Deposited diaphragms

Following the invention of deposited asbestos diaphragms, Stuart developed the Hooker S cell, which had vertical cathode fingers with deposited diaphragms. These S cells were very popular after World War II and were phased into operation throughout the world. In 1960, almost 60% of the chlorine production is the United States was in Hooker cells. 

As mentioned previously, the vacuum-deposited diaphragm developed in 1928, coupled with the vertical finger anode-cathode construction, initiated the Hooker S series cell. The S type cell continued until 1966, when the single C-60 cell was introduced. In 1970, the H series cell was introduced, with metal anodes replacing the graphite anodes. A summary of the major innovations in Hooker diaphragm-cell design is presented in Table 2.1. 

S-1 First successful deposited diaphragm cell. Consistent increases in the allowable amperage with minor electrical circuit changes... 

Separation of the anode and cathode products in diaphragm cells is achieved by using asbestos [1332-21 -4] or polymer-modified asbestos composite, or Polyramix deposited on a foraminous cathode. In membrane cells, on the other hand, an ion-exchange membrane is used as a separator. Anolyte—catholyte separation is realized in the diaphragm and membrane cells using separators and ion-exchange membranes, respectively. The mercury cells contain no diaphragm the mercury [7439-97-6] itself acts as a separator. 

Caustic Soda. Diaphragm cell caustic is commercially purified by the DH process or the ammonia extraction method offered by PPG and OxyTech (see Fig. 38), essentially involving Hquid—Hquid extraction to reduce the salt and sodium chlorate content (86). Thus 50% caustic comes in contact with ammonia in a countercurrent fashion at 60°C and up to 2500 kPa (25 atm) pressure, the Hquid NH absorbing salt, chlorate, carbonate, water, and some caustic. The overflow from the reactor is stripped of NH, which is then concentrated and returned to the extraction process. The product, about 62% NaOH and devoid of impurities, is stripped free of NH, which is concentrated and recirculated. MetaUic impurities can be reduced to low concentrations by electrolysis employing porous cathodes. The caustic is then freed of Fe, Ni, Pb, and Cu ions, which are deposited on the cathode. 

L. C. Curhn, T. F. Florkiewicz, and R. C. Matousek, Polyramix (PM), A Depositable Replacementfor Asbestos Diaphragms, Paper presented at London... 

An expandable anode involves compression of the anode stmcture using cHps during cell assembly so as not to damage the diaphragm already deposited on the cathode (Eig. 3a). When the cathode is in position on the anode base, 3-mm diameter spacers are placed over the cathode and the cHps removed from the anode. The spring-actuated anode surfaces then move outward to bear on the spacers, creating a controlled 3-mm gap between anode and cathode (Eig. 3b). This design has also been appHed to cells for the production of sodium chlorate (22). 

Other Metals. AH the sodium metal produced comes from electrolysis of sodium chloride melts in Downs ceUs. The ceU consists of a cylindrical steel cathode separated from the graphite anode by a perforated steel diaphragm. Lithium is also produced by electrolysis of the chloride in a process similar to that used for sodium. The other alkaH and alkaHne-earth metals can be electrowon from molten chlorides, but thermochemical reduction is preferred commercially. The rare earths can also be electrowon but only the mixture known as mischmetal is prepared in tonnage quantity by electrochemical means. In addition, beryIHum and boron are produced by electrolysis on a commercial scale in the order of a few hundred t/yr. Processes have been developed for electrowinning titanium, tantalum, and niobium from molten salts. These metals, however, are obtained as a powdery deposit which is not easily separated from the electrolyte so that further purification is required. 

Finally, nickel is electrolytically produced from the purified nickel-bearing solution. In electrowinning of nickel, the hydrogen discharge reaction competes with nickel deposition at the cathode. This counterproductive effect is minimized by keeping the acidic anolyte solution separate from the catholyte by means of a diaphragm cloth. 

For example, consider a system in which metallic zinc is immersed in a solution of copper(II) ions. Copper in the solution is replaced by zinc which is dissolved and metallic copper is deposited on the zinc. The entire change of enthalpy in this process is converted to heat. If, however, this reaction is carried out by immersing a zinc rod into a solution of zinc ions and a copper rod into a solution of copper ions and the solutions are brought into contact (e.g. across a porous diaphragm, to prevent mixing), then zinc will pass into the solution of zinc ions and copper will be deposited from the solution of copper ions only when both metals are connected externally by a conductor so that there is a closed circuit. The cell can then carry out work in the external part of the circuit. In the first arrangement, reversible reaction is impossible but it becomes possible in the second, provided that the other conditions for reversibility are fulfilled. 

For forced-convection studies, the cathodic reaction of copper deposition has been largely supplanted by the cathodic reduction of ferricyanide at a nickel or platinum surface. An alkaline-supported equimolar mixture of ferri- and ferrocyanide is normally used. If the anolyte and the catholyte in the electrochemical cell are not separated by a diaphragm, oxidation of ferrocyanide at the anode compensates for cathodic depletion of ferricyanide.3... 

These experiments were carried out with the copper deposition reaction, which creates a large density difference at high concentrations. The diffus-ivity data used were the diaphragm cell data of Cole and Gordon (C12a). These data, as correlated by Fenech (F3), were also used in later work on horizontal electrodes. The question whether molecular diffusivity data are adequate for the work in question, has been discussed in Section IV,C.5... 

Using diaphragm-type electrolytic cells, electrical energy is used in an optimal manner for dissolution and deposition. 

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