, the unit generation of hydrogen and oxygen gas. The electrolysis cell comprising:

can be used in hydrogen/oxygen welding or hydrogen a plurality of anode-forming electrodes interleaved with a plasma cutting. Other applications may relate to industrial 40 plurality of cathode forming electrodes, processes where a combustible Source of fuel is required,

Such as incinerators, and to the incineration of intractable a plurality of Separation membranes between each adja WaSteS. cent cathode and anode electrode; and It is a yet further preferred object to provide an electroly means for Supplying at least water to the anode and sis cell arrangement that allows the Selective Separation or 45 cathode electrodes, the Supply means being operable to admixture of hydrogen and oxygen gas into individual gas control pressure differential of the at least the water on opposed Sides of each membrane to Selectively maintain

StreamS.

The present invention further preferably is directed to gaSeS. Separation or admixture of liberated oxygen and hydrogen provision of a unitary welding unit which can provide all the welding or cutting requirements of a user. Advantageously, 50 useThe invention further discloses a burner arrangement for in the thermal destruction of gaseous pollutants, the no bottled Supply of hydrogen or oxygen is required. A burner comprising:

bottled Supply of any other gas also required is not. For example, argon is not required in Shrouded MIG/TIG appli a hemispherical burner chamber; cations. a Supply of hydrogen and oxygen gases in communication

It is a yet further preferred object of the invention to with the burner chamber via a tortuous path exiting by a provide a flashback arrester for a hydrogen/oxygen welding plurality of concentrically arranged nozzles directed towards or hydrogen plasma cutting tip. the epicenter of the hemispherical chamber; and Therefore, the invention discloses a cell arrangement for an inlet for the Supply of the gaseous pollutants, the electrolysis of water to liberate hydrogen and oxygen 60 and wherein the gaseous pollutants are combusted gases, the arrangement comprising: together with the hydrogen and oxygen gases. a plurality of anode-forming electrodes in a Stacked The invention yet further discloses a multi-modal welding relation, each anode electrode comprising a flat plate and cutting generator, comprising: through which passes one or more common first conductive a power Supply controllable to produce a plurality of AC interconnecting members, and 65 and DC output voltage Sources, and a plurality of cathode-forming electrodes in a Stacked an electrolysis unit coupled to the power Supply, and relation, each cathode electrode comprising a flat plate operable to Selectively produce hydrogen and oxygen Sepa

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S 6 rately or as admixed hydrogen and oxygen from a Supply of cell plates 10, one of which is shown in plana in FIG.1a and water by electrolysis due to a DC voltage source of the as a side view in FIG. 1b. Each plate 10 has three slots 12, power Supply; the hydrogen, oxygen and admixed hydrogen each one arranged in alternating Side edges of the plate 10. and oxygen, together with the output Voltage Sources, being The other sides of the cell plate 10 each are provided with available for connection to a welding and/or cutting appa a conductive bridge or flange 14. Typically twenty indi ratuS. vidual cell plates 10 are stacked to form one complete cell The invention yet further discloses a flashback arrester for 16 as shown as a side view in FIG. 2. The total number of a welding tip having use with combusted gases, the arrester plates can vary in accordance with the required Surface area, comprising a meshed barrier in the Stream of a passage for and thus, also is a function of plate diameter. the gases to be combusted, the meshed barrier having an The Stacking of adjacent individual cell plates 10 is in a opening with a size to allow free passage of the gases, and reversed order, So that the conductive bridges 12 of adjacent to impede passage of a flashback by the flashback flame So plates extend in opposed directions and with a relative that it is unable to pass the barrier and is extinguished. rotational offset of 60. This rotational offset is provided so BRIEF DESCRIPTION OF THE DRAWINGS that adjacent plates 10 are to bear opposite polarity. The 15 conductive bridges 14 are long enough to pass through a

FIGS. 1a and 1b show a single cell plate respectively as corresponding slot 12 in an adjacent plate 10, without a plan View and Side view; contacting that plate, and contact the next Subsequent plate FIG. 2 shows a Stacked array of cell plates, to form a conductive path between each alternate plate. In FIG. 3 shows, as a vertical cross-sectional view, an this way, the completed cell Structure 16 has three positive electrolysis cell bank; end terminals and three negative end terminals, although FIG. 4 is a vertical cross-sectional view showing an FIG. 2 shows only two of the positive terminals and one of arrangement of electrodes of part of another electrolysis cell the negative terminals. The cell Stack 16 is enveloped by an bank embodying the invention; insulating case 18 (shown in cut-away form). The cell plates FIG. 5 is a perspective view of part of one electrode 25 10 shown in FIGS. 1a, 1b and 2 are Suited to form in a shown in FIG. 4; parallel electrical arrangement, with each adjacent two cell FIG. 6 is a simplified representation of a Series arrange plates 10 forming either the anode or the cathode. ment of the electrodes shown in FIG. 4; Parallel stacked flat cell plates are described in Australian Patent

FIGS. 7a and 7b show the mechanical arrangement of a plates typically No. 487062. In that patent, a stack of twenty cell Single cell Stack in another embodiment; requires a potential difference across the individual electrodes

FIG. 8 shows the arrangement of a number of the cells 1.55–2.0 volts to liberate of each cell plate in the range of shown in FIGS. 7a and 7b, hydrogen and oxygen gas from the water containing an electrolyte of typically 15% Sodium

FIG. 9 shows the series electrical configuration of a hydroxide solution.

number of cells in a cell bank; FIG. 3 shows, as a vertical croSS-Sectional view, Seven FIGS. 10a and 10b show the mechanical configuration of 35 complete cell Stacks 16 arranged in a hexagonal matrix and a cell bank assembly; enclosed by a Steel casing 20, thereby to provide an elec FIGS. 11a and 11b show a yet further embodiment of a trolysis cell bank 25. The cell stacks 16 are insulated from cell plate; the steel casing 20 by nylon insulating bushes 22. The FIGS. 12a and 12b show a complementary cell plate to electrical interconnection of the individual cell stacks 16 is that of FIGS. 11a and 11b, 40 not shown, but typically the cells are connected between

FIG. 13 shows detail of the perforations and porting of the their respective positive (+) and negative (-) terminals by cell plates of FIGS. 11a, 11b, 12a and 12b; Straps to form a Series connection. FIG. 14 shows an exploded stacked arrangement of the It Sometimes can be the case that a parallel interconnec cell plates of FIGS. 11a, 11b, 12a and 12b; 45 tion of the cell stacks 16 is implemented. The actual elec FIG. 15a shows a schematic view of the gas separation trical interconnection will depend upon the number of system of FIG. 14; individual cell plates 10 comprising each cell Stack 16, the FIG. 15b shows a stylised representation of FIG. 15a, Supply Voltage and the current that can be drawn from the FIG. 15c shows an electrical equivalent circuit of FIG. Supply.

15a, 50 Water is consumed as the hydrogen and oxygen gas is FIG.16 shows a gas collection system for use with the cell liberated during the electrolysis reaction. One liter of water bank separation system of FIGS. 14 and 15a, generates 1860 liters of admixed oxygen and hydrogen at FIG. 17 shows, as a cross-sectional view, a hydraulic STP, in the volumetric proportion noted above. In the Scrubber and check valve; arrangement shown water is continually Supplied through FIG. 18 shows, as a cross-sectional view, a welding tip of 55 the inlet port 24.

FIG. 10 including a flashback arrester; The nylon covers 18 Separating adjacent Stacks have the FIGS. 19a and 19b show a burner for the destructive benefit of directing the liberated gas upwardly to be col combustion of pollutants, lected by, for example, a gas outlet 26 located at the top of FIG. 20 shows a block diagram of a multimodal welding the electrolysis cell bank 25. By virtue of volumetric dis and cutting apparatus, and 60 placement in a ratio of 1:1860, the liberated gases are FIG. 21 shows a Schematic diagram of the apparatus of Self-pressurizing as they pass from the outlet port 26 into the FIG. 20. interconnecting pipe work (not shown), which has a far narrower croSS-Sectional area than that of the cell bank.

DETAILED DESCRIPTION AND BEST MODE FIG. 4 is a vertical cross-sectional view showing the OF PERFORMANCE 65 mechanical configuration of an electrolysis cell in accor An electrolysis cell bank embodying the invention is dance with a further embodiment. The basic cell unit 30 is constructed of a number of hexagonally shaped electrolysis constituted by respective halves of a pair of interdigitated

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electrodes 32, 34 arranged much in the nature of interleaved cent ones thereof. The ionic flow naturally will take the path combs. Each electrode is formed by a conductive spine 36, of least resistance, hence short-circuits between cell units 38, typically constructed of resin bonded carbon material, 30, being a path otherwise of greater resistance, are avoided. mild Steel or conductive polymers, from which extend A large number of cells therefore can be arranged to extend eleven finger-like plates 40, 42, also constructed of carbon, longitudinally, and allow direct connection to a rectified Steel or conductive polymer. mains power Supply, thus obviating the need to electrically FIG. 5 is a perspective view of one of the electrodes 32 interconnect groups of cell units by Strapping, as has been in which the Spine 36 and plates 40 are rectangular in Shape. done in the prior art.

The electrodes need not necessarily be of the Shape shown, Each individual cell unit 30 satisfies the operational but rather can take on many other forms, one example of criteria regarding Voltage, the Surface area of the plates and which will presently be described. The common requirement So on, to Successfully electrolyze water, and thereby operates for all Such configurations is that the plates be parallel and essentially independently of the adjacent cell units 30. interconnected by a common member usually arranged Testing has established that for a temperature range of 90 orthogonally to the plates. C. to 50 C., a DC voltage in the range 1.47-1.56 V applied Each pair of electrodes 32, 34 are in a Staggered arrange 15 across one cell unit 30 (i.e. across one half of a complete ment So that the respective outermost plates 40a, 42a are electrode 32 or 34) a minimum (and the optimum) anode offset by approximately one half of the total length of each current density of 0.034 A/cm is required to generate a gas electrode 32, 34. The respective mid-point plates are iden flow rate of about 340-300 l/h per kWh respectively. The tified by the reference numerals 40b and 42b. discovery that the minimum plate Surface area corresponds FIG. 6 shows the Staggering arrangement in a simplified to the optimum gas flow rate means that the total volume form. Every sixth plate is located in the Space formed occupied can be kept to a minimum. By way of Specific between the first and eleventh plate of the respective example, a rectified 240 V main voltage nominally results opposed adjacent electrodes. in an average DC voltage of 215 V, hence for direct Referring to FIG. 4 again, two complete cell units 30 and 25 connection to the main Supply via a rectifier (i.e. without a part of the next respective adjacent cell units are shown. requiring a step-down transformer), a total of about one The total number of cell units is governed by the DC Supply hundred and forty cells are required. It is particularly advan Voltage, Since a minimum anode/cathode Voltage is required tageous not to require Voltage transformation equipment in to derive the electrolysis process, and each adjacent cell unit terms of equipment cost, technical Simplicity and the avoid is in a Series electrical connection of the parallel-arranged ance of losses.

plates 40, 42. In the electrolysis process, the cells 30 are FIG. 7a shows a partial cut-away side view of a cell unit immersed in water and electrolyte and a DC voltage is 50 in accordance with another embodiment. The cell unit 50 applied between the end-most plates 40c, 42c causing is similar in configuration to that of FIG. 4 except for the elemental ionic currents (some of which are represented by number and shape of interconnecting spine members and the the dashed arrows) to flow between the adjacent plates 40, 35 shape of the electrode plates.

42, and Some current-wise along the respective Spines 36,38 FIG. 7b shows an end view of the cell unit 50, and in and plates 40, 42 (shown by the solid arrows). A different particular the end-most plate 52c. The plate electrodes 52, 54 current path is followed at each mid-plate. For example, the are hexagonal in shape. Each plate 52, 54 has six intercon DC current travels from one end cell plate 42a, through the necting rod-like Spines 56, 58 passing therethrough, one near electrolyte, passing through the mid cell plate 40b and again 40 each vertice. Each alternate one of the Spines 56 represents through the electrolyte to the next end cell plate 42a. This a common positive conductor and the other Set of alternate proceSS causes the accumulation of net positive charge on Spines 58 represents negative conductors. Each adjacent one side of the mid-plate 40b, and a negative charge on the plate 52, 54 is electrically connected either to the positive other Side. conductors or the negative conductors. Spacing bushes 60 The ionic current flow is accompanied by disasSociation 45 are provided between adjacent plates 52, 54 to provide of the water molecules Such that oxygen and hydrogen gas electrical isolation and to provide a Space in which the water is produced respectively at the anode plate and cathode plate and electrolyte circulates. Connection of each spine conduc Surfaces. The cathode plate Surfaces are those Surfaces tor 56, 58 to the respective plate electrode 52, 54 typically towards which ionic current flows. The converse applies for is by a threaded nut or interference fit. The reason for the anode plate Surfaces. 50 connecting each plate 52, 54 to three common Spine con The Voltage applied across the end-most plates 40c is ductors 56, 58 is to achieve a uniform current distribution divided equally between the constituent cell units 30, with across the whole surface area of a plate 52, 54. that fraction of the Supplied Voltage appearing between the As can be seen in FIG. 7b, the positive spine conductors respective outer-most plates and mid-point plates 4.0a & 56 extend away from one end of the assembly for series 42b, 40b & 42a. 55 interconnection with other arrangements of cells, as do three The achievable current density is limited, in part, by the negative spine conductors 58 from the other end. All uncon effective electrical resistance of the electrolytic solution. The nected ends of the conductors are blanked-off with a non Smaller the gap between adjacent plates 40, 42 the leSS is the conductive end cap 62.

resistance. The interdigitated nature of the electrodes 32, 34 FIG. 8 shows a stylized form of three cell units 50 means that there is a large Surface area available per unit 60 electrically connected in Series (arranged longitudinally), Volume, and there is a minimum Separation between elec and particularly the passage of the Spine conductorS 56, 58. trode plates in all instances. In that case, the resistance of the The cell units 50 are enclosed within an insulating tube 64, electrolyte is kept low, hence efficiency of the conversion of typically made of PVC, which has an access for the com electrical energy to generate the hydrogen and oxygen gases munication of water to envelope the plates 52, 54 and for the is greater than in the prior art. 65 generated gases to escape.

By virtue of the Specific arrangement shown, it is not FIG. 9 shows the series electrical interconnection of a necessary to isolate each individual cell unit 30 from adja number of cell units 50 directly connected with the DC

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output side of an AC/DC converter 66 (such as a simple plates, much in the nature of the arrangement shown in diode bridge rectifier) without requiring a step-down trans FIGS. 7a and 7b. The additional two upper holes 104,106 former. each Support a conduit respectively for the out-flow of FIG. 10a shows an end view of the mechanical arrange oxygen and hydrogen gases, respectively. The additional ment of Seven assemblies (designated A-G), each consisting holes 108, 110 at the bottom of the sleeve 94 are provided of three series connected cell units 50 (as shown in FIG. 8), for the inlet of water and electrolyte to the respective cell forming a total cell arrangement 70. The cell assemblies 50 plates 90,98.

are located within a Steel cylinder 72 containing the water FIG. 13 shows an enlarged view of a portion of the cell and electrolyte required for the generation of the hydrogen plate 90 shown in FIG. 11a. The port hole 104 is connected and oxygen gases. Each group (A-G) of three cell units 50 to the hexagonal perforations 96 within the sleeve 94 by an is interconnected by means of a first group of Steel connect internal channel 112. A similar arrangement is in place for ing Straps 74 at one end and a Second group of Steel the other port hole 106, and for the water/electrolyte supply connecting straps 76 (not shown) at the other end, arranged holes 108, 110.

to be offset between the groups. While the first straps 74 If the hydrogen and oxygen gases liberated are to be kept alone are shown in FIG.10a, both sets of the straps 74.76 are 15 Separate (i.e. not to be formed as an admixture), then it is more clearly shown in FIG. 10b, which is a side view of the necessary to Separate those gases as they are produced. In groups A-G when unravelled. the prior art, this is achieved by use of diaphragms that block The PVC tubes 64 shown in FIG. 10a insulate adjacent the passage of gases and effectively isolate the water/ groups to avoid “short-circuiting effects between one electrolyte on each Side of the diaphragm. Ionic transfer thus another. The cell arrangement 70 is very compact, and in a is facilitated by the ionically conductive nature of the comparison with the prior art Brown arrangement is only diaphragm material (i.e. a water-diaphragm-water path). one third of the physical size for a comparable gas Volu This results in an increase in the ionic resistance, and hence, metric flow rate. Moreover, there also being a similar a reduction in efficiency. Prior art patent No. 487062 reduction in total mass. The Supply of water for the elec 25 describes another arrangement (see FIG. 6 thereof) that trolysis process is provided by an inlet 78 located at the utilizes magnets to cause the Separation of the gases. bottom of the cylinder 72, with the gases produced exit the FIG. 14 shows an exploded stacked arrangement of four cylinder 72 by an outlet 80 located at the top of the cylinder. cell plates, being an alternative Stacking of two (anode) cell Electrical connection to a DC power Supply is acroSS the plates 90 and two (cathode) cell plates 98. The two ends of totality of the cells, and in the arrangement is at a central the Stacked arrangement of cell plates delineates a Single cell terminal 82 on the underside of cell A and a central terminal unit 125. Interposed between each adjacent cell plate 90, 98 84 on the top side of cell G, respectively. is a PTFE separation 116. Although not shown in FIG. 14, FIGS. 11a and 12a show further embodiments of a first the cell unit includes Separate hydrogen and oxygen gas and second type of cell plate 90, 98 as an end view. FIGS. conduits that respectively pass through the Stacked arrange 11b and 12b are partial cross-sectional views along the 35 ment of cell plates via the port holes 106, 104 respectively. respective mid-lines as shown. Common reference numerals In a similar way, conduits are provided for the Supply of have been used where appropriate. The plates 90, 98 can water/electrolyte, respectively passing through the holes have the function of either an anode (+) or a cathode (-), as 108, 110 at the bottom of the respective plates 90,98. will become apparent. Each comprises an electrode disc 92 Only two pairs of anode/cathode cell plates are shown. that is perforated with hexagonally shaped holes 96. The 40 The number of Such plates can be greatly increased per cell disc 92 is made from steel or resin-bonded carbon or unit 125.

conductive polymer material. The disc 92 is housed in a Also not shown are the interconnecting conductive shafts circular rim or sleeve 94. The function of the perforations 96 that electrically interconnect alternate common cell plates. is to maximize the Surface area of the electrode disc 92 and The reason for having a large diameter hole in one cell plate minimize the weight over Solid constructions by 45%. 45 adjacent to a Smaller diameter hole in the next cell plate, is By way of example, for a disc having diameter of 280 So that an interconnecting Shaft will pass through the larger mm, the thickness of the disc must be 1mm in order to allow diameter hole, and not make an electrical connection (i.e. the current density (which ranges from 90 A/2,650 cm-100 insulated with PVC tubing) but rather only form an electrical A/2,940 cm of the anode or cathode) to be optimal. If the connection between alternate (common) cell plates. diameter of the plate is increased, which consequently 50 The cell unit 125 shown in FIG. 14 arrangement is an increases the Surface area, it is necessary to increase the exploded view. When fully constructed, all the elements are thickness of the plate in order to maintain uniformity of Stacked to be in intimate contact. Mechanical fastening is conductance for the desired current density. achieved by use of one of two adhesives Such as (a) The hexagonal perforations in a 1 mm thick disc have a “PUR-FECT LOK” (TM) 34-9002, which is a Urethane distance of 2 mm between the flat portions of the plates and 55 Reactive Hot Melt adhesive with a main ingredient of are 1 mm away from the next adjacent perforation, in order Methylene Bispheny/Dirsocynate (MDI), and (b) “MY-Tto maintain the same total Surface area prior to perforation, BOND” (TM) which is a PVC solvent based adhesive. Both and to allow the current density to be optimal. A 1 mm (plate adhesives are Sodium Hyroxide (20% present in the to plate) distance between the adjacent hexagonal perfora electrolyte) resistant. In that case, the water/electrolyte only tions is required because a Smaller distance will result in 60 resides within the area proscribed by the cell plate sleeve 94. thermal (resistive) losses and a larger distance will add to theThus the only path for the inlet of water/electrolyte is by overall weight of the plate. bottom channels 118, 122 and the only outlet for the gases The sleeve 94 is constructed of PVC material and incor is the top channels 112,120. In a system constructed and porates a number of equally spaced shaft holes 100,102. The tested by the inventor, the thickness of the cell plates 90, 98 holes are for the passage of interconnecting Shafts provided 65 is 1 mm (2 mm on the rim because of the PVC sleeve 94), in a stacked arrangement of the plates 90, 98 forming the with a diameter of 336 mm. The cell unit 125 is segmented common conductor for the respective anode and cathode from the next cell by an insulating PVC segmentation disc

Page 31

114. A Segmentation disc 114 is also placed at the beginning replenishing Supply of electrolyte is provided by way of and end of the entire cell bank. circulation through the water/electrolyte conduits 134, 135. If there is to be no control over separation of the liberated The circulation is caused by entrainment by the liberated gases, then the PTFE membranes 116 are not needed. gases, and by the circulatory inducing nature of the conduits The PTFE membrane 116 is fibrous and has 0.2 to 1.0 and columns.

micron interstices. A Suitable type is type Catalogue Code J, The upper extent of the tank 140 forms two scrubbing supplied by Tokyo Roshi International Inc (Advantec). The towers 156, 158, respectively for the collection of oxygen water/electrolyte fills the interstices and ionic current flows and hydrogen gases. The gases pass up respective columns only via the water-there is no contribution of ionic flow 142, 144, and out from the columns via openings therein at through the PTFE material itself. This leads to a reduction in a point within the interleaved baffles 146. The point where the resistance to ionic flow. The PTFE material also has a the gases exit the columns 142, 144 is beneath the water “bubble point” that is a function of pressure. Hence by level h, which serves to settle any turbulent flow and controlling the relative pressures at either side of the PTFE entrained electrolyte. The baffles 146 located above the level Separation sheets, the gases can be "forced' through the 15 h Scrub the gas of any entrained electrolyte, and the Scrubbed interstices to form an admixture, or otherwise kept Separate. gas then exits by respective gas outlet columns 148, 150 and Other advantages of this arrangement include a cheaper cost so to a gas receiver. The level h within the tank 140 can be of construction, improved operational efficiency and greater regulated by any convenient means, including a float Switch, resistance to faults. and with the replenishing water Supplied by the inlet pipe FIG. 15a is a stylized and exploded, schematic view of a 152.

linear array of three series-connected cell units 125. For The liberated gases will always separate from the water/ clarity, only six interconnecting Shafts 126-131 are shown. electrolyte solution by virtue of the difference in densities. The shafts 126-131 pass through the respective shaft holes Because of the relative height of the respective set of baffles, 102, 100 in the various cell plates 90, 98 in the stacked and due to the density differential between the gases and the arrangement. The polarity attached to each of the exposed water/electrolyte, it is not possible for the liberated hydro end shafts, to which the DC Supply is connected also is 25 gen and oxygen gases to mix. The presence of the full indicated. The shafts 126-131 do not run the full length of volume of water within the tank 140 maintains the cell plates the three cell banks 125. The representation is similar to the in an immersed State, and further Serves to absorb the shock arrangement shown in FIGS. 7a and 8. One third of the full of any internal detonations should they occur. DC Source Voltage appears acroSS each anode/cathode cell In the event that a gas admixture is required, then, firstly, plate pair 90, 98. the two flow valves 136, 137 respectively located in the Further, the gas conduits 132, 133, respectively for oxy oxygen gas outlet conduit 132 and water/electrolyte inlet gen and hydrogen, that pass through the port holes 104,106 port 134 are closed. This blocks the outlet path for the in the cell plates 90, 98 also are shown. In a similar way, oxygen gas and forces the inlet water/electrolyte to pass to water/electrolyte conduits 134, 135, passing through the 35 the inlet conduit 134 via a one-way check valve 139 and water port holes 108, 110 in the cell plates also are shown. pump 138. The water/electrolyte within the tank 140 is FIG. 15b particularly shows how the relative potential under pressure by virtue of its depth (volume), and the pump difference in the middle cell bank 125a changes. That is, the 138 operates to increase the pressure of water/electrolyte plate electrode 90a now functions as a cathode (i.e. rela occurring about the anode cell plates 90, 98a to be at an tively more negative) to generate hydrogen, and the plate 40 increased pressure with respect to the water/electrolyte on electrode 98a now functions as an anode (i.e. relatively more the other side of the membrane 116. This pressure differen positive) to generate oxygen. This is the case for every tial is Sufficient to cause the oxygen gas to migrate through alternate cell unit. The arrowheads shown in FIG. 15b the membrane. Thus, admixed oxygen and hydrogen are indicate the electron and ionic current circuit. FIG. 15c is an liberated via the gas output conduit 133 and column 144. electrical equivalent circuit representation of FIG. 15b, 45 Since there is no return path for the water/electrolyte Sup where the resistive elements represent the ionic resistance plied by the pump 138, the pressure about the cell plates 90, between adjacent anode/cathode plates. Thus, it can be seen 98a will increase further, and to a point where the difference that the cell units are connected in Series. is Sufficient Such that the water/electrolyte also can pass Because of the change of function of the cell plates 90a through the membrane 116. Typically, pressure differential and 98a, the complementary gases are liberated at each. 50 in the range of 1.5-10 psi is required to allow passage of gas, Hence, the respective channels 112 are connected to the and a pressure differential in the range of 10-40 psi for opposite gas conduit 132,133. Practically, this can be water/electrolyte.

achieved by the simple reversal of the cell plates 90, 98. While only three cell units 125 are shown, clearly any FIG. 16 shows the three cell units 125 of FIG. 15a number, connected in Series, can be implemented. connected to a gas collection arrangement. The cell units 55 FIG. 17 shows another embodiment of a check valve and 125 are located within a tank 140 that is filled with water/ scrubber unit 160 for scrubbing liberated gas(es) before electrolyte to the level h indicated. The water is consumed Subsequent use. The unit 160 is filled with water, typically as the electrolysis proceSS proceeds, and replenishing Supply to a level being about half the full height of the unit. The is provided via the inlet 152. The water/electrolyte level h level is regulated by a float Switch 162. Water is supplied by can be viewed via the Sight glass 154. In normal operation, 60 means of the inlet 164. A sight column 166 is also provided, the different Streams of oxygen and hydrogen are produced which Serves to give a visual indication of the water level. and passed from the cell units 125 to respective rising The hydrogen and/or oxygen gases from the gas receiver, columns 142,144. That is, the pressure of electrolyte on now under pressure, enter by an entry tube 168 having an opposed sides of the PTFE membranes 116 is equalized. opening 170 at the bottom end thereof. The gases travel Thus, the gases cannot admix. 65 down the tube 168 and out of the opening 170 to bubble The columns 142, 144 also are filled with the water/ upwardly on the inside of the inner column 172, which also electrolyte, and as it is consumed at the electrode plates, is filled with the Supplied water, thus performing a first

Page 32

Scrubbing action to remove the Sodium hydroxide electro One application of the hydrogen and oxygen gases pro lyte. The gas then enters another downwardly directed tube duced by the apparatus described above is in the thermal 174 and out the opened end thereof, passing again through destruction of waste, and without the consumption of atmo the water in the outer chamber 176 to be further Scrubbed. Spheric oxygen. This procedure requires an on-demand The gas is to be Stored under pressure within the Space above Supply of hydrogen and oxygen gas. The electrolysis appa the water level and be available for supply from the outlet ratus described above can, in a Scaled-up version, produce 178. the requisite gas flow rates in order to combust waste gases Admixed hydrogen and oxygen gases Supplied from the on a commercial Scale.

output 178 to, for example, a welding tip (not shown) are in FIGS. 19a and 19b show a configuration for a burner used the correct Stoichiometric proportions as a result of the in the destruction of Such gaseous polluting emissions. FIG. electrolysis process, and ensures that, on combustion, a 19a shows a cross-sectional view of a burner 200. The neutral flame is produced. The only products of the com croSS-Sectional view along the mid-line is shown in FIG. bustion process are heat and water vapour. 19b. The burner 200 has a combustion chamber 202 that is If the gases are produced Separately, two check-valve 15 hemispherical in Shape. The emissions, which may include Scrubbers 160 are employed, the gases can then be mixed in a mixture of fumes containing hydrocarbons and other a mixing chamber which also will produce the correct Volatile pollutants as a waste product of industrial processes, Stoichiometric mix. are injected to the combustion chamber by an inlet path 206. If there is an explosion which backS-up through the outlet There are two Sources of an admixture of gaseous hydrogen 178 from a welding tip, it will be quenched by the water and oxygen in Stoichiometric proportions of 2:1, one each to within the unit 160. The energy of the explosion will be an upper and lower quadrant of the combustion chamber absorbed by displacing the water in both the outer chamber 202. These gases are supplied by the two gas inlets 208 at 176 and the inner column 172. This displacement also cuts points diametrically opposed on the sides of the burner 200. off the flow of inlet gas to the tube 168. In this way, there will The mixture of hydrogen and oxygen and emissions formed be no possibility of the explosion further propagating 25 within the combustion chamber 202 is ignited by means of towards an electrolysis cell bank producing the gases. The a Spark plug 210, or the like, and burns at a temperature of water within the unit 160 therefore acts both as a gas not less than 4000 C., thus providing energy for molecular Scrubber and also as a check valve. disasSociation of all the pollutants into harmless compounds FIG. 18 shows a welding tip 180 in cross-sectional detail. that can be discharged to the atmosphere. No atmospheric oxygen is consumed in the burning proceSS. Complete

The hydrogen and oxygen gases are received along an inlet combustion tube 182, passing by a needle valve 184 and into an effect of theof combustion the pollutants is aided by the “focusing” chamber 202, which further expansion chamber 186. The expansion chamber 186 improves the mixing of the gas Streams. includes a flashback control apparatus, which comprises a cylindrically arranged flashback arrester 188, typically A thermocouple 212 measures the temperature within the formed of 5 micrometer Stainless Steel meshing. In normal 35 silicone fiber refractory heat insulatory material 214 Sur operation, the gases flow through the flashback arrester 188 rounding the combustion chamber 202. The cladding 216 and to the outlet or nozzle 190, where combustion, or gas applied to the burner 200 is typically made of stainless steel. ionisation during the production of plasma, takes place. The burner configuration is formed by seven (only four In the event that flashback occurs, the flashback arrester are shown) concentrically arranged sets of nozzles 212, as is 188 disallows further rearward passage of the flame, which 40 clearly shown in FIG. 19b. The nozzles 222 are directed to cannot physically pass through openings as Small as, for commonly intersect at the epicenter 204 of the combustion example, 5 micrometers. This is coupled with a heat Sink chamber 202. The cooling water, supplied by an inlet 218 effect of the material from which the arrester 188 is con and exiting by an outlet 220, is intended to maintain the Structed which operates to dissipate the energy of the flame, nozzles 222 at a temperature of less than 300° C. Above and thus, assist in extinguishing the flame. 45 300 C., hydroxy gas has the tendency to “back burn”. The use of hydrogen and/or oxygen in welding and The flow path of hydrogen and oxygen gases to the cutting by electrolysis allows temperatures of the order of nozzles 222 from the inlets 208 has four 90 (minimum) 6000 C. to be achieved with the ability to produce gas on correction changes. This is intended to Slow the linear demand. No gas stored in bottle form is required. It is further momentum of the hydroxy flame in the event of a flashback, possible to conduct fine flame welding with a high purity of 50 and So cause the flame to Self-extinguish. This is particularly gas, and also to be able to fuse ceramic materials. advantageous, as hydrogen burns at a rate of 3,600 m/s. All of the following materials can be welded: carbon steel, FIG. 20 shows in block diagram form a multi-modal cast iron, Stainless Steel, aluminium, brazing, Silver cutting and welding apparatus 230. The apparatus receives a Soldering, copper and ceramics. The following ferrous and supply of DC power provided to an AC/DC converter 232. non-ferrous materials, due to the available production of 55 An AC Supply is available for connection to AC electric arc pure hydrogen Subsequently passed through a DC arc pro welding apparatus 234, while the converted DC output viding a hydrogen plasma stream (H->H), can be readily Voltage is provided for connection with a DC electric arc cut: carbon Steel, cast iron, StainleSS Steel, aluminium, braz welding or cutting apparatus 236. The DC output Supply ing and copper. voltage also is provided to an electrolysis cell unit 238 for The embodiment of the invention can provide a continu 60 the generation of, in this case, Separated hydrogen and ous Supply of hydrogen gas at large flow rates. AS Such, it is oxygen gases. The hydrogen and oxygen gases both are well disposed to applications that consume large quantities provided to a hydroxy gas welding apparatus 240. The of hydrogen. An example of one Such proceSS is the Plascon hydrogen (and oxygen for Secondary injection) is made (TM) waste destruction process developed by the Australian available for connection with plasma cutting apparatus 242. CSIRO's Division of Manufacturing Technology. A sum 65 The hydrogen is passed through a DC arc to produce a mary of the Plascon process can be found in the CSIRO plasma Stream, and on a Secondary injection, the Oxygen is Journal “Ecos, Volume 68, Winter 1991'. introduced into the plasma Stream to produce an oxidizing

Page 33

plasma cutting effect which increases cutting efficiency. pass to the welding tip 265 where they are ignited and Thicknesses of up to 150 mm can be cut with this process. combusted to be used for the purposes of hydrogen/oxygen It should be noted that introducing oxygen downstream from welding.

the tungsten electrodes eliminates any oxidation of the If the hydrogen and oxygen gases are produced Separately electrodes. and required for hydrogen plasma cutting 242 and/or hydro The hydrogen gas alone also is provided to a MIG/TIG gen plasma MIG/TIG welding 244, the selection valve 266 apparatus 244, with the hydrogen in plasma form otherwise disallows the admixture of the two gases. taking the place of the conventional inert gas. An AC or DC of The power Supply unit 232 is a conventional arrangement a multi-tapped transformer 246, including a reactor wind

Supply also is required to form the plasma.

ing 267 and a range selector Switch 268 which allows a

The converter 232 can be of any conventional design, Selection of a chosen output voltage level. The generated typically having a multi-tapped transformer for the Selection Secondary AC Voltage also can be rectified by the rectifier of appropriate rectified DC voltages. The electrolysis unit 247 to produce a DC voltage output. All these output 238 can be of any of the embodiments previously described, Voltages pass another polarity Selector 269 allowing the user and including the Scrubber and check valve arrangements. to select between an AC or DC output and to select the The various cutting and welding apparatus 234, 236, 240, 15 appropriate polarity for the DC output. 242, 244, described also are conventional. The output 248 from the power supply unit 232 is shown The multi-modal apparatus 230 thus provides greater connected to the electrolysis cell bank 238. However, the flexibility for the user in being able to select from the one power Supply also can connect with other forms of welding unit the particular mode of cutting or welding required. and cutting such as indicated in FIG. 20. Clearly, an apparatus comprised of any Single or combina Another output 271 supplies the necessary DC power for tion of welding/cutting apparatus is contemplated by the hydrogen plasma shroud MIG/TIG welding 244 and hydro present invention. gen plasma Oxidising cutting applications 242. Yet another FIG. 21 shows the multi-modal apparatus 230 in greater AC output 272 and DC output 273 Supply the necessary detail. AS previously described, the electrolysis generator 25 current to produce an arc for the MIG and TIG processes. 238 Separately produces gaseous hydrogen and oxygen and Output voltages in the range of 20-60 Volts are required can also produce gaseous hydrogen and oxygen as an for the cell bank unit 238 and the electric arc units 234, 263, admixture. whereas the MIG/TIG welding 244 operates, typically, on an The power Supply unit 232 comprises a multi-tapped output voltage of 30–60 Volts (AC or DC). Plasma cutting transformer 246. The reduced voltage is rectified by a bridge and plasma Shrouding, as provided by the plasma unit 242, rectifier 247. The output rectified voltage is then connected typically

I claim:

requires the supply of 120 Volts DC.

by terminals 248 to the cell bank 238 containing 30 cells via a contactor 249 which is activated by a pressure Switch 250. 1. A cell arrangement for the electrolysis of water, the The Switch 250 is, in turn, activated by a pressure sensor 251 arrangement comprising:

which measures the gas pressure levels within the cell bank 35 a plurality of anode-forming electrodes in a parallel 238. Thus the contactor 249 is operable to remove the supply Stacked relation, each anode electrode comprising a flat of power to the cell bank 238 on the establishment of an plate, and through which plates one or more conductive operational pressure. The contactor 249 operates on demand first interconnecting members pass and are electrically with use of the gas. connected thereto, and

Thus, gas is produced as required, and typically for a total 40 a plurality of cathode-forming electrodes in a parallel of 15 liters at any one time. This 15 liters of gasses Stacked relation, each cathode electrode comprising a comprises 10 liters of hydrogen and 5 liters of oxygen. flat plate, and through which plates one or more con The gases are provided from the scrubbing towers 156, ductive Second interconnecting members pass and are 158 of the cell bank 238. As a closed loop system, the electrically connected thereto; preSSure in each tower will compensate for the other, thereby 45 and wherein the anode electrodes and the cathode elec maintaining constant desired gas production levels. If, trodes are interleaved, and the first interconnecting however, the water level is too high due to excessive use of members and the Second interconnecting members also either gas, the respective float Switch 254, 255 in the pass through without electrical connection to apertures respective tower 156,158 will disallow gas flow by shutting 50 in the cathode electrodes and the anode electrodes, the respective solenoid valve 256, 257. respectively.

The float Switches 254, 255 activate the Solenoid valves 2. The cell arrangement as claimed in claim 1, wherein a group of 256, 257 from an AC supply 258 tapped from the trans and a group of Stacked Stacked anode electrodes forms an anode cell block, former 246. Other float Switches located in the check valve cathode electrodes forms a cathode and scrubber units 160 and the pressuring pump 138, also 55 over only a portion ofeach cell block, and whereby anode cell block is interleaved its length with a corresponding receive the AC supply 258. cathode cell block.

Two flow regulators 261, 262 are incorporated for the 3. The cell arrangement as claimed in claim 2, wherein for purpose of maintaining the desired back-pressure in the each cell block, the respective first or Second interconnecting towers 156, 158 in order that the system will always have members extend only the length of the respective cell block. pressure even if the system is Switched off and/or should the 60 4. The cell arrangement as claimed in any one of claims gases be exhausted through gas outlets, the gas outlets 263, 1 to 3, wherein each electrode has a perforated inner portion, 264 of the check valves/scrubber units 160 or by the welding and an outer rim portion having holes through which the first tip 265. and Second interconnecting members pass. AS opposed to Separated generation in the cell bank 238, 5. The cell arrangement as claimed in claim 4, wherein the method of obtaining an admixture is once the hydrogen and 65 electrodes are circular in shape.

oxygen have passed through the check valve and Scrubber 6. A cell bank arrangement for the electrolysis of water units 160, a selection valve 266 allows the gases to mix and comprising a plurality of cell arrangements as claimed in

Page 34

claim 2 connected in Series, and one or more Said Series through which said collected gas passes, thereby creating a connected cell arrangements connected in a parallel connec back pressure on water in the tank. tion. 16. The electrolysis system as claimed in claim 12, further 7. The electrolysis cell bank arrangement as claimed in compriSIng:

claim 6, wherein there are the same number of Said cell a plurality of membranes, each of Said membranes located arrangements in each Series connection, and Said parallel between an adjacent anode electrode and cathode connection is formed by a close-packed array of Said Series electrode, Said membranes allowing the passage of connected cell arrangements and further comprises at least ionic current between adjacent electrodes, but Selec one interconnecting bridge at each end of each cell tively blocking the flow of gas therethrough dependent arrangement, the bridges at each end respectively intercon upon a controllable pressure differential acroSS the necting anode electrodes of each cell arrangement and the membrane.

cathode electrodes of each cell arrangement. 17. The electrolysis system as claimed in claim 16, further 8. The cell arrangement as claimed in claim 1, wherein comprising:

each electrode is hexagonally shaped, and the first intercon a first water Supply, Said first water Supply for providing necting members extend through an electrode at a point near 15 water to the Spaces Surrounding the anode electrodes, every alternate vertice, and the Second interconnecting and members extend through an electrode at the other ones of a Second water Supply, Said Second water Supply for alternate vertices. providing water to the Spaces Surrounding the cathode 9. A cell bank arrangement comprising a plurality of cell electrodes, arrangements as claimed in claim 1 formed as a linear array adjacent anode and cathode Spaces being Separated by a and interconnected in Series. Said membrane, and 10. The cell bank arrangement as claimed in claim 9, wherein one of the Said water Supplies can be selectively wherein the interconnecting members are rods, Said rods preSSurized by a pressurization unit So that a preSSure including first anode rods which extend contiguously from differential exists acroSS each membrane, thus permit one end of each cell arrangement to form the first anode rods ting the flow of gas liberated by the anode or cathode of an adjacent cell arrangement and Second cathode rods 25 electrode during electrolysis through the membrane. which extend contiguously from the other end of each cell 18. The electrolysis system as claimed in claim 17, arrangement to form the Second cathode rods of an adjacent wherein Said pressurization unit which pressurizes the one cell arrangement in the opposite direction. water Supply includes a pump means. 11. The plurality of cell bank arrangements as claimed in 19. The electrolysis system as claimed in claim 18, claim 10, wherein the cell bank arrangements are arranged wherein each Said water Supply has an inlet and an outlet in in a closed packed array and interconnected by conductive communication with a tank adapted for enveloping the bridges at one or both ends of each cell bank arrangement. anode electrodes and cathode electrodes, and wherein Said 12. An electrolysis System comprising: pump means is located within the inlet for either the anode a cell arrangement as claimed in claim 1, and further electrodes or the cathode electrodes.

comprising: 35 20. The electrolysis system as claimed in claim 19, further a tank adapted for containing and immersing Said cell comprising flow restrictor means through which Said liber arrangement in at least water, and ated gases pass, thereby creating a back pressure on the DC voltage Supply means, the positive Supply of which is water in the tank.

21. The electrolysis system as claimed in claim 19, further coupled to the anode electrodes and the negative Supply comprising of which is coupled to the cathode electrodes by a 40 which is coupled DC voltage Supply means, the positive Supply of respective ones of the first and Second interconnecting the negative Supply to the first interconnecting members, and members to liberate oxygen and hydrogen gases interconnecting members. of which is coupled to the Second respectively from Said anode electrodes and Said cath 22. The electrolysis system as claimed in claim 19, ode electrodes. wherein each of the outlets is in communication with a riser 13. The electrolysis system as claimed in claim 12, further 45 tube for the passage of liberated gas, and whereby each riser compriSIng: tube exits to baffle means at least partially immersed in water pipe means to collect Said hydrogen and oxygen gases as to Scrub Said liberated gas.

a gas admixture, and 23. The electrolysis system as claimed in claim 22, further gas Scrubbing means through which the collected gas comprising gas receiver means to Store Said liberated gas. passes, Said gas Scrubbing means having at least two 50 24. The electrolysis System as claimed in claim 23, Separate passageways through which the admixed gas wherein each electrode has a perforated inner portion, and an is forced to pass separated by at least one Scrubbing outer rim portion having apertures through which the first liquid. and Second interconnecting members pass. 14. The electrolysis system as claimed in claim 13, 25. The electrolysis system as claimed in claim 24, wherein Said Scrubbing means comprises: 55 wherein Said membranes extend only over Said inner portion a tank adapted for containing the Scrubbing liquid to a of an electrode.

partial level of the tank, and 26. The electrolysis System as claimed in claim 24, wherein the total Surface area of each electrode, constituted at least two vertically arranged columns within the tank, by a non-perforated portion of the front and back Surfaces the first column having an upper end thereof for receiv and the walls forming the perforations through the thickness ing the collected admixed gas and a lower end of the electrode, is Substantially the same as a non-perforated

thereof open to the Scrubbing liquid, and electrode of having the Same front and back overall Surface the Second column having an upper end thereof open to dimensions.

receive firstly Scrubbed gas and a lower end thereof 27. The electrolysis system as claimed in claim 26, open to the Scrubbing liquid, the Secondly Scrubbed wherein the Separation distance between the edges of adja gas passing to outlet port means. 65 cent perforations is Substantially the same as the thickness of 15. The electrolysis system as claimed in either one of the electrode and the principal dimension of a perforation is claims 13 or 14, further comprising flow restrictor means substantially twice the thickness of the electrode.

Page 35

28. The electrolysis system of claim 22, further compris and oxygen gas, and having a flashback arrester for Said Ing: welding tip, Said arrester comprising a meshed barrier in the a gas check valve including a tank containing a flame Stream of a passage for the gases to be combusted, the extinguishing liquid, and meshed barrier having an opening of a size to allow free pipe means at one end in communication with an inlet of 5 passage of the gases, and to impede passage of a flashback Said check valve and at the other end thereof opening by the flashback flame being unable to pass the barrier, So as into Said extinguishing liquid, and to be extinguished.

whereby, in use, any back-burning flame will force Said 36. The electrolysis system as claimed in claim 16, extinguishing liquid through Said pipe means, thus wherein the membrane is made of PTFE material. removing the Supply of at least hydrogen gas to Said 37. An apparatus comprising:

inlet. the electrolysis System of claim 16, and 29. The gas check valve as claimed in claim 28, wherein an oxidizing plasma cutting apparatus having Said pipe means comprises one or more Stand pipes forming a primary hydrogen injection means and a tortuous path for at least Said hydrogen gas and Said Secondary oxygen injection means extinguishing liquid. 15 wherein Said Separated hydrogen and oxygen gases are 30. The electrolysis system as claimed in claim 19, further Supplied to a respective Said injection means of Said comprising: cutting apparatus.

pipe means to collect the hydrogen and oxygen gases 38. The apparatus as claimed in claim 37, further com either as a gas admixture or Separated gases, and prising DC voltage Supply means to provide an arc to cause either (i) gas Scrubbing means through which the admixed a plasma of the primary injected hydrogen. gas passes, or (ii) two gas Scrubbing means through 39. An apparatus comprising:

which the Separated hydrogen and oxygen gases the electrolysis System of claim 12, and respectively pass, each Said gas Scrubbing means hav a hydrogen fired plasma furnace, Said furnace receiving at ing at least two separate passageways through which least Said hydrogen gas.

Said gas is forced to pass Separated by at least one 25 40. The apparatus as claimed in claim 39, further com Scrubbing liquid. prising a plurality of membranes, each of Said membranes 31. The electrolysis system as claimed in claim 30, located between an adjacent anode electrode and cathode wherein each said Scrubbing means comprises: electrode, Said membranes allowing the passage of ionic a tank adapted for containing the Scrubbing liquid to a current between adjacent anode and cathode electrodes, but partial level of the tank and at least two vertically blocking the flow of gas therethrough to Separately liberate arranged columns within the tank, oxygen gas and hydrogen gas from Said anode electrodes the first column having an upper end thereof receiving the and cathode electrodes.

collected admixed gas and a lower end thereof open to 41. The cell arrangement as claimed in claim 1, further the Scrubbing liquid, and comprising a plurality of membranes, each of Said mem the Second column having the upper end thereof open to 35 branes located between an adjacent anode electrode and receive firstly scrubbed gas and the lower end thereof cathode ionic electrode, Said membranes allowing the passage of current between adjacent electrodes, but Selectively open to the Scrubbing liquid, the Secondly Scrubbed gas blocking the flow of gas therethrough dependent upon a passing to outlet port means. controllable pressure differential across the membrane. 32. A multi-modal electro-gas generator for welding and 42. A cell arrangement for the electrolysis of water, the cutting, comprising: 40 arrangement comprising:

a power Supply controllable to produce a plurality of AC a plurality of anode-forming electrodes in a parallel and DC voltage Sources, and Stacked relation, each anode electrode comprising a flat an electrolysis System as claimed in claim 18, wherein plate, and through which plates one or more conductive Said electrolysis System is operable to Selectively pro first interconnecting members pass and are electrically duce either Separated hydrogen and oxygen gases or 45 connected thereto;

admixed hydrogen and oxygen gas from a Supply of a plurality of cathode-forming electrodes in a parallel water by electrolysis due to a DC voltage source of the Stacked relation, each cathode electrode comprising a power Supply; the hydrogen and oxygen gases or flat plate, and through which plates one or more con admixed hydrogen and oxygen gas, together with the ductive Second interconnecting members pass and are Voltage Sources, being available for connection to 50 electrically connected thereto, and welding and cutting apparatus. wherein the anode electrodes and the cathode electrodes 33. The multi-modal generator as claimed in claim 32, are interleaved, and each electrode is provided with a further comprising means for Scrubbing the hydrogen and plurality of flanges and Slots alternatingly arranged at OXygen gases or admixed hydrogen and oxygen gas.

34. The multi-modal generator as claimed in claim 33, 55 the edge margin of the electrodes, and whereby in the wherein the hydrogen and oxygen gases are adapted for interleaved arrangement of electrodes a flange passes connection to means for gas welding and means for plasma through a slot of an adjacent electrode without making cutting, and the hydrogen gas is adapted for connection to electrical connection there with to connect only with the any one or more of means for metal-inert-gas or tungsten next adjacent electrode. inert-gas plasma cutting and welding, and Said DC voltage 60 43. The cell arrangement as claimed in claim 42, further Sources are adapted for connection to any one or more means comprising a plurality of membranes, each of Said mem for plasma cutting and means for metal-inert-gas or branes located between an adjacent anode electrode and tungsten-inert-gas plasma cutting or welding, Said AC Volt cathode electrode, Said membranes allowing the passage of age Sources are adapted for connection to either one or both ionic current between adjacent electrodes, but Selectively of means for metal-inert-gas or tungsten inert-gas plasma blocking the flow of gas therethrough dependent upon a cutting and welding. 65 controllable pressure differential across the membrane. 35. The multi-modal electro-gas generator of claim 34, further comprising a welding tip for Said admixed hydrogen k k k k k

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UNITED STATES PATENT ANDTRADEMARK OFFICE

CERTIFICATE OF CORRECTION

INVENTOR(S) : SPIROS

It is certified that error appears in the above-identified patent and that said Letters Patent is hereby Corrected as shown below:

On the title page, Item (63), change "August 6, 1994" to -- September 6, 1994-- Signed and Sealed this

Twentieth Day of July, 1999

Q. TODD DICKINSON

Attesting Officer Acting Commissioner of Patents and Trademarks