CN119343482A

CN119343482A - Design of new electrochemical reactor

Info

Publication number: CN119343482A
Application number: CN202380042474.XA
Authority: CN
Inventors: 斯图尔特·罗伯特·吉利克
Original assignee: Mesak Private LLC
Current assignee: Mesak Private LLC
Priority date: 2022-05-23
Filing date: 2023-04-25
Publication date: 2025-01-21
Also published as: WO2023227313A2; AU2023274258A1; EP4529574A2; WO2023227313A3

Abstract

The present invention relates to an electrochemical reactor, which includes at least one fuel inlet connected to a fuel chamber fluid located inside the electrochemical reactor, and at least one product outlet connected to a product chamber fluid located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein at least one electrochemical membrane is folded or printed in a spiral shape around an enhanced reactor chamber of the electrochemical reactor, and wherein at least one electrochemical membrane includes at least one high-temperature proton exchange membrane.

Description

Novel electrochemical reactor design

Field of the invention

The present invention relates to a novel electrochemical reactor design. In particular, the present invention relates to novel electrochemical membrane designs and arrangements for electrochemical reactors with or without a strengthening reactor (e.g., taylor-Couette reactor (TCR)), which can be surrounded by an electrochemical reactor having a specially designed electrochemical membrane mounted within, for example, an annular cylindrical box.

Background

The electrochemical reactor includes one or more electrochemical membranes within which are electrochemical cells that require a supply of electrical energy to initiate and maintain one or more chemical reactions to facilitate the function of the electrochemical reactor.

There are many types of electrochemical reactors, but they are all composed of an anode, a cathode, and an electrolyte that allows ions, typically positively charged hydrogen ions (H ⁺), to move between the sides of the electrochemical membrane. At the anode, the catalyst subjects the fuel to an oxidation reaction that produces ions (H ⁺) and electrons. Ions move from the anode to the cathode through the electrolyte. Meanwhile, electrons flow from the anode to the cathode, and an external circuit of the direct current power supply is completed.

In order to fully and successfully destroy the energy industry, conventional electrochemical reactors face various challenges because the capacity of electrochemical reactors, as well as their durability, effectiveness, and productivity, are difficult to increase.

Hence, an improved electrochemical reactor design would be advantageous and in particular a more efficient, reproducible, durable and/or reliable electrochemical reactor with increased lifetime and productivity would be advantageous.

Summary of The Invention

The object of the present invention is therefore a new electrochemical reactor design.

In particular, it is an object of the present invention to provide a new electrochemical reactor design which solves the above mentioned problems of the prior art with effectiveness, durability, reliability, lifetime and productivity, as well as lower maintenance and manufacturing costs.

Accordingly, one aspect of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane is folded or printed in a spiral shape, concentric shape, radial shape or disc shape around the fuel chamber of the electrochemical reactor.

A further aspect of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane is folded or printed in a spiral shape, a concentric shape, a radial shape or a disc shape around the fuel chamber of the electrochemical reactor, and wherein the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane.

Another aspect of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein fuel provided to the fuel chamber is moved substantially in a radial direction with respect to the longitudinal direction of the electrochemical membrane and/or wherein the product is moved substantially in a longitudinal direction of the electrochemical membrane.

A further aspect of the invention relates to a enhanced reactor (INTENSIFIED REACTOR), such as a Taylor-Couette reactor (TCR), comprising an energy unit and an enhanced reaction chamber surrounded by an electrochemical reactor jacket, the enhanced reaction chamber comprising at least one fuel inlet and at least one hydrogen outlet (H ₂ -outlet) for gasifying reaction products in fluid connection with a fuel chamber located inside the electrochemical reactor, wherein the electrochemical reaction chamber comprises an electrochemical membrane separating the at least one fuel inlet and the at least one hydrogen outlet.

Yet another aspect of the invention relates to a enhanced reactor, such as a Taylor-Couette reactor (TCR), comprising an energy unit and an enhanced reaction chamber surrounded by an electrochemical reactor jacket, said enhanced reaction chamber comprising at least one fuel inlet and at least one hydrogen outlet (H ₂ -outlet) for gasifying reaction products in fluid connection with a fuel chamber located inside the electrochemical reactor, wherein the electrochemical reaction chamber comprises an inner ring in which the enhanced reactor, such as a Taylor-Couette reactor (TCR), may be placed and an electrochemical membrane according to the invention.

Further aspects of the invention relate to an electrochemical reactor comprising an electrochemical membrane and at least one fuel inlet in fluid connection with a spiral flow path (6) and a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein fuel provided to the fuel chamber is moved substantially in a radial direction with respect to the longitudinal direction of the electrochemical membrane and/or wherein the product is moved substantially in a longitudinal direction of the electrochemical membrane, and wherein the at least one electrochemical membrane may be at least one high temperature proton exchange membrane.

A further aspect of the invention relates to the use of an electrochemical reactor according to the invention, with or without a strengthening reactor according to the invention, such as a Taylor-Couette reactor (TCR), for at least partially converting a hydrocarbon composition into a composition comprising hydrogen (H ₂).

A further aspect of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane.

Another aspect of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane comprises at least two layers, and wherein a gap between the at least two layers of the electrochemical membrane defines the product chamber.

A further aspect of the invention relates to a cartridge comprising one or more cartridge elements, wherein the one or more cartridge elements comprise an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane.

An even further aspect of the invention relates to a cartridge comprising one or more cartridge elements, wherein the one or more cartridge elements comprise an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane.

An even further aspect of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane comprises at least one corrugated layer, such as at least two corrugated layers, for example at least three corrugated layers, such as at least four corrugated layers, for example at least five corrugated layers, such as at least six corrugated layers.

Brief Description of Drawings

Figure 1 shows a spiral electrochemical membrane formed in a single spiral around a reinforced reactor (e.g. a Taylor-Couette reactor (TCR)) in accordance with the invention,

Figure 2 shows an electrochemical membrane comprising two corrugated layers and forming a fuel chamber and a product chamber,

FIG. 3 shows an electrochemical membrane comprising a corrugated layer and top and bottom non-corrugated layers with fuel chambers and flow paths above and below the top and bottom non-corrugated layers, product chambers between the non-corrugated layers, and

Fig. 4 shows an electrochemical membrane comprising two corrugated layers and a top non-corrugated layer and a bottom non-corrugated layer, with a fuel chamber and flow path above the top non-corrugated layer and below the bottom non-corrugated layer, and a product chamber between the non-corrugated layers,

Fig. 5 shows the same 4-layer electrochemical film as shown in fig. 4, further illustrating hot spots in the top non-corrugated layer.

Fig. 6 shows various archimedes' spiral structures suitable for use in the present invention, ranging from spiral structures comprising a single spiral to spiral structures comprising multiple simultaneous spirals originating from the same radius, such as 3 simultaneous spirals, to 7 spirals and 20 spiral structures.

Fig. 7 shows an example of a configuration of an electrochemical membrane formed around a reinforced reactor (e.g., taylor-Couette reactor (TCR)) in the center of a spiral.

Fig. 8 shows an example of a simultaneous 3D printing configuration of an electrochemical membrane surrounding a strengthening reactor (e.g., taylor-Couette reactor (TCR)) in the center of the spiral.

Fig. 9 shows an example of a cassette in the form of a radial star electrochemical reactor mounted around a central enhanced reactor, such as a Taylor-Couette reactor (TCR).

Fig. 10 shows an example of a cassette in the form of a disk electrochemical reactor mounted around a central enhanced reactor, such as a Taylor-Couette reactor (TCR).

The present invention will now be described in more detail below.

Detailed Description

The inventors of the present invention have discovered various methods to increase the surface area of the electrochemical membrane of the electrochemical reactor of the present invention, allowing for increased reactivity of the electrochemical membrane during use, increased productivity and increased durability and increased effectiveness.

Even further preferred embodiments of the present invention relate to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane is folded or printed in a spiral shape, concentric shape, radial shape or disc shape in a cassette mounted around a reinforced reactor chamber of the electrochemical reactor. The primary function of the electrochemical reactor according to the invention may be to act as an electrochemical hydrogen separator.

A further preferred embodiment of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane is folded or printed in a spiral shape, concentric shape, radial shape or disc shape in a cassette mounted around a reinforced reactor chamber of the electrochemical reactor, and wherein the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane.

In embodiments of the invention, the electrochemical membrane may have a circular cross-sectional area, a substantially circular cross-sectional area, or an elliptical cross-sectional area. Preferably, the cross-sectional area may be relative to the longitudinal direction of the electrochemical membrane.

Preferably, the circular cross-sectional area, the substantially circular cross-sectional area or the elliptical cross-sectional area of the electrochemical membrane may comprise an inner ring and an outer ring. The inner ring may be connected to the outer ring by a helical path, a concentric path, a radial path, or a complex path.

The electrochemical membrane may be folded or printed in a spiral shape, a concentric shape, a radial shape, or a disc shape in a cartridge mounted around a cross-sectional area of the enhanced reactor chamber of the electrochemical reactor.

Preferably, the spiral shape is an open-ended spiral shape. The open-ended helix may be a helix in which, when starting closest to the central location, the distance from the central location may increase for radial movement in the helix, preferably in a direction away from the starting location (from the inner ring).

The central portion of the spiral electrochemical membrane and the starting portion of the spiral electrochemical membrane may be the same or may be different. Preferably, the central portion of the spiral electrochemical membrane and the initial portion of the spiral electrochemical membrane may be different.

In embodiments of the invention, the fuel cells of the electrochemical reactor may be disposed in a spiral shape between overlapping spiral electrochemical membranes. Preferably, the spiral electrochemical membranes may overlap without touching.

Preferably, the spiral shape of the electrochemical membrane may be an archimedes spiral shape. An archimedean spiral can have the property that any straight line extending from the original point through the spiral structure can intersect a continuous turn of the spiral. The intersection of the successive turns of the helix may be provided at a location having a constant or substantially constant separation distance.

In embodiments of the invention, the electrochemical membrane may be provided with one or more non-conductive radial flow spacer bars to prevent the electrochemical membrane from contacting itself during electrical operation to avoid electrical shorting of the electrochemical process and also to provide a mechanically resilient flow path for any residual fuel (such as hydrocarbon composition) and gasification reaction products as they travel from the inner ring to the outer ring. Preferably, the spacer bars may be disposed circumferentially (at longitudinal intervals) along the spiral length of the electrochemical membrane.

The spiral may start at any radial distance from the central portion.

Preferably, the helix may be an archimedes helix.

To further increase the volumetric throughput of fuel and gasification gas in the electrochemical reactor, the number of flow paths for fuel and gasification gas may be increased. Multiple helices may be used, in particular archimedes helices may be suitable, with the helices starting at intervals of X degree arcs-depending on the number of helices included.

The use of multiple spirals can be used to reduce the measured length (per cross-sectional area) of each spiral and thereby reduce the residence time (per spiral) of the gas or fluid. Furthermore, the use of multiple spirals can increase gas or fluid rate throughput because each shorter spiral will produce lower pressure loss and provide multiple flow paths, increasing the total flow cross-sectional area.

In embodiments of the invention, the radial length of the electrochemical membrane may preferably be greater than the longitudinal length of the electrochemical membrane. Preferably, the radial length of the electrochemical membrane may be at least 10% greater than the longitudinal length of the electrochemical membrane, such as at least 25% greater, for example at least 50% greater, such as at least 75% greater, for example at least 100% greater, such as at least 150% greater, for example at least 200% greater, such as at least 250% greater, for example at least 300% greater, such as at least 400% greater, for example at least 500% greater, such as at least 600% greater, for example at least 700% greater. One flow path may relate to the distance that fuel and/or gasification reaction products move from the inner ring to the outer ring along a spiral flow path between and defined by the electrochemical membrane surfaces.

In embodiments of the invention, the spiral electrochemical membrane may comprise a single spiral electrochemical membrane or multiple spirals of electrochemical membranes. Preferably, the plurality of electrochemical membrane helices may comprise 2 helices, such as 3 helices, for example 5 helices, such as 7 helices, for example 10 helices, such as 15 helices, for example 20 helices.

The fuel chamber may provide radial flow of fuel relative to the longitudinal direction of the electrochemical membrane. Preferably, the fuel and gasification reaction products entering the electrochemical reactor and the electrochemical membrane flow path may move in a radial direction, preferably follow and be defined by a spiral electrochemical membrane, and move from an inner ring of the electrochemical reactor adjacent to an enhanced reactor (e.g., a Taylor-Couette reactor (TCR)) to an outer ring of the electrochemical reactor.

In the electrochemical reactor according to the invention, the fuel chamber may be mounted in a spiral shape, concentric shape, radial shape or disk shape around the inner ring of the electrochemical reactor, preferably guided and delimited by at least one electrochemical membrane.

In an embodiment of the present invention, an electrochemical reactor includes:

(i) An electrochemical membrane folded in a spiral shape, a concentric shape, a radial shape, or a disk shape around an inner ring of the electrochemical reactor;

And

(Ii) A fuel chamber mounted in a spiral shape, a concentric shape, a radial shape, or a disk shape around an inner ring of the electrochemical reactor.

In further embodiments of the invention, the spaces between successive electrochemical membranes of the spiral-shaped, concentric-shaped, radial-shaped or disk-shaped electrochemical membranes may constitute a fuel chamber and a flow path for residual fuel and reaction products.

By providing these spiral, concentric, radial, or disk shaped structural paths, radial flow continuity of, for example, residual fuel and/or gasification reaction products from the inner ring to the outer ring of the electrochemical membrane may be provided, resulting in improved separation, conversion, and productivity.

The electrochemical membrane may comprise a spiral-shaped, concentric-shaped, radial-shaped or disk-shaped electrochemical membrane, wherein fuel introduced into the fuel inlet and/or formed gasification reaction products move along the membrane surfaces of these shapes from the inner ring to the outer ring. Preferably, the movement of the fuel and/or the formed gasification reaction products may be in a radial direction with respect to the longitudinal direction of the electrochemical membrane.

During this movement along the electrochemical membrane from the inner ring to the outer ring, the concentration of gasification reaction products may increase and the concentration of added fuel may decrease, as the fuel may be converted to gasification reaction products and the resulting products may be removed and transferred into the product chamber.

In embodiments of the present invention, the gasification reaction product may be a gasification reaction product gas. The gasification reaction product gas may be in supercritical fluid phase conditions.

In a further embodiment of the invention, the product collected in the product chamber may be moved in the longitudinal direction of the electrochemical membrane to the product outlet.

Preferably, the movement of the fuel and/or the formed gasification reaction products may be in a radial direction with respect to the longitudinal direction of the electrochemical membrane, and the products collected in the product chamber may be moved in the longitudinal direction of the electrochemical membrane to the product outlet.

In embodiments of the invention, the spiral-shaped, concentric-shaped, radial-shaped, or disk-shaped electrochemical membrane may have a length that extends through the entire length or a portion of the length (both longitudinal and radial) of the fuel chamber of the electrochemical reactor.

The electrochemical reactor according to the invention may comprise a waste material outlet.

The waste outlet may be fluidly connected to an outer ring of the electrochemical membrane.

Preferably, the waste material may include water, contaminants, unconverted hydrocarbons, methane (CH ₄), carbon dioxide (CO ₂), carbon monoxide (CO), and the like.

Electrochemical membranes according to the invention may allow the transport of molecules, atoms and/or ions from the fuel chamber to the product chamber.

In an embodiment of the invention, the electrochemical membrane according to the invention may allow the transport of hydrogen ions (H ⁺) from the hydrogen donor in the fuel chamber to form hydrogen gas (H ₂) in the product chamber. The hydrogen ions may be separated from the hydrogen donor in the fuel chamber at the anode. The hydrogen ions (H ⁺) may then be transported through the electrolyte, and at the cathode on the product chamber within the electrochemical membrane, the hydrogen ions (H ⁺) accept electrons to form hydrogen atoms, which may then be allowed to combine with another hydrogen atom to form hydrogen gas (H ₂), which may be trapped in the product chamber.

Preferably, the spiral membrane may be in the form of an archimedes spiral.

In an embodiment of the invention, the electrochemical membrane may be provided with an anode, which may preferably face the fuel chamber.

In a further embodiment of the invention, the electrochemical membrane may be provided with a cathode, preferably the cathode may face the product chamber.

An electrochemical membrane according to the invention may comprise two or more electrochemical cells, wherein the one or more electrochemical cells are formed in a corrugated shaped layer to create and contain a plurality of parallel product and/or fuel chambers. The corrugated layer provided with several anodes may face the fuel chamber and the cathode may face the product chamber. The opposite arrangement is also possible.

The at least one electrochemical membrane may include an anode and a cathode. Preferably, the at least one electrochemical membrane may comprise an electrolyte.

In an embodiment of the invention, the electrochemical membrane may be a proton-conducting electrochemical membrane.

Electrochemical membranes with proton conductivity may involve the transport of an acidic electrolyte, such as (H ⁺), through an electrochemical electrolyte disposed between two porous electrodes and formed, for example, from a proton conducting metal oxide layer.

In the electrochemical reactor according to the invention, hydrogen (H ₂) can be oxidized at the anode side of the electrochemical membrane, hydrogen (H ₂) can be oxidized to protons (H ⁺), which protons (H ⁺) then conduct through the electrolyte until they eventually recombine with electrons to reform hydrogen atoms and recombine with other hydrogen atoms to produce hydrogen gas at the cathode (H ₂).

Protons (H ⁺) must move through the electrolyte, and thus electrochemical membrane materials having a major proton conductivity at high temperatures may be required as electrolytes.

Preferably, the electrochemical membrane and electrolyte according to the invention may have a high redox stability, preferably accompanied by a high mechanical and thermal stability and a high durability and optimal operation.

The electrochemical reactors and structures provided in accordance with the present invention can provide an efficient method of producing high purity hydrogen for various applications from one or more hydrocarbons (e.g., CH ₄) while capturing greenhouse gases (e.g., CO ₂ and/or CO), which can be identified as having major environmental and climate-related benefits.

The reaction of fuel may include several stages:

Stage I may include the partial oxidation of fossil fuels (e.g., hydrocarbons, methane, natural gas, biogas, shale gas, or gasified coal), such as with CO ₂, air, or H ₂ O, to produce synthesis gas (CO, CO ₂, and H ₂);

Stage II may include a Water Gas Shift Reaction (WGSR) to convert carbon monoxide (CO) from the synthesis gas to carbon dioxide (CO ₂) and more hydrogen (H ₂) via water (H ₂ O);

Stage III may comprise electrochemical separation of CO ₂/H₂ by means of an electrochemical membrane according to the invention, for example a mixed proton-electron conducting (MPEC) membrane.

In embodiments of the present invention, electrochemical membrane materials having mixed proton-electron conductivity and significant chemical stability under reducing and hydrothermal conditions may be preferred.

In further embodiments of the invention, the at least one electrochemical membrane between the fuel and/or product chambers may comprise at least one layer, wherein the at least one layer may be a corrugated layer.

By providing an electrochemical membrane comprising at least one corrugated layer, the surface area available for allowing the transport of molecules, atoms and/or ions from the fuel chamber to the product chamber may be increased, resulting in improved utilization and/or productivity of the electrochemical membrane and the electrochemical reactor. The addition of further enhanced continuous strips of anode and cathode along each of the corrugated lands can reduce hot spots by helping to maintain a uniformly distributed current density within the electrochemical layer.

The corrugated layer according to the present invention may comprise one or two outer layers, and a plurality of grooves creating a corrugated structure. In a corrugated layer of the multilayer type, one or more intermediate layers may be interposed between, for example, the grooves of two layers. The effect of the corrugated layer may depend on the number of outer layers/intermediate layers and the number of grooves.

By increasing the number of intermediate layers, stacked cells may be provided, resulting in increased structural integrity and durability of the electrochemical membrane. Instead of (or in addition to) adding one or more intermediate layers in the electrochemical membrane, two, for example, single-sided corrugated layers may be put together with the contact sites at the grooves or at least parts of the grooves of the corrugated layers.

The corrugated layer, which includes a single face, includes a fluted layer attached to a fuel-or gas-permeable material or a material similar to the electrochemical membrane used in the corrugated layer.

The size of the grooves of the corrugated layer may be as small as possible to provide as large a cumulative surface area as possible, but not so small as to potentially prevent or hinder access to the fuel material.

Preferably, the grooves of the corrugated layer may have a size (height) in the range of 0.5mm-10mm, such as in the range of 1mm-8mm, for example in the range of 1.5mm-6mm, such as in the range of 2mm-5mm, for example in the range of 3mm-4 mm.

In embodiments of the present invention, the electrochemical membrane may include a single corrugated layer, a double corrugated layer, a triple corrugated layer, a quad corrugated layer. The corrugated layers may be provided with more than four layers, however, the number of corrugated layers may be set according to the use, desired durability, application and accessibility of the electrochemical reactor.

In a preferred embodiment of the present invention, the layers of the electrochemical membrane may include an anode, an electrolyte, and a cathode.

Increasing the number of corrugated layers of the electrochemical membrane may also provide higher rigidity, higher mechanical strength, and thus reduced risk of mechanical damage to the electrochemical membrane and the electrochemical reactor. This may also reduce the risk of product production loss and increase productivity through increased electrochemical membrane life.

The grooves may be provided in different shapes. In embodiments, the grooves of the corrugated layer may be wavy, zigzag, circular, or crenellated.

When the electrochemical membrane comprises 2 or more layers, at least one layer may be corrugated.

In an embodiment of the invention, the electrochemical membrane comprises a two-layer structure. Preferably, the two-layer structure comprises two corrugated layers of the electrochemical membrane.

In yet another embodiment of the invention, the electrochemical membrane comprises a three-layer structure. The three-layer structure may comprise at least one corrugated layer, such as at least two corrugated layers, e.g. three corrugated layers. In order to save space in the electrochemical membrane, it may be preferred that the three-layer structure may comprise one corrugated layer and two straight or substantially straight layers in either side of the corrugated layer. This will also provide built-in operational redundancy (build-in operational redundancy) for the product chambers of one layer in one direction.

In a further embodiment of the invention, the electrochemical membrane comprises a four layer structure. The four-layer structure may comprise at least two corrugated layers, such as at least three corrugated layers, for example four corrugated layers. Preferably, the four-layer structure may comprise two corrugated layers facing each other and combined at the top of the groove, and two straight or substantially straight layers on either side of the two corrugated layers. This may also provide built-in operational redundancy for the product chambers of one layer in both directions.

When two corrugated layers are facing and combined with each other, the two corrugated layers may be separated by a product permeable element.

One advantage of having three or more layers in an electrochemical membrane, such as four or more layers in a membrane, may be that such an electrochemical membrane may provide built-in operational redundancy for the product chamber and result in a significant reduction in vulnerability to collateral damage due to the formation of hot spot holes or scales (tares) in the electrochemical membrane (e.g., due to localized thermal damage on the electrochemical membrane). These hot spots may result in mixing of the fuel and the product, whereby the product stream may be contaminated. Increased mechanical stability, durability, and reliability all extend life and reduce replacement frequency, and reduce overall operating costs.

A preferred embodiment of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane.

A further preferred embodiment of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane comprises at least two layers, and wherein a gap between the at least two layers of the electrochemical membrane defines the product chamber.

A further preferred embodiment of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane comprises at least one corrugated layer, such as at least two corrugated layers, for example at least three corrugated layers, such as at least four corrugated layers, for example at least five corrugated layers, such as at least six corrugated layers.

In embodiments of the invention, at least one electrochemical membrane may be folded or printed in a spiral shape, concentric shape, radial shape, or disk shape in a cassette surrounding the enhanced reactor chamber.

In further embodiments of the invention, the at least one electrochemical membrane may comprise at least two layers, and wherein a gap between the at least two layers of the at least one electrochemical membrane defines a product chamber.

Preferably, the at least two layers may include a contact site combining the at least two layers in a portion of the at least one electrochemical membrane.

The product chamber may be defined by a gap between at least two layers of the at least one electrochemical membrane and between contact sites combining the at least two layers in a portion of the at least one electrochemical membrane.

In yet another embodiment of the invention, the at least one electrochemical membrane may comprise at least one corrugated layer, such as at least two corrugated layers, for example at least three corrugated layers, such as at least four corrugated layers, for example at least five corrugated layers, such as at least six corrugated layers.

In embodiments of the invention, the center of the electrochemical reactor may include a strengthening reactor or portion thereof, such as a Taylor-Couette reactor (TCR) or portion thereof.

The electrochemical reactor and the enhanced reactor (e.g., taylor-Couette reactor (TCR)) may preferably be two separate items that may be combined by including the enhanced reactor (e.g., taylor-Couette reactor (TCR)) within the electrochemical reactor (preferably in the center of the electrochemical reactor) to improve hydrogen production.

Preferably, the center of the electrochemical reactor comprises a Taylor-Couette reactor (TCR) or a portion thereof.

A portion of the enhanced reactor (e.g., taylor-Couette reactor (TCR)) may relate to a rotating central portion of the enhanced reactor (e.g., taylor-Couette reactor (TCR)), which may be a portion that generates a stream of the enhanced reactor (e.g., taylor-Couette reactor (TCR)) in fuel provided in the fuel chamber.

Preferably, the electrochemical reactor comprises a core portion comprising a strengthening reactor, such as a Taylor-Couette reactor (TCR). The enhanced reactor, such as a Taylor-Couette reactor (TCR), may be surrounded by a fuel chamber. The fuel chamber may be surrounded by one or more electrochemical membranes according to the invention. The one or more electrochemical membranes according to the invention may each comprise a product chamber, or two or more product chambers may be formed from at least two layers within each electrochemical membrane. The enhanced reactor (e.g., taylor-Couette reactor (TCR)), the fuel chamber, the one or more electrochemical membranes, and the product chamber may be surrounded by a housing that holds and protects an active portion (ACTIVE PART) of the electrochemical reactor.

A booster reactor (e.g., a Taylor-Couette reactor (TCR)) may be fluidly connected to the inner annulus of the electrochemical membrane and/or in fluid contact with the fuel chamber of the electrochemical membrane.

In a preferred embodiment, the present invention relates to an electrochemical reactor comprising a intensification reactor, such as a Taylor-Couette reactor (TCR), and an electrochemical membrane according to the invention.

Electrochemical reactors according to the invention, with or without (preferably with) a strengthening reactor, such as a Taylor-Couette reactor (TCR), may preferably be adapted to convert fuel, such as hydrocarbon compositions with or without carbon dioxide (CO ₂), into compositions comprising hydrogen (H ₂).

Preferably, at least a partial conversion of fuel to hydrogen (H ₂) or the means for performing gasification may be accomplished with a strengthening reactor, such as a Taylor-Couette reactor (TCR), which is arranged in the centre of the electrochemical membrane according to the invention.

The Taylor-Couette reactor (TCR) may be a device that has been designed to utilize Taylor-Couette flow, which allows many flow states and conditions to occur and chemical conversions with precise control of a variety of reactor characteristics.

A finishing reactor, such as a Taylor-Couette reactor (TCR), may consist of a cassette shell into which a first (rotating) inner cylinder may be inserted so that a first annular gap may be formed.

The cartridge housing may contain one or more electrochemical membranes of the present invention.

A preferred embodiment of the invention relates to a intensification reactor, for example a Taylor-Couette reactor (TCR), comprising an energy unit and an intensification reaction chamber enclosed by an electrochemical reactor shell, which intensification reaction chamber comprises at least one fuel inlet and at least one hydrogen outlet (H ₂ -outlet), for example at least one hydrogen outlet (H ₂ -outlet) for gasifying reaction products, which is in fluid connection with a fuel chamber located inside the electrochemical reactor, wherein the electrochemical reaction chamber comprises an electrochemical membrane according to the invention.

Another preferred embodiment of the invention relates to a enhanced reactor, such as a Taylor-Couette reactor (TCR), comprising an energy unit and an enhanced reaction chamber surrounded by an electrochemical reactor shell, said enhanced reaction chamber comprising at least one fuel inlet and at least one hydrogen outlet (H ₂ -outlet), such as at least one hydrogen outlet (H ₂ -outlet) for gasifying reaction products in fluid connection with a fuel chamber located inside the electrochemical reactor, wherein the electrochemical reaction chamber comprises an electrochemical membrane separating the at least one fuel inlet and the at least one hydrogen outlet.

The electrochemical reactor may preferably comprise at least one waste material outlet, in particular at least one carbon dioxide outlet (CO ₂ -outlet) for residual fuel and gasification reaction products.

A preferred embodiment of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel provided to the fuel chamber is moved substantially in a radial direction with respect to the longitudinal direction of the electrochemical reactor and/or wherein the product is moved substantially in a longitudinal direction of the electrochemical reactor.

Further preferred embodiments of the invention relate to an electrochemical reactor comprising an electrochemical membrane and at least one fuel inlet in fluid connection with a spiral flow path (6) and a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel provided to the fuel chamber is moved substantially in a radial direction with respect to the longitudinal direction of the electrochemical membrane and/or wherein the product is moved substantially in the longitudinal direction of the electrochemical membrane, and wherein the at least one electrochemical membrane may be at least one high temperature proton exchange membrane.

Preferably, the fuel chamber and the product chamber may be separated by at least one electrochemical membrane.

In embodiments of the present invention, the substantially radial direction may be substantially perpendicular to the substantially longitudinal direction.

The terms "substantially in a radial direction" and/or "substantially in a longitudinal direction" refer to movement directed primarily in a radial direction or longitudinal direction, respectively, but may include longitudinal helical rotation of the radial flow spacer bars to extend the flow path helical for improved fuel contact/residence time.

Preferably, "substantially radial direction", a "substantially vertical direction" and/or "substantially longitudinal direction" may deviate from the radial direction, the vertical direction and/or the longitudinal direction by at most 20%, such as at most 15%, e.g. by at most 10%, e.g. by at most 5%, e.g. by at most 2%, e.g. by at most 1%.

Preferably, the fuel is a hydrocarbon composition. The hydrocarbon composition may comprise hydrocarbon liquids or gases, such as methane (CH ₄), biogas, water (H ₂ O), carbon dioxide (CO ₂), carbon monoxide (CO), and contaminants.

In the context of the present invention, the term "radial" relates to movement along a radius from the center of the electrochemical reactor at a distance that may increase as the fuel (or gasification reaction products) moves from the inner ring of the electrochemical membrane to the outer ring of the electrochemical membrane (e.g., in a spiral direction, concentric direction, or radial direction).

Preferably, the product disposed in the product chamber and received at the product outlet may be hydrogen (H ₂).

A preferred embodiment of the invention relates to the use of the cartridge according to the invention, with or without a strengthening reactor, such as a Taylor-Couette reactor (TCR) according to the invention, for at least partially converting a hydrocarbon composition into a composition comprising hydrogen (H ₂).

Hydrocarbon compositions obtained from subterranean reservoirs (or introduced at the surface; as in geothermal well options) can be fuels according to the present invention, and it is a well-known worldwide interest to reduce or even avoid the emission of these powerful greenhouse gas components and reaction products from these fuels, such as carbon dioxide (CO ₂) and methane (CH ₄), to the atmosphere, reducing serious environmental problems and impact on global warming.

It is therefore of interest to find more environmentally friendly alternative energy sources or alternative utilisation of existing energy sources, such as fuel or hydrocarbon compositions, in a more climatically favourable way. Enhanced reactors according to the invention, such as Taylor-Couette reactors (TCRs) and electrochemical membranes, are solutions for such improved utilization, wherein the energy source may be provided in the form of a fully or partially hydrogen-enriched (H ₂) composition which may be produced in an efficient, productive and environmentally friendly and climate-friendly manner.

The enhanced reactor according to the present invention may preferably be a Taylor-Couette reactor (TCR).

In an embodiment of the invention, the enhanced reactor chamber of the electrochemical reactor may further comprise at least one water inlet (H ₂ O-inlet) and/or at least one air inlet (O ₂ -inlet). When an electrochemical reactor with or without a strengthening reactor, such as a Taylor-Couette reactor (TCR), may be used to inject carbon dioxide (CO ₂) into the reservoir, at least one water inlet (H ₂ O-inlet) and/or at least one air inlet (O ₂ -inlet) may preferably be present. This can lead to further energy production, in particular hydrogen (H ₂), by:

Boudouard reaction in which a hydrocarbon feed and carbon dioxide (CO ₂) are reacted to provide a carbon monoxide source other than hydrogen, and/or

Autothermal reforming (ATR), in which synthesis gas (comprising hydrogen (H ₂) and carbon monoxide (CO)) can be produced by partial oxidation of a hydrocarbon feed, such as methane (CH ₄) or biogas, with carbon dioxide (CO ₂) and/or water (H ₂ O) and/or oxygen, and/or

Steam Methane Reforming (SMR), in which synthesis gas (comprising hydrogen (H ₂) and carbon monoxide (CO)) can be produced by reaction of hydrocarbons with water (H ₂ O), and/or

-A Water Gas Shift Reaction (WGSR) in which carbon monoxide (CO) is converted via a reaction with water (H ₂ O) to provide hydrogen (H ₂).

The at least one product outlet may be at least one hydrogen outlet (H ₂ -outlet).

The electrochemical reactor according to the invention may comprise at least one carbon dioxide outlet (CO ₂ -outlet) in addition to at least one hydrogen outlet (H ₂ -outlet). It was found that the CO ₂ -outlet could be connected to the outer ring of the electrochemical membrane and could also be considered a valuable (e.g. carbon credit) product.

Preferably, at least one hydrogen outlet (H ₂ -outlet) can be separated from at least one fuel inlet and/or at least one carbon dioxide outlet (CO ₂ -outlet) by an electrochemical membrane according to the invention.

In embodiments of the present invention, at least one electrochemical membrane may separate hydrogen (H ₂) from the hydrocarbon composition, nitrogen, carbon monoxide, water, and/or carbon dioxide mixture by an electrochemical separation process. The electrochemical separation process may apply an electrical current to at least one electrochemical membrane and hydrogen may be electrochemically dissociated over a catalyst of the anode, transported through the hydrated proton exchange material, and then recovered over the catalytic cathode.

The membrane (electrochemical membrane) according to the invention may be a proton exchange membrane.

In the context of this document, the terms "electrochemical membrane" and "membrane" may be used interchangeably.

In a further embodiment of the invention, at least one electrochemical membrane according to the invention may comprise at least one proton exchange material.

Preferably, the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane described herein.

In embodiments of the invention, the high temperature exchange membrane may be operated, possibly be capable of being operated, may be suitable for operation, at a temperature above 100 ℃, such as above 200 ℃, for example above 300 ℃, such as above 400 ℃, for example above 500 ℃, such as above 600 ℃, for example above 700 ℃, such as above 800 ℃, for example above 900 ℃, such as above 1000 ℃, for example above 1100 ℃, such as above 1200 ℃, for example in the range of 100 ℃ to 1200 ℃, for example in the range of 500 ℃ to 1000 ℃, such as in the range of 650 ℃ to 850 ℃, such as in the range of 675 ℃ to 800 ℃, for example in the range of 700 ℃ to 750 ℃.

The proton exchange membrane may be a solid oxide proton exchange membrane. Preferably, the proton exchange membrane may be a high temperature solid oxide proton exchange membrane.

The at least one proton exchange material may be selected from the group consisting of an Electrochemical Hydrogen Separator (EHS), a Proton Ceramic Electrochemical Cell (PCEC), a solid oxide cell (SOEC), a mixed solid oxide cell (H-SOEC), a Proton Exchange Membrane (PEM), or a combination thereof.

A fuel, such as a hydrocarbon composition, preferably in combination with water, may be transported from at least one fuel inlet into a fuel chamber where the hydrocarbon composition (along with optional, externally sourced, surface injected carbon dioxide CO ₂) may be converted to different reaction products, including hydrogen (H ₂). The hydrogen gas (H ₂) produced can then be electrochemically transferred through at least one electrochemical membrane, preferably a proton exchange material, to the hydrogen outlet (H ₂ -outlet) of the electrochemical reactor.

Various reactions can occur in the fuel chamber and the enhanced reactor chamber, and in particular gasification of the incoming hydrocarbon composition can preferably be provided, resulting in the formation of hydrogen (H ₂). The hydrogen gas (H ₂) produced can then be transferred electrochemically through at least one electrochemical membrane to at least one product outlet, such as a hydrogen outlet (H ₂ -outlet).

It may be desirable to supply energy to an enhanced reactor, such as a Taylor-Couette reactor (TCR), to provide the necessary rotation of the central element to produce, for example, a Taylor-Couette stream, an ignition source for the reaction to provide the minimum activation energy required to initiate the chemical reaction (after which the net exothermic reaction may self-propagate within the reactor), and to promote the electrolytic reaction in the electrochemical reactor, if desired. The applied energy may come entirely or partially from the geological environment or the chemical reaction itself or mechanically, for example via heat transfer within the tool, a heat recovery system (HERS), a turbo-expander, a turbo-generator, etc., or a combination of the above. However, to provide and ensure sufficient energy to the enhanced reactor (e.g., taylor-Couette reactor (TCR)) and electrochemical membrane, energy may be provided from an external source via cable or fluid injection, if desired. The external source may preferably be obtained from wind energy, solar energy and the like.

In an embodiment of the invention, the electrochemical reactor may comprise means for supplying energy or power to the electrochemical reactor.

In further embodiments of the invention, the electrochemical reactor may comprise means for connecting a cable.

The cable may at least initially provide power and energy for starting and/or operating processes, such as gasification and electrochemical processes. During operation, the process may generate enough power and energy to support the process, and it may become unnecessary to supply power and energy, and the process may even generate excess energy that may be output to the surface.

Without being bound by theory, it is believed that the pressure and/or temperature in the underground operation of the electrochemical reactor according to the invention may contribute so much energy to the process that excess energy may be formed, which may then be output.

The cable may also provide means for outputting energy if/when the electrochemical reactor is providing excess energy.

A preferred embodiment of the present invention relates to a system for recovering a composition comprising hydrogen (H ₂) with fluids or gases from a subterranean reservoir, the system comprising a processing unit (processing rig) comprising an electrochemical reactor with/without a strengthening reactor, the electrochemical reactor at least partially converting a hydrocarbon composition into a composition comprising hydrogen (H ₂), wherein the system further comprises a unit for separating hydrogen from the reaction products and providing Carbon Capture Utilization and Storage (CCUS) of CO ₂.

In the context of this document, the term "treatment device" may refer to a collection of surface and downhole equipment that receives a hydrocarbon composition flow stream (from the surface or geological reservoir) into a wellbore and CO ₂ from an external source at the surface. The surface equipment may include processes that facilitate separation (of components), chemical or physical treatment, compression or additional pumping of the hydrocarbon composition and its components for storage, further treatment or export and sale.

The electrochemical reactor of the present invention may be used at the surface or in a wellbore. Preferably, the reactor may be used in a wellbore.

In embodiments of the invention, the electrochemical reactor may be placed within a wellbore at a vertical depth substantially equal to the hydrocarbon reservoir or geothermal reservoir, wherein the exhaust of the reactor (e.g., the exhaust of CO ₂) may be pumped into the hydrocarbon reservoir or geothermal reservoir.

Preferably, the carbon dioxide captured by the means for providing carbon capture of CO ₂ (CO ₂) may comprise CO ₂ naturally occurring in the hydrocarbon composition or CO ₂ produced by at least partially converting the hydrocarbon composition into a composition comprising hydrogen (H ₂), and/or CO ₂ introduced from an external source and injected from the surface.

In embodiments of the present invention, carbon dioxide (CO ₂) captured according to the present invention (from a hydrocarbon composition, hydrocarbon converted to hydrogen and/or introduced from an external source and injected from the surface) may also comprise carbon monoxide (CO).

Preferably, the composition comprising hydrogen (H ₂) may be an organic composition comprising hydrogen (H ₂).

According to the invention, a fuel, such as a hydrocarbon composition, may be at least partially converted to a composition comprising hydrogen (H ₂). The term "at least partially" may relate to a hydrocarbon composition that may be converted to a composition comprising hydrogen (H ₂), e.g. at least 5% (w/w) hydrocarbon composition may be converted to a composition comprising hydrogen (H ₂), such as at least 10% (w/w) hydrocarbon composition, e.g. 20% (w/w) hydrocarbon composition, such as at least 30% (w/w) hydrocarbon composition, e.g. 40% (w/w) hydrocarbon composition, such as at least 50% (w/w) hydrocarbon composition, e.g. 60% (w/w) hydrocarbon composition, such as at least 70% (w/w) hydrocarbon composition, e.g. 80% (w/w) hydrocarbon composition, such as at least 90% (w/w) hydrocarbon composition, e.g. 95% (w/w) hydrocarbon composition, such as at least 97% (w/w) hydrocarbon composition, e.g. 99% (w/w) hydrocarbon composition may be converted to a composition comprising hydrogen (H ₂).

The effect of an electrochemical membrane with or without (preferably with) a strengthening reactor according to the invention, such as a Taylor-Couette reactor (TCR), may be enhanced by:

-geothermal heating alone (in underground treatment);

Geothermal heating in combination with heat pumps and/or heat exchangers (treatment in the subsurface, on the ground or above ground), or

Geothermal heating in combination with electric heating (either in subsurface treatment or in surface or superficially treatment);

-introducing a catalyst material;

-individual geological pore pressures (in subsurface treatments);

combinations of geologic pore pressure with the above listed temperatures, or

-Externally supplied, surface injected carbon monoxide (CO) and/or carbon dioxide (CO ₂);

-improved electrolyte chemistry within the electrochemical membrane layer of the electrochemical reactor;

-a Heat Energy Recovery System (HERS), a cogeneration system (CHP), a turbo-expander, a turbo-generator or the like.

Preferably, the reactor according to the invention is operated under underground conditions.

Preferably, the reactor may at least partially convert the hydrocarbon composition to a composition comprising hydrogen (H ₂).

The electrochemical reactor according to the invention, preferably with a strengthening reactor, such as a Taylor-Couette reactor (TCR), may comprise means for injecting, for example, carbon monoxide (CO) and/or carbon dioxide (CO ₂) into the reservoir. Carbon monoxide (CO) and/or carbon dioxide (CO ₂) injection into a subterranean reservoir may be performed via:

The same well as the well used for obtaining hydrogen (H ₂), and/or

A well different from the well for obtaining hydrogen (H ₂), but in fluid communication with the well for obtaining hydrogen (H ₂), or

-A well into the reservoir, wherein hydrogen (H ₂) is no longer produced or has been produced.

Preferably, the carbon monoxide (CO) and/or carbon dioxide (CO) ₂ subjected to carbon capture may be carbon monoxide (CO) and/or carbon dioxide (CO ₂) produced by a device for at least partially converting a hydrocarbon composition to a composition comprising hydrogen (H ₂).

In embodiments of the invention, carbon monoxide (CO) and/or carbon dioxide (CO) ₂ may be contained in the hydrocarbon composition and may also be provided from an external source or may be a combination of carbon monoxide (CO) and/or carbon dioxide (CO ₂) from an external source with carbon monoxide (CO) and/or carbon dioxide (CO ₂) produced by a device for at least partially converting a hydrocarbon composition to a composition comprising hydrogen (H ₂).

Preferably, a composition comprising hydrogen (H ₂) may be obtained from the product outlet and may be enriched in (H ₂).

In an embodiment of the invention, the composition comprising hydrogen (H ₂) comprises at least 1% (w/w) hydrogen (H ₂), for example at least 5% (w/w) hydrogen (H ₂), such as at least 10% (w/w), for example at least 15% (w/w), such as at least 20% (w/w), for example at least 25% (w/w), such as at least 30% (w/w), for example at least 40% (w/w), such as at least 50% (w/w), for example at least 60% (w/w), such as at least 70% (w/w), for example at least 80% (w/w), such as at least 85% (w/w), for example at least 90% (w/w), such as at least 95% (w/w), for example at least 98% (w/w) hydrogen (H ₂).

In embodiments of the invention, the reservoir may comprise water, and the water may be formed during at least partial conversion of the hydrocarbon composition to a composition comprising hydrogen (H ₂).

Electrolysis according to the present invention may also occur in combination with elevated subsurface temperatures and pressures to improve at least partial conversion of fuel (e.g., hydrocarbon composition) to a composition comprising hydrogen (H ₂).

Preferably, the electrochemical reactor according to the invention, with or without a strengthening reactor, may be placed at least 100 meters TVD underground, such as at least 150 meters TVD underground, for example at least 250 meters TVD underground, such as at least 500 meters TVD underground, for example at least 750 meters TVD underground, such as at least 1000 meters TVD underground, for example at least 1500 meters TVD underground, such as at least 2000 meters TVD underground, for example at least 2500 meters TVD underground, such as at least 5000 meters TVD underground, for example at least 7500 meters TVD underground, such as at least 10,000 meters TVD underground, for example at least 12,500 meters TVD underground, such as at least 15,000 meters TVD underground.

In embodiments of the invention, the electrochemical reactor with or without the strengthening reactor may be at least 100 meters below the treatment device, such as at least 150 meters below the treatment device, e.g. at least 250 meters below the treatment device, such as at least 500 meters TVD below the treatment device, e.g. at least 750 meters TVD below the treatment device, such as at least 1000 meters TVD below the treatment device, e.g. at least 1500 meters TVD below the treatment device, such as at least 2000 meters TVD below the treatment device, e.g. at least 2500 meters TVD below the treatment device, such as at least 5000 meters TVD below the treatment device, e.g. at least 7500 meters TVD below the treatment device, such as at least 10,000 meters TVD below the treatment device, e.g. at least 12,500 meters TVD below the treatment device, such as at least 15,000 meters TVD below the treatment device.

Carbon capture according to the present invention may involve a process of capturing carbon monoxide (CO) and/or carbon dioxide (CO) that is initially present in a hydrocarbon composition or that is produced during conversion of the hydrocarbon composition (or a portion thereof) to a hydrogen composition before it enters the atmosphere (CO ₂).

Carbon capture may include carbon monoxide (CO) and/or carbon dioxide (CO ₂) also provided from externally supplied sources, where carbon monoxide (CO) and/or carbon dioxide (CO ₂) may not originate from a reservoir or hydrocarbon composition, but may be provided from above surface, such as from the atmosphere, through above-surface carbon capture, or from any external CO ₂ market source or industrial supply.

Operationally or commercially, it may be advantageous to inject the waste gas (e.g., CO ₂ or CO) into adjacent geological reservoirs or formations (or vertically below or above hydrocarbon reservoirs) within the same or different well or wellbore.

The electrochemical reactor according to the invention may be used in geothermal processes wherein the hydrocarbon composition may be injected from the surface.

Preferably, carbon monoxide (CO) and/or carbon dioxide (CO ₂) initially present in the hydrocarbon composition or produced during conversion of the hydrocarbon composition (or portion thereof), or provided from an external supply, may be transported to and stored in the same reservoir as the one from which the gasified hydrocarbon composition was obtained, or may be transported and stored in a different reservoir or geological formation via the same or a different well or wellbore. Preferably, carbon dioxide (CO ₂) initially present in the hydrocarbon composition or produced during conversion of the hydrocarbon composition (or portion thereof), or provided from an external supply, may be stored in the same reservoir via the same or a different wellbore.

In a preferred embodiment of the invention, the electrochemical reactor with the electrochemical membrane may be placed underground during operation. Preferably, the electrochemical reactor with the electrochemical membrane may be placed in a subterranean wellbore. Preferably, the electrochemical reactor with electrochemical membrane may not be placed within the reservoir except that it is held within a wellbore that is drilled within, along or through the reservoir and placed at an equivalent vertical depth of the reservoir.

Preferably, subsurface refers to the depth of the reactor below the earth's surface and below the sea floor in the sea.

The location of the reactor may preferably be at least 100 meters TVD underground, such as at least 150 meters TVD underground, for example at least 250 meters TVD underground, such as at least 500 meters TVD underground, for example at least 750 meters TVD underground, such as at least 1000 meters TVD underground, for example at least 1500 meters TVD underground, such as at least 2000 meters TVD underground, for example at least 2500 meters TVD underground, such as at least 5000 meters TVD underground, for example at least 7500 meters TVD underground, such as at least 10,000 meters TVD underground, for example at least 12,500 meters TVD underground, such as at least 15,000 meters TVD underground.

Preferably, the subsurface may involve hydrocarbon drilling or geothermal drilling.

In embodiments of the invention, the chemical reaction of the hydrocarbon composition to produce a composition comprising hydrogen (H ₂) may include vaporizing the hydrocarbon composition at a high temperature.

Depending on the vertical depth of the electrochemical reactor placed within the wellbore, some or all of the fluids and gases may naturally enter their supercritical fluid phase due to hydrostatic or geothermal temperatures and pressures present within the wellbore. The supercritical phase of the fluid may further enhance the gasification process and reduce the energy required to treat the hydrocarbon composition.

At shallower depths, supercritical conditions may also be induced or artificially created within the tool by techniques in which the internal pressure within the tool may be increased via applied surface pressure, flow restrictions causing backpressure, weighted annular fluids, or a combination of these.

The chemical reaction of the hydrocarbon composition to produce a composition comprising hydrogen (H ₂), such as a gasification process, may require a significant amount of heat.

In embodiments of the invention, the conversion of fuel to hydrogen (H ₂) in the product chamber may include at least one gasification process when provided to the fuel chamber. The gasification process may be an initial gasification process, preferably in a enhanced reactor such as a Taylor-Couette reactor (TCR). This gasification process is also known as Indirect Internal Reforming (IIR) before the reaction products enter the electrochemical reactor.

The continuous electrochemical reaction can transfer hydrogen from the reaction product concentration within the flow path to the product chamber and dynamically reduce the hydrogen concentration in the flow path. This simultaneous and spontaneous transfer and removal of hydrogen can reduce the hydrogen concentration along the flow path, which can then bias the chemical equilibrium of the gasification chemical reaction to produce more hydrogen in the flow path concentration, increasing the hydrogen production and cumulative transfer to the product chamber.

The electrochemical reactor according to the present invention may convert fuel into a composition comprising carbon dioxide (CO ₂) or carbon monoxide (CO) when supplied to the fuel chamber. The composition comprising carbon dioxide (CO ₂) or carbon monoxide (CO) may be produced into a revenue stream and stored for collection and capture at a waste outlet. Initiation of the composition comprising carbon dioxide (CO ₂) or carbon monoxide (CO) may comprise at least one gasification process, preferably in a enhanced reactor.

Transferring hydrogen from the gasification reaction product to the product chamber via the electrochemical membrane, for example, in a spiral electrochemical membrane path, can increase the concentration of waste in the path. Water and exhaust gases such as CO ₂ or CO may thus be obtained at an increased concentration at the at least one waste material outlet, allowing for the discharge or collection of concentrated exhaust gases such as CO ₂ or CO for revenue stream or capture purposes. The flow streams of product (hydrogen) and waste (e.g., CO ₂ and CO) may also be exchanged or interchanged if desired for operational optimization.

A significant amount of heat may be required to drive the chemical reaction of the hydrocarbon composition to produce a composition comprising hydrogen (H ₂), e.g., a gasification process, may be above the minimum chemical reaction activation energy and may be in the range of 100 ℃ to 1200 ℃, e.g., in the range of 500 ℃ to 1000 ℃, such as in the range of 650 ℃ to 850 ℃, such as in the range of 675 ℃ to 775 ℃, e.g., about 700 ℃.

Any residual fuel and gasification reaction products may also undergo Direct Internal Reforming (DIR) or further gasification within the electrochemical reactor to produce hydrogen (H ₂).

In embodiments of the invention, electrochemical reactor performance may be further improved by wellbore pressure, which may depend on various parameters such as the depth of the wellbore (or depth of the reactor in the wellbore), the particular subsurface reservoir, the location of the subsurface reservoir, different rock types surrounding the subsurface reservoir and/or wellbore, different fluid/gas content, geological structure and/or formation thickness, and the like.

Geothermal heating and/or geologic pore pressure may be used as an energy source or significant energy contribution to heat and accelerate chemical reactions, such as gasification processes, of hydrocarbon compositions to compositions comprising hydrogen (H ₂), resulting in significant reductions in energy costs of production. Geological temperature and pore pressure can also be used as energy sources to transform portions of the reactant composition supercritical (e.g., CO ₂、H₂ and H ₂ O) to increase the speed, energy, and efficiency of the reaction.

Geothermal heating and/or geologic pore pressure may be from geothermal energy and is energy from the interior of the earth. Geothermal energy is thought to originate from the formation of planets and radioactive decay of matter. The high temperature and pressure inside the earth may cause some of the rock to melt and the solid mantle to exhibit plasticity, causing part of the mantle to convect upwards, as it is lighter than surrounding rock and the core-mantle boundary may reach temperatures above 4000 ℃.

Geothermal heating and/or geologic pore pressure, for example using water from hot springs, has been used for bathing since the old stone age and for space heating since the ancient roman age, however, recently geothermal power (a term for generating electricity from geothermal energy) has become more important. It is estimated that geothermal resources of the earth are theoretically sufficient to meet the energy demands of humans, although only a small fraction is currently being advantageously exploited, typically in areas close to the boundaries of the building panels.

The depth of the reservoir may determine temperature, pressure and geothermal energy when recovering water from the water reservoir, recovering hydrocarbon composition from the gas reservoir or recovering hydrocarbon composition from the oil reservoir. In general, the deeper the reservoir is below the earth's surface, the higher the geothermal energy and the higher the temperature, although geologic anomalies do exist, the higher the temperature and pressure are found at shallower depths than would be predicted by normal geologic gradients.

Thus, the inventors of the present invention have surprisingly discovered a method for producing a composition comprising hydrogen (H ₂) using geothermal energy. The production of a composition comprising hydrogen (H ₂) may preferably be provided with reduced emissions and emissions of strong greenhouse gases (GHG), such as carbon dioxide (CO ₂) and/or methane (CH ₄). This may be further improved by increasing the surface injection of methane (CH ₄) (e.g., biogas or biomethane), carbon monoxide (CO), and/or carbon dioxide (CO ₂) from an external supply.

Such improvement may be achieved by an electrochemical reactor with or without (preferably with) a strengthening reactor according to the invention.

In embodiments of the invention, the subsurface reservoir may be a liquid hydrocarbon reservoir, such as an oil reservoir (a subsurface oil reservoir), a gaseous hydrocarbon reservoir, such as a gas or condensate reservoir (a subsurface gas reservoir) or a geothermal reservoir (a subsurface geothermal reservoir).

Preferably, the electrochemical reactor with/without the enhanced reactor according to the invention may be adapted for recovery of products, in particular hydrogen composition (H ₂ -composition), using a subterranean reservoir. Preferably, the subsurface reservoir may be a liquid hydrocarbon reservoir, such as an oil reservoir (a subsurface oil reservoir), a gaseous hydrocarbon reservoir, such as a gas or condensate reservoir (a subsurface gas reservoir) or a geothermal reservoir (a subsurface geothermal reservoir).

The enhanced reactor according to the present invention may comprise a rotational energy unit. The rotation unit may preferably rotate about a central axis of the reactor. In embodiments of the invention, the electrochemical reactor may comprise a robust reactor, such as a Taylor-Couette reactor (TCR).

The energy units may be supplied to a intensification reactor, such as a Taylor-Couette reactor (TCR), and/or an electrochemical membrane of the present invention.

In embodiments of the invention, the enhanced reactor, such as a Taylor-Couette reactor (TCR), may provide rotation in the range of 100rpm to 30,000rpm, such as in the range of 500rpm to 8,000rpm, such as in the range of 1,000rpm to 6,000rpm, such as in the range of 1500rpm to 5,000rpm, such as in the range of 2,000rpm to 4,000rpm, such as in the range of 2500rpm to 3,500rpm, such as about 3,000 rpm.

The inventors of the present invention have found that by providing an electrochemical reactor according to the present invention as a cartridge comprising one or more cartridge elements according to the present invention, scalability, maintainability, sustainability and/or cost can be significantly improved. The cartridge configuration may allow for sequential/staged repair or replacement, field repair or replacement, resulting in less downtime, less material wastage, and higher productivity.

A preferred embodiment of the invention relates to a cartridge comprising one or more cartridge elements, wherein the one or more cartridge elements comprise an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane.

A further preferred embodiment of the invention relates to a cartridge comprising one or more cartridge elements, wherein the one or more cartridge elements comprise an electrochemical reactor comprising at least one fuel inlet in fluid connection with a fuel chamber located inside the electrochemical reactor, at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane.

The product chamber may be located inside the electrochemical membrane.

Preferably, the membrane separating the fuel and product chambers may comprise at least one electrochemical reactor layer.

In an embodiment of the invention, the fuel chamber may comprise at least one waste/exhaust outlet in fluid connection with the outer ring.

In the context of the present invention, the term "cartridge" may refer to a container or cartridge holding an electrochemical membrane according to the present invention in its shape and/or structure, providing a fuel chamber and ready to receive an enhanced reactor, such as a Taylor-Couette reactor (TCR), and then ready for use.

In embodiments of the invention, the one or more cartridge elements may be one or more annular cylindrical cartridge elements.

A cartridge according to the present invention may comprise a plurality of cartridge elements, such as 2 or more cartridge elements, for example 3 or more cartridge elements, such as 5 or more cartridge elements, for example 7 or more cartridge elements, such as 10 or more cartridge elements, for example 12 or more cartridge elements, such as 15 or more cartridge elements, for example 20 or more cartridge elements, such as 25 or more cartridge elements, for example 50 or more cartridge elements, such as 75 or more cartridge elements, for example 100 or more cartridge elements.

In embodiments of the invention, one or more annular cylindrical cartridges may be provided with a central aperture for receiving a strengthening reactor, such as a Taylor-Couette reactor (TCR).

In further embodiments of the invention, the fuel chamber may be formed between an interior space formed between the cartridge and a intensification reactor (e.g., a Taylor-Couette reactor (TCR)).

When the cassette comprises a plurality of cassette elements, the cassette elements may be stacked on top of each other, providing a central aperture through the cassette comprising the plurality of cassette elements.

The central aperture of the cassette or one or more annular cylindrical cassette elements may form a reinforced reactor chamber and may allow insertion of a reinforced reactor, such as a Taylor-Couette reactor (TCR). When a reinforcing reactor (e.g., a Taylor-Couette reactor (TCR)) may be inserted into the central aperture of the annular cylindrical cartridge, a fuel chamber may be formed between the outer surface of the reinforcing reactor (e.g., a Taylor-Couette reactor (TCR)) and the inner ring of the electrochemical membrane.

The enhanced reactor may be a fluidic oscillator.

The fluidic oscillator may be based on the coanda and/or bernoulli effect.

Preferably, the fluidic oscillator may be selected from oscillating baffle reactors, jet devices that induce hydrodynamic cavitation or allow pulsating flow by ultrasonic or mechanical vibration, static mixer reactors, microreactors, ejector loop reactors or reactors based on Taylor-Couette flow (e.g., taylor-Couette reactor, TCR). Preferably, the enhanced reactor or fluidic oscillator may be a Taylor-Couette flow based reactor (particularly Taylor-Couette reactor, TCR).

In embodiments of the invention, the at least one electrochemical membrane of the annular cylindrical cartridge may comprise a spiral membrane structure, a corrugated membrane structure, a concentric radial membrane structure, a radial star membrane structure or a disc membrane structure.

The annular cylindrical box may comprise a spiral membrane structure or a concentric radial membrane structure, or a radial star membrane structure, or a disc membrane structure in combination with a corrugated membrane structure.

The electrochemical membrane of the annular cylindrical box may comprise a single electrochemical membrane or a plurality of electrochemical membranes, wherein the plurality of electrochemical membranes may be arranged with one electrochemical membrane around another electrochemical membrane with a radius increasing from the center of the annular cylindrical box.

In embodiments of the invention, the electrochemical membrane of the annular cylindrical cartridge may comprise a spiral membrane structure in which the radius of the electrochemical membrane (relative to the center of the electrochemical membrane) continuously increases as it is formed around the center of the annular cylindrical cartridge.

In another embodiment of the invention, the electrochemical membrane of the annular cylindrical cartridge may comprise a concentric radial membrane structure, wherein cylindrical membranes having a constant but increasing radius (relative to the center of the electrochemical membrane) may be placed around each other, wherein the concentric radial membrane structure having the smallest radius and the concentric radial membrane having the larger radius closest to the center of the annular cylindrical cartridge are disposed around as the radius increases.

The radial star electrochemical membrane structure may comprise several electrochemical membranes according to the invention, preferably a plurality of individual electrochemical membranes being held by radial flow spacer bars. The plurality of individual electrochemical membranes may be provided in various sizes to increase the total electrochemical membrane surface area as the radius increases from the center of the cartridge. Preferably, the radial star-shaped electrochemical membrane structure is not provided as an annular cartridge element. But for ease of use and handling the assembled star structure may be contained within an outer annular box housing. Fig. 9 shows an example of a radial star-shaped electrochemical membrane structure.

The disc electrochemical membrane structure may allow for easy replacement of the cylindrical disc, easy enlargement or reduction, and easy 3D printing of complex shapes during manufacturing. The electrochemical disk membrane structure may comprise an electrochemical membrane according to the invention. The flow path dimensions of the disk electrochemical membrane structure may be varied by height (straight, converging, diverging, wavy), width (straight, converging, diverging, or wavy), obstructions in the channels (baffles, traps, turbulent columns, etc.), direction (spiral, straight, star-shaped, Z-shaped, lobed, etc.), cross-sectional shape (circular, semicircular, rectangular, or triangular), cross-sectional shape (with or without sub-channels), number of flow path outlets (or dead ends) and inlets, being adapted to adjust residence time (e.g., provide long, medium, or very short residence time for the membrane), an even number of archimedes spirals that offset the cathode and anode relative to each other. The disc reactor may comprise a plurality of disc membranes stacked to a desired axial length. Fig. 10 shows an example of a disc membrane structure. A configuration using 3D printing may be used to print the above complex flow paths.

The electrochemical membrane may preferably surround the fuel chamber of the electrochemical reactor.

It should be noted that the embodiments and features described in the context of one aspect of the invention also apply to other aspects of the invention.

The invention will now be described in further detail in the following detailed description of the drawings.

Fig. 1a shows a radial view of a spiral membrane (1) according to the invention, and fig. 1b shows a longitudinal view of the spiral electrochemical membrane (1) as shown in fig. 1 a.

Fig. 1a and 1b show examples of spiral electrochemical membranes (1) mounted around a rotating enhanced reactor (e.g. Taylor-Couette reactor (TCR)), the rotating enhanced reactor (2) being centrally located in the spiral in the enhanced reaction chamber (24). The spiral electrochemical membrane (1) comprises a fuel chamber (3). The fuel chamber (3) may extend from the inner ring (4) to the outer ring (5) along a flow path (6) formed by the spiral-shaped electrochemical membrane (1). The inner ring (4) contains both fuel (such as a hydrocarbon composition) and reaction products from its gasification reaction within the inner ring (4). As any remaining fuel, such as hydrocarbon composition and gasification gas, moves along the flow path (6) of the spiral electrochemical membrane (1) from the inner ring (4) towards the outer ring (5). Fuels, such as hydrocarbon compositions, may be further reacted to produce hydrogen ions (H ⁺) and gasification gases. The hydrogen contained in the gasification reaction product reacts with the electrochemical membrane and is removed from the hydrocarbon composition stream flow path (6). The longer the hydrocarbon composition and gasification reaction product move along the flow path (6), the lower the concentration of hydrocarbons in the flow path (6) and the higher the concentration of remaining gasification gas, and the higher the concentration of hydrogen (H ₂) formed within the product chamber (10). Preferably, water and exhaust gases such as CO ₂ or CO may be obtained at the outer ring (5). At least one waste material outlet (not shown) may be provided in fluid connection with the outer ring (5) allowing exhaust gases, such as CO ₂ or CO, to be expelled or collected.

As the fuel (hydrocarbon composition) and the gasification reaction products move from the inner ring (4) along the flow path (6), the anode (8) disposed on the outer surface of the spiral-shaped electrochemical membrane (1) (and also on the outer surface of the corrugated layer (18)) is capable of generating hydrogen ions (protons, H ⁺), which move through the electrolyte (7) within the corrugated layer (18) to the cathode (9) (the inner surface of the corrugated layer (18), which also acts as a surface of the product chamber (10), where the hydrogen ions receive electrons and reform hydrogen atoms, which then recombine with another hydrogen atom (H) and generate hydrogen gas (H ₂) in the product chamber (10).

Non-conductive radial flow spacer bars (15) are provided circumferentially (at longitudinal intervals) along the spiral length of the electrochemical membrane (1) to prevent the electrochemical membrane from contacting itself and to provide a flow path (6) for fuel (e.g. hydrocarbon composition) and gasification reaction products as they travel from the inner ring (4) to the outer ring (5).

The spiral electrochemical membrane (1) illustrated in fig. 1 may or may not comprise an electrochemical membrane comprising a corrugated layer (18). The corrugated layer (18) may comprise a single corrugated layer, such as a dual corrugated layer, for example a triple corrugated layer, such as a quad corrugated layer.

Fig. 2a shows an electrochemical membrane (1) for an electrochemical reactor according to the invention with two corrugated layers (18) and a view (fig. 2 b) of how the membrane can be spiral to form a spiral-shaped electrochemical membrane (1) according to the invention with a centrally placed strengthening reactor, such as a Taylor-Couette reactor (TCR), placed in a strengthening reaction chamber (24). The corrugated layer (18) is provided with anodes (8) facing the fuel chamber (3) and cathodes (9) facing the product chamber (10). An electrolyte (7) may be placed between the anode (8) and the cathode (9). Hydrogen (H ₂) may be generated as described above and stored in the product chamber (10). The fuel may be provided to the fuel chamber (3), for example via a fuel permeable liner (11) of the structure of the auxiliary electrochemical membrane (1). The backing (11) may be used as a layer of the corrugated layer (18) of the electrochemical membrane (1). The gasket (11)/layer is provided with an anode (8), the anode (8) being connected to the corrugated layer (18) on the fuel cell side of the electrochemical membrane (1). The corrugated layer (18) is further provided with a cathode (9), the cathode (9) being connected to the gas-permeable liner (13) on the product chamber side of the electrochemical membrane (1). A flow path (6) is formed on one or both sides of the electrochemical membrane (1).

Fig. 3 shows a 3-layer electrochemical membrane (1) in which two layers (12) (top and bottom) are straight and one corrugated layer (18) is provided with an anode (8), an electrolyte (7) and a cathode (9) to promote the formation of hydrogen (H ₂) as previously described. The fuel chamber may be an area outside the top layer (12) and the bottom layer (12). A product chamber (10) is formed between the layer (12) and the corrugated layer (18). Fuel may be provided to the fuel chamber (3) surrounding the top layer (12) and the bottom layer (12), and the flow path (6) is formed on one or both sides of the electrochemical membrane (1).

Fig. 4 shows a 4-layer electrochemical membrane (1) in which two layers (12) (top layer (12) and bottom layer (12)) are straight and two corrugated layers (18) are disposed between the straight layers (12). The fuel chamber (3) may be an area outside the top layer (12) and the bottom layer (12) and a product chamber (10) is formed between the layer (12) and the corrugated layer (18). The two corrugated layers may be separated by a gas permeable liner (13) that allows hydrogen (H ₂) to transfer from one product chamber (10) to the other. The layer (12) and corrugated layer (18) may be provided with an anode (8), an electrolyte (7) and a cathode (9) to promote the formation of hydrogen (H ₂), as previously described. A flow path (6) is formed on one or both sides of the electrochemical membrane (1).

Fig. 5 shows a 4-layer electrochemical membrane as depicted in fig. 4 and illustrates the advantage of multiple layers (12/18) in an electrochemical membrane, namely a significantly reduced vulnerability to indirect damage due to the formation of hot spot holes (14) or scale in the layer (12) of the electrochemical membrane (1), e.g. due to local thermal damage on the electrochemical membrane (1). These hot spots (14) may cause mixing of the fuel and the product, whereby the product stream may be contaminated. However, when working with, for example, 3 or 4 layers of electrochemical membranes, hot spots (14) in one layer may allow hydrogen (H ₂) product to migrate into an adjacent product chamber (10). Thus, this provides intentional built-in redundancy for durability, reliability, longevity, and productivity, while improving mechanical strength and robustness to reduce the probability of tool failure events.

Fig. 6 illustrates a spiral structure according to the present invention for an electrochemical membrane. Fig. 6a shows a single spiral, preferably a single archimedes spiral. In order to increase the volumetric throughput of fuel and gasification gas in the electrochemical membrane, the number of flow paths (6) for fuel and gasification gas may be increased, and multiple spirals may be used, wherein each spiral used provides a separate flow path (6). Preferably, the multiple helix may be an archimedean multiple helix, wherein the individual helices each begin at intervals of X degree arcs [ fig. 6b ] — depending on the number of helices included. An advantage of using multiple spirals may be to reduce the measured length per spiral (per cross-sectional area) and thus reduce the gas residence time (per spiral). Furthermore, the use of multiple spirals can increase gas rate throughput because as each spiral flow path (6) is shorter, it provides lower pressure loss and the total cross-sectional area available for flow increases. (i.e. from one flow path (6) to a plurality of flow paths (6), the flow paths (6) being open to flow from the inner ring (4) to the outer ring (5).

One flow path (6) may relate to the distance fuel and/or gasification gas moves from the inner ring to the outer ring along the spiral electrochemical membrane surface.

This flow path allows the electrochemical membrane to electrochemically screen valuable gasification reaction products from a strengthening reactor, such as a Taylor-Couette reactor (TCR), into a separate flow stream for sale or capture.

In fig. 6, the spiral electrochemical membrane may illustrate a single spiral electrochemical membrane (fig. 6 a), a 3 spiral electrochemical membrane (fig. 6 b), a 7 spiral electrochemical membrane (fig. 6 c), and a 20 spiral electrochemical membrane (fig. 6 d).

Archimedes' spiral allows multiple spirals to be initiated simultaneously from the central loop of an enhanced reactor (e.g., taylor-Couette reactor (TCR)), increasing the volumetric throughput and reducing residence time and pressure drop within the spiral when necessary. The number of spirals is customized to optimize the process.

Fig. 7 shows an example of the construction of an electrochemical membrane (1) mounted around a reinforced reactor (2) (e.g., taylor-Couette reactor (TCR)) in the center of a spiral.

In step I, the cathode (9) may be prepared from a cathode material as a series of capillaries that create a product chamber (10), and the capillaries may be connected to a series of product chambers. These capillaries act like pseudo-corrugations.

In step II, an electrolyte (7), such as a ceramic solid oxide coating, may be placed on the surface of the cathode (9) provided in step I.

In step III, a flexible insulator (16) may be placed to avoid contact between the anode (8) and the cathode (9).

In step (IV), a coating of anode material may be placed on the electrolyte (7) provided in step II.

In step (V), the finished electrochemical membrane (1) comprises a series of capillaries with an electrolyte coating (7) comprising on the inside a cathode (9) facing the product chamber (10) and on the outside an anode (8) facing the fuel chamber (3), wherein the cathode (9) and the anode (8) are separated by the electrolyte (7) and a flexible insulator (16).

The provided electrochemical membrane (1) may be mounted, for example, within an annular cylindrical box and placed around a centrally placed enhanced reactor (2), such as a Taylor-Couette reactor (TCR), providing a spiral-shaped electrochemical membrane (1) around the enhanced reactor, such as a Taylor-Couette reactor (TCR). The spiral electrochemical membrane (1) comprises a fuel chamber (3). The fuel chamber (3) may extend from the inner ring (4) to the outer ring (5) along a flow path (6) formed by the spiral-shaped electrochemical membrane (1).

Fig. 8 shows an example of a configuration of a spiral electrochemical membrane (1) with internal corrugations (18), the spiral electrochemical membrane (1) being printed around a reinforced reactor (2) in the center of the spiral, such as a Taylor-Couette reactor (TCR). The anode (8), electrolyte (7) and cathode (9) layers may be simultaneously 3D printed onto the liner (11) in a corrugated build pattern using multi-head printers (17), each with its own specific "ink" (e.g., ink of metal, electrolyte and insulator) to be deposited. Radial flow spacer bars (15) of insulating material are printed on the liner circumferentially and perpendicular to the longitudinal product chambers (10) at intervals to maintain the flow path between the individual spiral electrochemical membrane (1) wraps. Printing is continued until the desired outer diameter is reached. The space inside the two corrugated layers (18) may form a product chamber (10), and a fuel chamber (3) is provided outside the two corrugated layers (18). A gas-permeable liner (13) may be provided between the two corrugated layers (18).

Fig. 9 shows a cassette (19) in the form of a radial star-shaped reactor (20), which cassette (19) comprises a plurality of radial star-shaped membrane structures (21), which radial star-shaped membrane structures (21) comprise electrochemical membranes according to the invention. The plurality of radial star-shaped membrane structures (21) are individual electrochemical membranes held by radial flow spacer bars (15). In fig. 9, a plurality of radial star-shaped membrane structures (21) are provided in various sizes to increase the total electrochemical membrane surface area as the radius increases from the center of the cassette (19). The cassette (19) is provided with a central aperture for receiving a strengthening reactor (2) in the form of a Taylor-Couette reactor (TCR).

Fig. 10 shows a cassette (19) in the form of a cylindrical disc reactor (22), which cassette (19) may comprise a plurality of disc membranes (23) stacked to a desired axial length. The disc membrane structure (23) may preferably comprise an electrochemical membrane according to the invention. The cassette (19) is provided with a central aperture for receiving a strengthening reactor (2) in the form of a Taylor-Couette reactor (TCR).

Reference numerals

1) Electrochemical reactor

2) Enhanced reactors, e.g. Taylor-Couette reactor (TCR)

3) Fuel chamber

4) Inner ring

5) Outer ring

6) Flow path

7) Electrolyte composition

8) Anode

9) Cathode electrode

10 Product chamber

11 Liner/layer)

12 Electrochemical membrane layer (comprising anode, electrolyte and cathode)

13 Air-permeable liner

14 Hot spot)

15 Radial flow spacer bar

16 Flexible insulator

17 3D printhead (comprising various materials)

18 Corrugated electrochemical membrane layer (comprising anode, electrolyte and cathode)

19 Box (D)

20 Radial star reactor

21 Radial star-shaped membrane structure

22 Disc reactor

23 Disc film structure

24 A reaction chamber is enhanced.

Claims

1. An electrochemical reactor, comprising at least one fuel inlet connected to a fuel chamber fluid located inside the electrochemical reactor, and at least one product outlet connected to a product chamber fluid located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane is folded or printed in a spiral shape around the fuel chamber of the electrochemical reactor, and wherein the at least one electrochemical membrane comprises at least one high-temperature proton exchange membrane.

2. An electrochemical reactor according to claim 1, wherein the electrochemical membrane is provided with an anode surface (8) facing the fuel chamber and the spiral flow path (6), and/or wherein the electrochemical membrane is provided with a cathode surface (9) facing the product chamber.

3. An electrochemical reactor according to any one of the preceding claims, wherein the electrochemical membrane is a proton conducting electrochemical membrane.

4. An electrochemical reactor according to any of the preceding claims, wherein the at least one electrochemical membrane between the fuel chamber and/or the product chamber can include at least one layer, wherein at least one layer can be a corrugated layer.

5. An electrochemical reactor according to any one of the preceding claims, wherein the centre of the electrochemical reactor comprises an intensified reactor or part thereof, such as a Taylor-Couette reactor (TCR) or part thereof.

6. The electrochemical reactor according to any one of the preceding claims, wherein when fuel is provided to the fuel chamber, conversion of the fuel into hydrogen ( _H2 ) in the product chamber comprises at least one gasification process.

7. An electrochemical reactor according to any one of the preceding claims, wherein the high temperature electrochemical membrane is capable of operating at a temperature above 100°C.

8. An electrochemical reactor according to any one of the preceding claims, wherein the electrochemical reactor comprises means for supplying energy or power to the electrochemical reactor.

9. A box comprising one or more box elements, wherein the one or more box elements comprise an electrochemical reactor, the electrochemical reactor comprising at least one fuel inlet fluidly connected to a fuel chamber located inside the electrochemical reactor, and at least one product outlet fluidly connected to a product chamber located inside the electrochemical reactor, wherein the fuel chamber and the product chamber are separated by at least one electrochemical membrane, wherein the at least one electrochemical membrane comprises at least one high-temperature proton exchange membrane.

10. The cartridge of claim 9, wherein the one or more cartridge elements are one or more annular cylindrical cartridge elements.

11. Cassette according to any of claims 9-10, wherein the cassette, in particular the one or more annular cylindrical cassette elements, is provided with a central hole for receiving an intensified reactor.

12. The cartridge of claim 11, wherein the fuel chamber is formed between an internal space formed between the cartridge and the enhanced reactor.

13. An enhanced reactor, such as a Taylor-Couette reactor (TCR), comprising an energy unit and an enhanced reaction chamber surrounded by an electrochemical reactor jacket, the enhanced reaction chamber comprising at least one fuel inlet and at least one hydrogen outlet ( _H2 -outlet); wherein the electrochemical reaction chamber comprises an electrochemical membrane separating the at least one fuel inlet and the at least one hydrogen outlet.

14. An electrochemical reactor comprising an electrochemical membrane and at least one fuel inlet fluidly connected to a spiral flow path (6) and a fuel chamber located inside the electrochemical reactor, and at least one product outlet fluidly connected to a product chamber located inside the electrochemical reactor, wherein the fuel provided to the fuel chamber moves substantially in a radial direction relative to the longitudinal direction of the electrochemical membrane and/or wherein the product moves substantially in a longitudinal direction of the longitudinal direction of the electrochemical membrane, and wherein at least one electrochemical membrane can be at least one high-temperature proton exchange membrane.

15. Use of an electrochemical reactor according to any one of claims 1 to 8 or claim 14, or a cartridge according to any one of claims 9 to 12, or an enhanced reactor according to claim 13, such as a Taylor-Couette reactor (TCR), for at least partially converting a hydrocarbon composition into a composition comprising hydrogen ( _H2 ).