Technical Field

[0001] The disclosure relates to a hydrogen production system. In particular, to a hydrogen producing device and a method of producing hydrogen from a cartridge containing metalloids or metalloids alloys and catalysts.

Background

[0002] Hydrogen is viewed as a viable option as a renewal energy source. In use it produces no greenhouse gas emissions and may help reduce the impact that energy consumption creates in the environment. However, hydrogen production is currently reliant upon fossil fuel refining processes that release large amounts of greenhouse gases during synthesis.

[0003] The primary approach for commercial synthesis of hydrogen is via electrolysis, in which hydrogen is split from water. Electrolysis is an expensive method requiring substantial amounts of electricity, large industrial plants, and must occur near power stations. Additionally, both the storage and transport of hydrogen gas is substantially difficult and limited in its applicability.

[0004] Any discussion of documents, acts, materials, devices, articles or the like which have been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant of the present disclosure as it existed before the priority date of each of the appended claims.

Summary

[0005] There is provided a hydrogen generation system using cartridges containing metalloids or metalloid alloys and catalysts. In particular, the use of cartridges allows for the safe handling of the key reactive component and the production of small-scale hydrogen generation systems for portable use. [0006] According to a first aspect, there is provided a hydrogen production system, comprising: a cartridge comprising: a receptacle; a metalloid or metalloid alloy; and a catalyst; a hydrogen production device comprising: a reaction chamber configured to receive the cartridge and a reaction liquid; and a laser integrated in or adjacent to the reaction chamber; wherein the laser is configured to direct a beam to a target surface of the cartridge to create a breach in the target surface, allowing the metalloid or metalloid alloy and catalyst to mix with the reaction liquid creating a reaction mixture; and wherein the laser is further configured to control the onset and rate of hydrogen generation from the reaction mixture by controlling the heating of a reaction area surrounding the breach.

[0007] In an embodiment, the hydrogen production device further comprises an ultrasound source configured to control the onset and rate of hydrogen generation of the reaction mixture by controlling the heating of the reaction area surrounding the breach or removing steam and hydrogen gas bubbles from the target surface.

[0008] According to a second aspect, there is provided a hydrogen production system, comprising: a cartridge comprising: a receptacle; a metalloid or metalloid alloy; and a catalyst; a hydrogen production device comprising: a reaction chamber configured to receive the cartridge and a reaction liquid; a laser integrated to or adjacent to the reaction chamber; and an ultrasound source integrated to or adjacent to the reaction chamber; wherein the laser is configured to direct a beam to a target surface of the cartridge to create a breach in the target surface, allowing the metalloid and catalyst to mix with the reaction liquid creating a reaction mixture; and wherein the ultrasound source is configured to control the onset and rate of hydrogen generation in the reaction mixture by controlling the heating of the reaction area surrounding the breach or removing steam and hydrogen gas bubbles from the target surface.

[0009] In an embodiment, the hydrogen production device further comprises a collection chamber for receiving a gaseous hydrogen created from the mixture.

[0010] In an embodiment, the metalloid or metalloid alloy comprises silicon, ferrosilicon, carbon- silicon, calcium-silicon, aluminium silicon, magnum silicon or aluminium- ferrosilicon.

[0011] In an embodiment, the metalloid or metalloid alloy comprises SiH containing materials.

[0012] In an embodiment, the metalloid or metalloid alloy is in a solid state, a powdered state, or a liquid state.

[0013] In an embodiment, the reaction liquid is water.

[0014] In an embodiment, the reaction liquid is a water-based solution comprising oxides, alkalis or salts.

[0015] In an embodiment, the oxides, alkalis or salts comprises amines, primary or secondary alcohols, sea salt, sodium carbonate, magnum oxide, lime, sodium hydroxide, potassium hydroxide, calcium hydroxide, magnesium hydroxide, or a mixture.

[0016] In an embodiment, the catalyst comprises iron, aluminium, sodium carbonate, magnum oxide, lime, sodium hydroxide, potassium hydroxide, calcium hydroxide, magnesium hydroxide, or a mixture.

[0017] In an embodiment, the catalyst is in a solid state, a powdered state, or a liquid state. [0018] In an embodiment, the laser is configured to emit a beam with a wavelength in the range of 350 nm to 10,600 nm.

[0019] In an embodiment, the laser is configured to emit a continuous beam.

[0020] In an embodiment, the laser is configured to emit a pulsed beam.

[0021] In an embodiment, the laser pulses with a duration in the range of 10 ps to 1 ms.

[0022] In an embodiment, the laser is configured to pulse with a frequency range between 10

Hz to 6,000 kHz.

[0023] According to a third aspect, there is provided a method of hydrogen production, comprising: storing a metalloid or a metalloid alloy and a catalyst in a cartridge; loading the cartridge into a reaction chamber; immersing the cartridge in a reaction liquid; focusing a laser at a target surface of the cartridge; thermal cutting the target surface of the cartridge with the laser to create a breach allowing the metalloid or metalloid alloy and the catalyst to mix with the reaction liquid creating a reaction mixture; and controlling the onset and rate of hydrogen production in the reaction mixture with the laser via a controlled heating of a reaction area substantially surrounding the breach.

[0024] In an embodiment, the method further comprises controlling the onset and rate of hydrogen production in the reaction mixture with an ultrasound source via a controlled heating of the reaction area surrounding the breach or removing steam and hydrogen gas bubbles from the target surface.

[0025] According to a fourth aspect, there is provided a method of hydrogen production comprising: storing a metalloid or a metalloid alloy and a catalyst in a cartridge; loading the cartridge into a reaction chamber; immersing the cartridge in a reaction liquid; focusing a laser at a target surface of the cartridge; thermal cutting the target surface of the cartridge with the laser to create a breach allowing the metalloid or metalloid alloy and the catalyst to mix with the reaction liquid creating a reaction mixture; and controlling the onset and rate of hydrogen production in the reaction mixture with the laser and an ultrasound source via a controlled heating of the reaction area surrounding the breach or removing steam and hydrogen gas bubbles from the target surface.

Brief Description of Drawings

[0026] A non-limiting example will now be described with reference to the following drawings:

[0027] FIG. 1 is a schematic representation of a hydrogen production system.

Description of Embodiments

General Terms

[0028] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Hydrogen Production System

[0029] FIG 1 illustrates an exemplary system 10 for hydrogen generation. The system 10 comprises a cartridge 12 and a hydrogen production device 14. The contents of the cartridge 12 are a metalloid or metalloid alloy and catalyst, which are reactants to produce gaseous hydrogen. The cartridge 12 is loaded in a reaction chamber 16 with a reaction liquid 18, wherein the reaction liquid 18 is another reactant to produce a gaseous hydrogen when mixed with the metalloid or metalloid alloy and catalyst. A laser 20 mounted adjacent to the reaction chamber 16 is configured to thermally cut a target surface of the cartridge 12 with a laser beam 22 to create a breach. The creation of the breach allows the contents of the cartridge 12 to mix with the reaction liquid 18 to form a reaction mix. The laser 20 subsequently controls the onset and rate of reaction of the reaction mix with a controlled heating of the reaction mix using the laser beam 22. This results in the generation of the gaseous hydrogen from the reaction mix which may be subsequently harvested for use as a renewable energy source.

[0030] The cartridge 12 comprises a receptacle that is configured to be durable and substantially seal the contents from the external environment. The receptacle is dimensioned to enable ease of loading in the reaction chamber 16, such that the target surface of the cartridge 12 will face an emitter 24 of the laser 20. The receptacle is made from a material that is susceptible to thermal cutting from the laser 20, has physical properties that enable it to be durable for manual and/or mechanical handling, and is chemically inert to its contents, being the metalloid or metalloid alloy and catalyst. This advantageously allows for the cartridge 12 to be handled or stored without contamination of the contents and enables both manual and machine handling when loading it in the reaction chamber 16.

[0031] In a preferred embodiment, the cartridge 12 may be adapted to be stackable with other cartridges 12, using means such as interlocking grooves and protrusions integrated into each cartridge 12. This advantageously allows the cartridges 12 to be stacked upon each other, allowing for easier storage and transportation. Additionally, the cartridges 12 may be stacked into a feed mechanism 26 of the hydrogen production device 14 to enable automated and/or consistent placement of the cartridges 12 into the reaction chamber 16.

[0032] The hydrogen production device 14 comprises a reaction chamber 16 for the safe housing of the reagents for hydrogen generation and a laser 20 for the thermal cutting of a loaded cartridge 12 and stimulation of chemical reactions.

[0033] The reaction chamber 16 is made from a material or materials that are inert to the reactants and their subsequent reaction by-products as well as the pressure and heat created by the chemical reaction. Additionally, the reaction chamber 16 is configured with a glass window 28 to allow the laser beam 22 to pass through and enter the reaction chamber 16, allowing it to thermally cut a loaded cartridge 12 and to subsequently heat a reaction area that substantially surrounds the breach. [0034] The laser 20 may be any conventional laser with either a specific set of parameters or a set of adjustable parameters. Additionally, the laser 20 may be configured to emit a continuous or pulsed laser beam 22. In a preferred embodiment, the laser 20 is configured to have a pulsed laser beam 22 and adjustable wavelength, pulse duration and pulse frequency. In an embodiment, the laser 20 is configured to emit a laser beam 22 with a wavelength in the range of 350 nm to 10,600 nm. In another embodiment, the laser 20 configured with the pulsed laser beam 22 is configured with a pulse duration in the range of 10 ps to 1 ms and/or a frequency range between 10 Hz to 6,000 kHz. In a further embodiment, the laser 20 with a minimal power of 1 W.

[0035] It would be appreciated by a person skilled in the art that the laser 20 may be adapted to change the position of the laser beam 22 on the target surface of the cartridge 12. The laser 20 may be mounted to a movable stage, rails, or other means of movement in the x- and y- axes. Additionally, the laser 20 may be pivotably mounted so allow for changes in angle.

[0036] A liquid reservoir 30 is in fluid connection with the reaction chamber 16 for provision of the reaction liquid 18 when required. The liquid reservoir 30 is configured with a liquid regulator 32 to control the amount of the liquid 18 that is stored in the reaction chamber 16. Additionally, the reaction chamber 16 may be configured with a drain 34 to allow the removal of a used reaction mixture or a contaminated reaction liquid. This advantageously allows for the correct volume of reaction liquid to the contents of the cartridge 12, enabling the correct stoichiometry for optimal hydrogen production. Additionally, it advantageously allows for the cleaning of the reaction chamber 16 via flushing with the reactant liquid 18.

[0037] An ultrasound source 36 may be mounted adjacent to the reaction chamber 16. The ultrasound source 36 may be an ultrasound transmitter configured to emit an ultrasound beam that affects the target surface of the cartridge 12. The ultrasound source 36 may be configured to heat the reaction area that substantially surrounds the breach via ultrasound acoustic vibration. Additionally, the ultrasound source 36 may be configured to remove unwanted material from the target surface of the cartridge 12 via mechanical vibration and/or cavitation. The unwanted material may be detritus created from the thermal cutting of the laser 20 or may be steam and hydrogen gas bubbles that are generated during the production of the gaseous hydrogen. In a preferred embodiment, the ultrasound source 36 is configured with a minimal power of 50 W. [0038] A collection chamber 38 is in fluid connection with the reaction chamber 16 via a connection tube 40. In an embodiment, the collection chamber 38 is configured to store the gaseous hydrogen. In a preferred embodiment, the collection chamber 38 is configured with a water chamber 42 for washing the gaseous hydrogen produced in the reaction chamber 16 prior to collection of the subsequently cleaned gaseous hydrogen.

[0039] It would be appreciated by a person skilled in the art that the collection chamber 38 may be configured as a replaceable container such as a hydrogen fuel cell. Alternatively, the collection chamber 38 may be configured as a receptacle for storing the replaceable container. In this embodiment, the collection chamber 38 is in fluid connection with the replaceable container, enabling it to collect the gaseous hydrogen produced by the hydrogen production device 14.

[0040] The hydrogen production device 14 may have the feed mechanism 26 mounted to the reaction chamber 16. This advantageously allows for the cartridge 12 to be fed directly into the reaction chamber 16 such that the cartridge 12 is optimally positioned with the target surface facing the incoming laser beam 22. Additionally, the feed mechanism 26 may substantially reduce the amount of contamination that can enter the internal environment of the reaction chamber 16. It would be appreciated by a person skilled in the art that the feed mechanism 26 may also be automated, such that it may automatically feed another cartridge 12 from a stack of cartridges when the current cartridge 12 is spent and the hydrogen production has ceased.

[0041] In an embodiment, the metalloid or metalloid alloy includes the following elements or compounds: silicon, ferrosilicon, carbon- silicon, calcium-silicon, aluminium silicon, magnum silicon, aluminium-ferrosilicon, or SiH containing materials. Examples of SiH containing materials include SiH chlorosilanes, alkoxysilanes and silicones.

[0042] In an embodiment, the content of the cartridge 12, being the metalloid or metalloid alloy and catalysts, are in a solid state, a powdered state or a liquid state. It would be appreciated by the person skilled in the art that the liquid state may be an emulsion or fluid state. [0043] In an embodiment, the reaction liquid 18 is water or a water-based solution of oxides, alkalis or salts. In another embodiment, the water-based solution of oxides, alkalis or salts comprises amines, primary or secondary alcohols, sea salt, sodium carbonate, magnum oxide, lime, sodium hydroxide, potassium hydroxide, calcium hydroxide, magnesium hydroxide, or their mixture.

[0044] In an embodiment, the catalysts are in a solid state, a powdered state or a liquid state. It would be appreciated by the person skilled in the art that the liquid state may be a solution in a liquid.

[0045] In a preferred embodiment, the hydrogen production device 14 may be configured with a plurality of modular sections to add or remove features. In an example, the laser 20 may be a separate module to the reaction chamber 16, allowing a user to mount it closer or further away from the reaction chamber 16 in the hydrogen production device 14.

[0046] In an embodiment, the hydrogen production system 14 may include a plurality of sensors for measuring hydrogen production parameters. These parameters may include the volume of hydrogen produced, the purity of the hydrogen produced, the level of reaction mixture, the chemical composition of the reaction mixture, and the charge of metalloid or metalloid alloy and catalyst in the cartridge 12.

[0047] In a further embodiment, the hydrogen production system 14 may include a microcontroller that is interfaced with the plurality of sensors and the components of the hydrogen production device 14. The microcontroller is programmed to monitor the measurements of the plurality of sensors and automatically adjust various parameters of the hydrogen production system 10 or enact a specific set of instructions. In an example, the microcontroller may be programmed to automatically load a cartridge 12 from the feed mechanism 26 into the reaction chamber 16 and dispense the reaction liquid 18 from the liquid reservoir 30 when it detects that the reaction chamber 16 is empty. In another example, the microcontroller may be programmed to automatically change the settings of the laser 20 upon detecting that the chemical composition of the reaction liquid 18 has changed due to the release of the contents of the cartridge 12 and subsequent mixing to form the reaction mixture. In this example, the microcontroller will alter the settings of the laser 20 to switch from parameters that enable thermal cutting of the target surface of the cartridge 12 to the heating of the reaction area that substantially surrounds the breach. In a further example, the microcontroller may be programmed to automatically discharge a spent cartridge 12 and the spent reaction mixture from the reaction chamber 16 after it detects the cessation of hydrogen production. In this example, the microcontroller may be further programmed to rinse the reaction chamber 16 with reaction liquid 18 from the liquid reservoir 30. It would be appreciated by the person skilled in the art, that the microcontroller may be further programmed to follow any other sets of instructions relating to the automated functioning of the hydrogen production system 10.

Method of Hydrogen Production

[0048] A method for hydrogen production initially comprises creating the cartridge 12 by storing the metalloid or the metalloid alloy and the catalyst in the receptacle. The cartridge 12 is subsequently fed into the reaction chamber 16 of the hydrogen production device 14. The cartridge 12 is immersed in a specific volume of reaction liquid 18 to ensure the correct stoichiometry for hydrogen production. The laser 20 is activated, emitting the laser beam 22 to thermally cut the target surface of the cartridge 12 to create a breach. Once the breach has occurred, the metalloid or metalloid alloy and the catalyst escapes from the cartridge 12 to mix with the reaction liquid creating the reaction mixture. The laser 20 is subsequently used to control the onset and rate of hydrogen production in the reaction mixture by a controlled heating of the reaction area substantially surrounding the breach. The controlled heating of the reaction area is facilitated by the altering of a set of parameters of the laser 20.

[0049] In an embodiment, the method for hydrogen production may further comprise the use of an ultrasound source 36. The ultrasound source 36 may be used, alongside the laser 20, to control the onset and rate of hydrogen production in the reaction mixture by the controlled heating of the reaction area. The controlled heating of the reaction area being facilitated by ultrasound acoustic vibration and/or by the removal of unwanted material from the target surface of the cartridge 12.

[0050] It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.