WO2023227313A2

WO2023227313A2 - New electrochemical reactor design

Info

Publication number: WO2023227313A2
Application number: PCT/EP2023/060809
Authority: WO
Inventors: Stuart Robert GILLICK
Original assignee: Metharc Aps
Priority date: 2022-05-23
Filing date: 2023-04-25
Publication date: 2023-11-30
Also published as: WO2023227313A3

Abstract

The present invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 around the intensified reactor chamber of the electrochemical reactor, and wherein the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane.

Description

NEW ELECTROCHEMICAL REACTOR DESIGN

Technical field of the invention

The present invention relates to a new electrochemical reactor design. In particular the present invention relates to new electrochemical membrane design and layout for an electrochemical reactor with or without an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), which may be surrounded by the electrochemical reactor having a specially designed electrochemical membrane installed, e.g. within a doughnut shaped cylindrical cartridge.

Background of the invention

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

There are many types of electrochemical reactors, but they all consist of an anode, a cathode, and an electrolyte that allows ions, often positively charged hydrogen ions (H⁺), to move between the two sides of the electrochemical membrane. At the anode a catalyst causes the fuel to undergo oxidation reactions that generate ions (H⁺) and electrons. The ions move from the anode to the cathode through the electrolyte. At the same time, electrons flow from the anode to the cathode completing the external circuit of the direct current electricity supply.

Traditional electrochemical reactors face various challenges in order to fully and successfully disrupt the energy sector, since their capacity is difficult to increase as well as the durability, effectivity and productivity of the electrochemical reactor.

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

Summary of the invention

Thus, an object of the present invention relates to a new electrochemical reactor design. In particular, it is an object of the present invention to provide a new electrochemical reactor design that solves the above-mentioned problems of the prior art with effectivity, durability, reliability, longevity and productivity, together with a lower cost of maintenance and manufacturing.

Thus, one aspect of the invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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, concentric, radial or disc shape around the fuel chamber of the electrochemical reactor.

A further aspect of the present invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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, concentric, radial or 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 present invention relates to a electrochemical reactor comprising a least one fuel inlet in fluid connection to 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 a fuel provided to the fuel chamber moves substantially in the radial direction relative to the longitudinal direction of the electrochemical membrane and/or wherein the product moves substantially in the longitudinal direction of the longitudinal direction of the electrochemical membrane.

A further aspect of the present invention relates to an intensified reactor, e.g. a Taylor- Couette Reactor (TCR), comprising an energy unit and an intensified reaction chamber surrounded by an electrochemical reactor jacket, said intensified reaction chamber comprises at least one fuel-inlet, and at least one hydrogen-outlet (H₂-outlet) for gasification reaction products in fluid connection to 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 present invention relates to an intensified reactor, e.g. a Taylor- Couette Reactor (TCR), comprising an energy unit and an intensified reaction chamber surrounded by an electrochemical reactor jacket, said intensified reaction chamber comprises at least one fuel-inlet, and at least one hydrogen-outlet (H₂-outlet) for gasification reaction products in fluid connection to a fuel chamber located inside the electrochemical reactor; , wherein the electrochemical reaction chamber comprises both an inner annulus (where the intensified reactor, e.g. a Taylor-Couette Reactor (TCR), may be placed) and an electrochemical membrane according to the present invention.

A further aspect of the present invention relates to an electrochemical reactor comprising an electrochemical membrane and a least one fuel inlet in fluid connection to a fuel chamber located inside the electrochemical reactor and spiral flow paths (6), at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein a fuel provided to the fuel chamber moves substantially in the radial direction relative to the longitudinal direction of the electrochemical membrane and/or wherein the product moves substantially in the longitudinal direction of 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.

Still another aspect of the present invention relates to the use of the electrochemical reactor according to the present invention, with or without an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), according to the present invention for converting a hydrocarbon composition at least partly into a composition comprising hydrogen (H₂).

A further aspect of the present invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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.

Yet an aspect of the present invention relates to a electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 where in the interspace between the at least two layers of the electrochemical membrane defines a product chamber.

A further aspect of the present invention relates to a cartridge comprising one or more cartridge elements, wherein the one or more cartridge elements comprise an electrochemical reactor, the electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 present invention relates to a cartridge comprising one or more cartridge elements, wherein the one or more cartridge elements comprise an electrochemical reactor, the electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 electrochemical reactor the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane.

An even further aspect of the present invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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, e.g. at least three corrugated layers, such as at least four corrugated layers, e.g. at least five corrugated layers, such as at least six corrugated layers.

Brief description of the figures

Figure 1 shows a spiral shaped electrochemical membrane formed around an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), in a single spiral according to the present invention, Figure 2 shows an electrochemical membrane comprising two corrugated layers and forming a fuel chamber and a product chamber,

Figure 3 shows an electrochemical membrane comprising one corrugated layer and a top non-corrugated layer and a bottom non-corrugated layer and the presence of a fuel chamber and flow path above the top non-corrugated layer and below the bottom noncorrugated layer, and product chambers between the non-corrugated layers, and

Figure 4 shows an electrochemical membrane comprising two corrugated layers and a top non-corrugated layer and a bottom non-corrugated layer and the presence of a fuel chamber and flow path above the top non-corrugated layer and below the bottom noncorrugated layer, and product chambers between the non-corrugated layers,

Figure 5 shows the same 4 layered electrochemical membrane as shown in figure 4, with the further illustration of a hot spot in the top non-corrugated layer.

Figure 6 shows various Archimedean spiral structures suitable for the present invention ranging from a spiral structure comprising a single spiral to a spiral construction comprising multiple, simultaneous spirals originating from the same radius, like 3 simultaneous spirals, to 7 spirals and to 20 spiral structures.

Figure 7 shows an example of the construction of an electrochemical membrane to be shaped around an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), in the centre of the spiral.

Figure 8 shows an example of a simultaneously 3D printed construction of an electrochemical membrane around an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), in the centre of the spiral.

Figure 9 shows an example of a cartridge in the form of a radial star electrochemical reactor installed around a central intensified reactor e.g., Taylor-Couette Reactor (TCR).

Figure 10 shows an example of a cartridge in the form of a disc electrochemical reactor installed around a central intensified reactor e.g., Taylor-Couette Reactor (TCR).

The present invention will now be described in more detail in the following. Detailed description of the invention

The inventors of the present invention found various ways to increase the surface area of the electrochemical membrane of an electrochemical reactor of the present invention allowing increased reactivity, increase productivity and increase durability and increased effectivity of the electrochemical membrane during use.

An even further preferred embodiment of the present invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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, concentric, radial or disc shape in a cartridge installed around the intensified reactor chamber of the electrochemical reactor. The principal function of the electrochemical reactor according to the present invention may to be used as an electrochemical hydrogen separator.

In a further preferred embodiment of the present invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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, concentric, radial or disc shape in a cartridge installed around the intensified reactor chamber of the electrochemical reactor, and wherein the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane.

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

Preferably, the circular shaped cross-sectional area, the substantially circular shaped cross- sectional area or the oval shaped cross-sectional area of the electrochemical membrane may comprise an inner annulus and an outer annulus. The inner annulus may be linked to the outer annulus by spiral, concentric, radial or complex pathways.

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

Preferably, the spiral shape is an open-end spiral shape. An open-end spiral may be a spiral where the distance from a centre point may be increasing for the radial movement in the spiral, preferably in the direction away from the starting point (from the inner annulus), when starting closest to the centre point.

The centre point of the spiral electrochemical membrane and the starting point of the spiral electrochemical membrane may or may not be the same. Preferably, the centre point of the spiral electrochemical membrane and the starting point of the spiral electrochemical membrane may not be the same.

In an embodiment of the present invention the fuel chamber of the electrochemical reactor may be provided in a spiral shape between the overlapping spiral shaped electrochemical membrane. Preferably the spiral shaped electrochemical membrane may be overlapping without touching.

Preferably, the spiral shape of the electrochemical membrane may be in an Archimedean spiral shape. The Archimedean spiral may have the property that any straight line extending from the origin through the spiral structure may intersect successive turnings of the spiral. The intersection of successive turnings of the spiral may be provided in points with a constant, or a substantially constant, separation distance.

In an embodiment of the present invention the electrochemical membrane may be provided with one or more non-conducting radial flow spacer strips to keep the electrochemical membrane from contacting from itself during electrical operation to avoid an electric shorting of the electrochemical process, and to also provide a mechanical resilient flow path for any residual fuel, such as a hydrocarbon composition, and gasification reaction products as they travel from the inner annulus to the outer annulus. Preferably, the spacer strips may be provided circumferentially (at intervals longitudinally) along the spiral length of the electrochemical membrane.

Spirals may begin at any radial distance from the centre point.

Preferably, the spiral may be an Archimedean spiral.

In order to further increase volume through-put of fuel and gasification gases in the electrochemical reactor, the number of flow paths for fuel and gasification gases may be increased. Multi-spirals may be used, in particular Archimedean multi-spirals may be suitable, with spirals starting at intervals of X deg of arc - depending on the number of spirals included.

The use of multi-spirals may be used to reduce the measured length of each spiral (per cross-sectional area) and thus the gas or fluid residence time (per spiral). Furthermore, use of multi-spirals may increase gas or fluid rate through-put since each shorter spiral would generate a lower pressure loss and provide for multiple flow paths, increasing the total flow cross-sectional area.

In an embodiment of the present invention the radial length of the electrochemical membrane may preferably be larger than the longitudinal length of the electrochemical membrane. Preferably, the radial length of the electrochemical membrane may be at least 10% larger than the longitudinal length of the electrochemical membrane, such as at least 25% larger, e.g. at least 50% larger, such as at least 75% larger, e.g. at least 100% larger, such as at least 150% larger, e.g. at least 200% larger, such as at least 250% larger, e.g. at least 300% larger, such as at least 400% larger, e.g. at least 500% larger, such as at least 600% larger, e.g. at least 700% larger. One flow path may relate to the distance where the fuel and/or the gasification reaction products move from the inner annulus along spiral shaped flow path(s) between and bounded by the electrochemical membrane surfaces to the outer annulus. In an embodiment of the present invention the spiral shaped electrochemical membrane may comprise a single spiral electrochemical membrane or multiple spirals of electrochemical membrane. Preferably, the multiple spirals of electrochemical membrane may comprise 2 spirals, such as 3 spirals, e.g., 5 spirals, such as 7 spirals, e.g., 10 spirals, such as 15 spirals, e.g., 20 spirals.

The fuel chamber may provide a radial flow of the fuel, relative to the longitudinal direction of the electrochemical membrane. Preferably, fuel and gasification reaction products entering the electrochemical reactor and the electrochemical membrane flow paths, may be moving in radial direction, preferably following and bounded by the spiral-shaped electrochemical membrane and moving from the inner-annulus of the electrochemical reactor adjacent to the intensified reactor, e.g. a Taylor-Couette Reactor (TCR), and towards the outer annulus of the electrochemical reactor.

In the electrochemical reactor according to the present invention, the fuel chamber may be installed in a spiral, concentric, radial or disc shape around the inner annulus of an electrochemical reactor, preferably guided and bounded by the at least one electrochemical membrane.

In an embodiment of the present invention the electrochemical reactor comprises:

(i) an electrochemical membrane folded in a spiral, concentric, radial or disc shape around the inner annulus of an electrochemical reactor; and

(ii) a fuel chamber installed in a spiral, concentric, radial or disc shape around the inner annulus of an electrochemical reactor.

In a further embodiment of the present invention the space between the successive electrochemical membranes of the spiral, concentric, radial or disc shaped electrochemical membranes may constitute the fuel chamber and flow paths for residual fuel and reaction products.

By providing these spiral, concentric, radial or disc shaped structural pathways, a radial flow continuity for e.g. residual fuel and/or gasification reaction products from the inner annulus to the outer annulus of the electrochemical membrane may be provided resulting in an improved separation, conversion and productivity. The electrochemical membrane may comprise a spiral, concentric, radial or disc shaped electrochemical membrane where the fuel introduced into the fuel inlet and/or the gasification reaction products formed, moves from the inner annulus along these shaped membrane surfaces to the outer annulus. Preferably, the movement of the fuel and/or the gasification reaction products formed, may be moving in radial direction relative to the longitudinal direction of the electrochemical membrane.

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

In an embodiment of the present invention the gasification reaction products may be gasification reaction product gases. The gasification reaction product gases may be at supercritical fluid phase conditions.

In a further embodiment of the present 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 gasification reaction products formed, may be moving in radial direction relative to the longitudinal direction of the electrochemical membrane and the product collected in the product chamber may be moved in the longitudinal direction of the electrochemical membrane to the product outlet.

In an embodiment of the present invention, the spiral, concentric, radial or disc shaped electrochemical membrane may have a length extending throughout the length or part of the length of the fuel chamber of the electrochemical reactor (both longitudinally and radially).

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

The waste material outlet may be in fluid connection to the outer annulus of the electrochemical membrane.

Preferably, the waste material may include water, contaminants, unconverted hydrocarbons, methane (CH₄), carbon dioxide (CO₂), carbon monoxide (CO), and the like. The electrochemical membrane according to the present invention may allow transport of molecules, atoms, and/or ions from the fuel chamber to the product chamber.

In an embodiment of the present invention, the electrochemical membrane according to the present invention may allow transport of hydrogen ions (H⁺) from a hydrogen donor in the fuel chamber to form hydrogen gas (H₂) in the product chamber. The hydrogen ion may be separated from the hydrogen donor in the fuel chamber at an anode. The hydrogen ion (H⁺) may then be transported through the electrolyte and at the cathode on the product chamber within the electrochemical membrane the hydrogen ion (H⁺) accepts an electron to form a hydrogen atom, which then may be allowed to join with another hydrogen atom to form hydrogen gas (H₂) which may be captured in the product chamber.

Preferably the form of the spiral shaped membrane may be an Archimedean spiral.

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

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

The electrochemical membrane according to the present invention may comprise two or more electrochemical cells with one or more of the electrochemical cells formed in layers of a corrugated shape to create and contain a multitude of parallel product chambers and/or fuel chambers . The corrugated layers provided with several anodes may be facing the fuel chamber and cathodes may be facing the product chamber. The reverse arrangement may also be performed.

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

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

The electrochemical membrane with proton conduction may involve transport of an acidic electrolyte e.g., (H+), through the electrochemical electrolyte placed between two porous electrodes and formed of e.g., a proton-conducting metal oxide layer. In an electrochemical reactor according to the present invention, the hydrogen (H₂) may be oxidized at the anode side of the electrochemical membrane, hydrogen (H₂) may be oxidized to protons (H⁺) which are then conducted through the electrolyte until they finally re-combine with an electrons to re-form hydrogen atoms, and with other hydrogen atoms to produce hydrogen gas (H₂) at the cathode.

The protons (H⁺) must move through the electrolyte, therefore, an electrochemical membrane material with dominant protonic conductivity at elevated temperatures may be required as electrolyte.

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

The electrochemical reactor and the construction provided according to the present invention may be offering an efficient way to produce high-purity hydrogen for a variety of applications from one or more hydrocarbons (e.g., CH₄) while capturing greenhouse gases (e.g. CO₂ and/or CO) which can be identified as a major benefit of great environmental and climate relevance.

The reaction of the fuel may comprise several stages:

Stage I may include partial oxidation of fossil fuel (e.g., hydrocarbons, methane, natural gas, biogas, shale gas or gasified coal), e.g., with CO₂, air or H₂O resulting in a synthesis gas (CO, CO₂ and H₂);

Stage II may include the water gas shift reaction (WGSR) to transform the carbon monoxide (CO) from the synthesis gas via water (H₂ O) to carbon dioxide (CO₂) and more hydrogen (H₂);

Stage III may include CO₂/H₂ electrochemical separation by means of an electrochemical membrane according to the present invention, e.g., a mixed protonic-electronic conducting (MPEC) membrane.

In an embodiment of the present invention an electrochemical membrane material may be preferred which has mixed protonic-electronic conductivity and pronounced chemical stability under reducing and hydrothermal conditions.

In a further embodiment of the present invention the at least one electrochemical membrane between the fuel chamber and/or the product chamber may comprise at least one layer, wherein 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 transport of molecules, atoms, and/or ions from the fuel chamber to the product chamber may be increased resulting in an improved utilization and/or productivity of the electrochemical membrane and the electrochemical reactor. The addition of further reinforced continuous strips of anode and cathode along each of the corrugation flute ridges may reduce the hot spots by helping to maintain an evenly distributed current density within the electrochemical layers.

The corrugated layers according to the present invention may comprise one or two outer plies, and numerous flutes creating the corrugated structure. In multi-ply types of corrugated layers, one or more intermediate plies may be inserted between the flutes of e.g., two plies. The effect of the corrugated layer may depend on the number of outer/intermediate plies and number of flutes.

By increasing the number of intermediate plies it may be possible to provide stacked flutes creating an increased structural integrity and durability of the electrochemical membrane. Instead of (or in addition to) adding one or more intermediate plies in the electrochemical membrane, two e.g., single face type corrugated layer may be put together with the contact point at the flutes, or at least part of the flutes, of the corrugated layer.

The single face comprising a corrugated layer comprising one ply of fluted layer attached to a fuel permeable material or a gas permeable material or a material similar to the electrochemical membrane used in the corrugated layer.

The size of the flutes of the corrugated layer may be as small as possible to provide as large a cumulative surface area as possible, but not so small that access of the fuel material may be prevented or impeded.

Preferably the size (the height) of the flutes of the corrugated layer may be in the range of 0.5-10 mm, such as in the range of 1-8 mm, e.g., in the range of 1.5-6 mm, such as in the range of 2-5 mm, e.g., in the range of 3-4 mm.

In an embodiment of the present invention the electrochemical membrane may comprise a single corrugated layer, a double corrugated layer, a triple corrugated layer, a quadruple 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 usage, durability needed, the application and accessibility to the electrochemical reactor. In a preferred embodiment of the present invention the layers of the electrochemical membrane may comprise an anode, electrolyte and cathode.

Increasing the number of corrugated layers of the electrochemical membrane may also provide higher rigidity, higher mechanical strength and therefore a lower risk of mechanical damages to the electrochemical membrane and to the electrochemical reactor. This may also reduce the risk of loss of product production and improved productivity through improved electrochemical membrane longevity.

The flutes may be provided in different shapes. In an embodiment the flutes of the corrugated layers may be in a waveform; in a serrated shape; round shapes; or castellated.

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

In an embodiment of the present invention, the electrochemical membrane comprises a two layered structure. Preferably the two layered structure comprise two corrugated layers of the electrochemical membrane.

In yet an embodiment of the present invention the electrochemical membrane comprises a three-layered structure. The three-layered structure may comprise at least one corrugated layer, such as at least two corrugated layers, e.g., three corrugated layers. To save space in the electrochemical membrane it may be preferred that the three-layered structure may comprise one corrugated layer and two straight, or substantially straight layers in either side of the corrugated layer. This would also provide for built-in operational redundancy for the product chamber of one layer in one direction.

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

When two corrugated layers are facing each other and combined, the two corrugated layers may be separated by a product permeable element. One advantage of having three or more layers in the electrochemical membrane, such as four or more layers in the membrane, may be that such electrochemical membrane may provide built-in operational redundancy for the product chamber and result in a significant reduction in vulnerability to consequential damage due to the formation of hot-spot hole or tares in the electrochemical membrane, e.g. due to local heat damages on the electrochemical membrane. These hot-spots may cause mixing of fuel and product, whereby the product stream may be contaminated. Increased mechanical stability, durability and reliability all increase lifetime, and reduce the frequency of replacement, and lessen overall operational costs.

A preferred embodiment of the present invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 present invention relates to an electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 where in the interspace between the at least two layers of the electrochemical membrane defines a product chamber.

A yet preferred embodiment of the present invention relates to a electrochemical reactor comprising at least one fuel inlet in fluid connection to 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, e.g. at least three corrugated layers, such as at least four corrugated layers, e.g. at least five corrugated layers, such as at least six corrugated layers.

In an embodiment of the present invention the electrochemical reactor where in the at least one electrochemical membrane may be folded or printed in a spiral, concentric, radial or disc shape in a cartridge installed around the intensified reactor chamber. In a further embodiment of the present invention the at least one electrochemical membrane may comprise at least two layers and where in the interspace between the at least two layers of the at least one electrochemical membrane defines a product chamber.

Preferably, the at least two layers may comprise contact-points combining the at least two layers in part of the at least one electrochemical membrane.

The interspace between the at least two layers of the at least one electrochemical membrane and between the contact points combining the at least two layers in part of the at least one electrochemical membrane may define the product chamber.

In yet an embodiment of the present invention the at least one electrochemical membrane may comprise at least one corrugated layer, such as at least two corrugated layers, e.g., at least three corrugated layers, such as at least four corrugated layers, e.g., at least five corrugated layers, such as at least six corrugated layers.

In an embodiment of the present invention the centre of the electrochemical reactor may comprise an intensified reactor or part hereof, e.g., a Taylor-Couette Reactor (TCR) or part hereof.

The electrochemical reactor and the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), may preferably be two separate items that may be combined by including the intensified reactor, e.g., the Taylor-Couette Reactor (TCR), within the electrochemical reactor, preferably in the centre of the electrochemical reactor improving the production of hydrogen.

Preferably, the centre of the electrochemical reactor comprises a Taylor-Couette Reactor (TCR) or part hereof.

Part of the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), may relate to the rotating central part of the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), which may be the part of creating the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), flow in the fuel provided in the fuel chamber.

Preferably, the electrochemical reactor comprises a core part comprising the intensified reactor, e.g., a Taylor-Couette Reactor (TCR). The intensified reactor, e.g., a Taylor-Couette Reactor (TCR), may be surrounded by the fuel chamber. The fuel chamber may be surrounded by the one or more electrochemical membranes according to the present invention. The one or more electrochemical membranes according to the present invention may each contain the product chamber or two or more product chambers may be formed by at least two layers within each electrochemical membrane. The intensified reactor, e.g., a Taylor-Couette Reactor (TCR), the fuel chamber, the one or more electrochemical membrane and the product chambers may be surrounded by a casing holding and protecting the active part of the electrochemical reactor.

The intensified reactor, e.g., a Taylor-Couette Reactor (TCR) may be in fluid connection with 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 an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), and an electrochemical membrane according to the present invention.

The electrochemical reactor with or without (preferably with) the intensified reactor, e.g. a Taylor-Couette Reactor (TCR), according to the present invention may preferably be suitable for converting a fuel like a hydrocarbon composition with or without carbon dioxide (CO₂) to a composition comprising hydrogen (H₂).

Preferably, conversion of at least part of the fuel to hydrogen (H₂) or the means for performing gasification may be done with an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), provided in the centre of an electrochemical membrane according to the present invention.

The Taylor-Couette Reactor (TCR) may be an apparatus that has been designed to utilize the Taylor-Couette flow, which allows many flow regimes and conditions to occur as well as chemical conversions with precise control of various reactor characteristics.

The intensified reactor e.g., Taylor-Couette Reactor (TCR) may consist of a cartridge shell in which a first (rotating) inner cylinder may be inserted so that a first annular gap may be formed.

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

A preferred embodiment of the present invention relates to an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), comprising an energy unit and an intensified reaction chamber surrounded by a electrochemical reactor shell, said intensified reaction chamber comprises at least one fuel-inlet, and at least one hydrogen-outlet (H₂-outlet), e.g. for gasification reaction products in fluid connection to a fuel chamber located inside the electrochemical reactor; wherein the electrochemical reaction chamber comprises an electrochemical membrane according to the present invention.

Another preferred embodiment of the present invention relates to an intensified reactor, e.g. a Taylor-Couette Reactor (TCR), comprising an energy unit and an intensified reaction chamber surrounded by a electrochemical reactor shell, said intensified reaction chamber comprises at least one fuel-inlet, and at least one hydrogen-outlet (H₂-outlet), e.g. for gasification reaction products in fluid connection to 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 (CO₂-outlet) for residual fuel and gasification reaction products.

A preferred embodiment of the present invention relates to a electrochemical reactor comprising a least one fuel inlet in fluid connection to 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 a fuel provided to the fuel chamber moves substantially in the radial direction relative to the longitudinal direction of the electrochemical reactor and/or wherein the product moves substantially in the longitudinal direction of the longitudinal direction of the electrochemical reactor.

A further preferred embodiment of the present invention relates to an electrochemical reactor comprising an electrochemical membrane and a least one fuel inlet in fluid connection to a fuel chamber located inside the electrochemical reactor and a spiral flow paths (6), at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein a fuel provided to the fuel chamber moves substantially in the radial direction relative to the longitudinal direction of the electrochemical membrane and/or wherein the product moves substantially in the longitudinal direction of 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 an embodiment of the present invention the substantially radial direction may be substantially perpendicular to the substantially longitudinal direction.

The term "substantially in the radial direction" and/or "substantially in the longitudinal direction" relates to a movement directed mainly in the radial direction or the longitudinal direction, respectively, but may include helical spiralling of the radial flow spacer strips longitudinally to lengthen the flow path spiral for improved fuel contact/residence time.

Preferably, the "substantially radial direction"; the "substantially perpendicular direction" and/or the "substantially longitudinal direction" may deviate by at most 20% from radial direction; the perpendicular direction and/or the longitudinal direction, such as by 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 a hydrocarbon liquid or gas e.g., methane (CH₄), biogas, water (H₂O), carbon dioxide (CO₂), carbon monoxide (CO) and contaminants.

In the context of the present invention the term "radial" relates to a movement along a radius from a centre of the electrochemical reactor at a distance which may be increasing as the fuel (or gasification reaction products) moves from the inner annulus of the electrochemical membrane to the outer annulus of the electrochemical membrane - e.g., the movement in a spiral, concentrically or radial direction.

Preferably, the product provided in the product chamber and received at the product outlet may be hydrogen (H₂).

A preferred embodiment of the present invention relates to the use of the electrochemical reactor according to the present invention, the cartridge according to the present invention with or without the intensified reactor, e.g., a Taylor-Couette Reactor (TCR) according to the present invention for converting a hydrocarbon composition at least partly into a composition comprising hydrogen (H₂).

Hydrocarbon compositions obtained from a sub-surface reservoirs (or introduced at surface; as in the geothermal well option) may be a fuel according to the present invention, and there is a well-known worldwide interest to reduce or even avoid emission of these potent greenhouse gas components and reaction products from these fuels, like carbon dioxide (CO₂) and methane (CH₄), into the atmosphere reducing the serious environmental problems and the effects on global warming. Thus, there is an interest in finding alternative energy sources or alternative utilization of existing sources e.g., fuel or hydrocarbon compositions in a climate beneficial way that are more environmentally friendly. The intensified reactor, e.g., a Taylor-Couette Reactor (TCR), and the electrochemical membrane according to the present invention are a solution to this improved utilization, where an energy source may be provided in the form of a composition enriched wholly or partly in hydrogen (H₂) which may be produced in an effective, productive and environmentally friendly and climate beneficial manner.

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

In an embodiment of the present invention the intensified reactor chamber of the electrochemical reactor may further comprise at least one water inlet (H₂O-inlet) and/or at least one air-inlet (O₂-inlet) . The at least one water inlet (H₂O-inlet) and/or at least one air-inlet (O₂-inlet) may preferably be present when the electrochemical reactor with or without the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), may be used for injecting carbon dioxide (CO₂) into a reservoir. This may result in further production of the energy source, in particular hydrogen (H₂) by:

Boudouard Reaction, where a hydrocarbon feed and carbon dioxide (CO₂) are reacted to provide a source of carbon monoxide in addition to hydrogen, and/or Auto-Thermal Reforming (ATR), where syngas (comprising hydrogen (H₂) and carbon monoxide (CO)), may be produced by partially oxidizing a hydrocarbon feed (such as methane (CH₄) or biogas) with carbon dioxide (CO₂) and/or water (H₂O) and/or oxygen, and/or

Steam Methane Reforming (SMR) wherein syngas (comprising hydrogen (H₂) and carbon monoxide (CO)) may be produced by reaction of hydrocarbons with water (H₂O), and/or

Water Gas Shift Reaction (WGSR) where the carbon monoxide (CO) is converted via reaction with water (H₂O) to provide Hydrogen (H₂).

The at least one product outlet may be least one hydrogen-outlet (H₂-outlet).

In addition to the at least one hydrogen-outlet (H₂-outlet) the electrochemical reactor according to the present invention may also comprise at least one carbon dioxide-outlet (CO₂-outlet). The CO₂-outlet may be found in connection with the outer annulus of the electrochemical membrane and may also be considered a product with value (e.g., carbon credits). Preferably, the at least one hydrogen-outlet (H₂-outlet) may be separated by the at least one fuel inlet and/or the at least one carbon dioxide-outlet (CO₂-outlet) by an electrochemical membrane according to the present invention.

In an embodiment of the present invention the at least one electrochemical membrane may separate hydrogen (H₂) from the hydrocarbon composition, nitrogen, carbon monoxide, water, and/or carbon dioxide mixture by an electrochemical separation method. The electrochemical separation method may apply an electric current to at least one electrochemical membrane and hydrogen can be electrochemically dissociated on a catalyst of the anode, transported across the hydrated proton exchange material, and then recovered on the catalytic cathode.

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

In the present context the terms "electrochemical membrane" and "membrane" may be used interchangeably.

In a further embodiment of the present invention the at least one electrochemical membrane according to the present 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 an embodiment of the present invention the high temperature exchange membrane may operate, may be capable of operating, maybe suitable for operating, at a temperature above 100°C, such as above 200°C, e.g. above 300°C, such as above 400°C, e.g. above 500°C, such as above 600°C, e.g. above 700°C, such as above 800°C, e.g. above 900°C, such as above 1000°C, e.g. above 1100°C, such as above 1200°C, e.g. in the range of 100-1200°C, e.g. in the range of 500-1000°C, such as in the range of 650-850°C, such as in the range of 675-800°C, e.g. in the range of 700-750°C.

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 protonic ceramic electrochemical cell (PCEC); a solid oxide electrolysis cell (SOEC); a hybrid solid oxide electrolysis cell (H-SOEC); Proton Exchange Membrane (PEM); or a combination hereof.

The fuel, e.g., the hydrocarbon composition, preferably in combination with water, may be transported from the at least one fuel-inlet into a fuel chamber where the hydrocarbon composition (together with the optional, externally sourced, surface injection of carbon dioxide, CO₂) may be converted to different reaction products, including hydrogen (H₂). The hydrogen (H₂) produced may then be electrochemically transferred through the at least one electrochemical membrane, preferably a proton exchange material, to the hydrogen-outlet (H₂-outlet) of the electrochemical reactor.

In the fuel chamber and intensified reactor chamber various reactions may occur, in particular gasification of the hydrocarbon composition introduced may preferably be provided, resulting in the formation of hydrogen (H₂). The hydrogen (H₂) produced may subsequently be electrochemically transferred through the at least one electrochemical membrane to the at least one product outlet, e.g., a hydrogen-outlet (H₂-outlet).

It may be necessary to supply energy to the intensified reactor, e.g. a Taylor-Couette Reactor (TCR), to provide the necessary rotation of the central element creating e.g. the Taylor-Couette flow, the ignition source for reaction (to provide the minimum activation energy required to initiate chemical reactions (thereafter the net-exothermic reactions may self-propagate within the reactor)) and (as necessary) to facilitate the electrolytic reactions in the electrochemical reactor. The energy applied may come fully or partly from the geological surroundings or the chemical reactions as such or mechanically e.g, via Heat Transfer, Heat Energy Recovery Systems (HERS), Turbo-Expanders, turbine generators or the like within the tool or a combination of the above. However, to provide, and ensure, sufficient energy to the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), and electrochemical membrane, if necessary, energy may be provided from external sources, via an electrical cable or fluid injection. The external sources may preferably be obtained from wind power, solar power or the like.

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

In a further embodiment of the present invention the electrochemical reactor may comprise means for connecting an electrical cable. The electrical cable may provide power and energy, at least initially, for starting and/or running the process, e.g., the gasification and electrochemical processes. During operation, the process may generate sufficient power and energy to support the process and it may become needless to supply power and energy, and the process may even generate an excess of energy that may be exported to the surface.

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

The electric cable may equally provide a means to export energy, if/when an excess of energy is provided by the electrochemical reactor.

A preferred embodiment of the present invention relates to a system for recovering a composition comprising hydrogen (H₂) utilising fluid or gas from a sub-surface reservoir, the system comprising a processing rig, the processing rig comprises an electrochemical reactor with/without an intensified reactor converting a hydrocarbon composition at least partly into a composition comprising hydrogen (H₂), wherein the system further comprises means for separating the hydrogen from the reaction products and providing carbon capture utilisation and storage (CCUS) of CO₂.

In the present context the term "processing rig" may relate to a collection of surface and downhole equipment that receives both the hydrocarbon composition flow stream (from either surface or a geological reservoir) entering the wellbore and the externally sourced CO₂ at surface. This surface equipment may comprise processes to aid in; separation (into constituents), chemical or physical treatment, compression, or additional pumping of the hydrocarbon composition & it's constituents to storage, further processing or export & sale.

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

In an embodiment of the present invention the electrochemical reactor may be placed inside a wellbore at a substantially equivalent vertical depth of the hydrocarbon reservoir or the geothermal reservoir, where the exhaust of the reactor (e.g., exhaust of CO₂) may be pumped into the hydrocarbon reservoir or the geothermal reservoir.

Preferably, the carbon dioxide (CO₂) captured by means for providing carbon capture of CO₂ may include the CO₂ naturally present in the hydrocarbon composition or produced from converting the hydrocarbon composition at least partly into a composition comprising hydrogen (H₂), and/or introduced from an external source and injected from the surface.

In an embodiment of the present invention the carbon dioxide (CO₂) captured according to the present invention (from the hydrocarbon composition, the conversion of hydrocarbon to hydrogen, and/or introduced from an external source and injected from the surface) may also include carbon monoxide (CO).

Preferably, the composition comprising hydrogen (H₂) may be an organic composition comprising hydrogen (H₂).

According to the present invention the fuel, e.g., the hydrocarbon composition, may at least partly be converted into a composition comprising hydrogen (H₂). The term "at least partly" may relate to at least 1% (w/w) of the hydrocarbon composition may be converted into a composition comprising hydrogen (H₂), e.g. at least 5% (w/w) of the hydrocarbon composition may be converted into a composition comprising hydrogen (H₂), such as at least 10% (w/w) of the hydrocarbon composition, e.g. 20% (w/w) of the hydrocarbon composition, such as at least 30% (w/w) of the hydrocarbon composition, e.g. 40% (w/w) of the hydrocarbon composition, such as at least 50% (w/w) of the hydrocarbon composition, e.g. 60% (w/w) of the hydrocarbon composition, such as at least 70% (w/w) of the hydrocarbon composition, e.g. 80% (w/w) of the hydrocarbon composition, such as at least 90% (w/w) of the hydrocarbon composition, e.g. 95% (w/w) of the hydrocarbon composition, such as at least 97% (w/w) of the hydrocarbon composition, e.g. 99% (w/w) of the hydrocarbon composition.

The effect of the electrochemical membrane with or without (preferably with) the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), according to the present invention may be enhanced by: the geothermal heating alone (at sub-surface treatment); geothermal heating in combination with heat pumps and/or heat exchangers (at the sub-surface, surface or super-surface treatment); or the geothermal heating in combination with electrical heat (at sub-surface treatment or at the surface or super-surface treatment); incorporation of catalyst materials; the geological pore pressures alone (at sub-surface treatment); geological pore pressures in combinations with the temperature combinations listed above; or externally supplied, surface injected, carbon monoxide (CO) and/or carbon dioxide, (CO₂); improved electrolyte chemistry within the electrochemical membrane layers of the electrochemical reactor; heat energy recover systems (HERS), combined heat and power systems (CHP), Turbo-Expanders, turbine generators or the like.

Preferably, the reactor according to the present invention is working at sub-surface conditions.

Preferably, the reactor may be converting a hydrocarbon composition at least partly into a composition comprising hydrogen (H₂).

The electrochemical reactor (preferably with the intensified reactor, e.g., a Taylor-Couette Reactor (TCR),) according to the present invention may comprise means for injecting e.g., carbon monoxide (CO) and/or carbon dioxide (CO₂) into a reservoir. The injection of carbon monoxide (CO) and/or carbon dioxide (CO₂) into a subsurface reservoir may be performed via: the same well as the well for obtaining the hydrogen (H₂); and/or a well different from the well for obtaining the hydrogen (H₂), but which well is in fluid communication with the well for obtaining the hydrogen (H₂); or a well into a reservoir where hydrogen (H₂) is no longer generated or has ever been generated.

Preferably, the carbon monoxide (CO) and/or carbon dioxide (CO₂) subjected to carbon capture may be carbon monoxide (CO) and/or carbon dioxide (CO₂) produced from the means for converting a hydrocarbon composition at least partly into a composition comprising hydrogen (H₂).

In an embodiment of the present invention, the carbon monoxide (CO) and/or carbon dioxide (CO₂) may be contained with the Hydrocarbon composition and may also be provided from externally sources or be a combination of carbon monoxide (CO) and/or carbon dioxide (CO₂) from externally sources in combination with carbon monoxide (CO) and/or carbon dioxide (CO₂) produced from the means for converting a hydrocarbon composition at least partly into a composition comprising hydrogen (H₂).

Preferably, the composition comprising hydrogen (H₂) may be obtained from the product outlet and may be enriched in hydrogen (H₂). In an embodiment of the present invention the composition comprising hydrogen (H₂) comprises at least 1% (w/w) hydrogen (H₂), e.g. at least 5% (w/w) hydrogen (H₂), such as at least 10% (w/w), e.g. at least 15% (w/w), such as at least 20% (w/w), e.g. at least 25% (w/w), such as at least 30% (w/w), e.g. at least 40% (w/w), such as at least 50% (w/w), e.g. at least 60% (w/w), such as at least 70% (w/w), e.g. at least 80% (w/w), such as at least 85% (w/w), e.g. at least 90% (w/w), such as at least 95% (w/w), e.g. at least 98% (w/w).

In an embodiment of the present invention the reservoir may comprise water and water may be formed during the conversion of the hydrocarbon composition at least partly into a composition comprising hydrogen (H₂).

Electrolysis according to the present invention may also occur in combination with increased subsurface temperature and pressure to improve the conversion of fuel (e.g., the hydrocarbon composition) at least partly into a composition comprising hydrogen (H₂).

Preferably, the electrochemical reactor with or without the intensified reactor according to the present invention may be placed at least 100 meters TVD sub-surface, such as at least 150 meters TVD sub-surface, e.g. at least 250 meters TVD sub-surface, such as at least 500 meters TVD sub-surface, e.g. at least 750 meters TVD sub-surface, such as at least 1000 meters TVD sub-surface, e.g. at least 1500 meters TVD sub-surface, such as at least 2000 meters TVD sub-surface, e.g. at least 2500 meters TVD sub-surface, such as at least 5000 meters TVD sub-surface, e.g. at least 7500 meters TVD sub-surface, such as at least 10,000 meters TVD sub-surface, e.g. at least 12,500 meters TVD sub-surface, such as at least 15,000 meters TVD sub-surface.

In an embodiment of the present invention the electrochemical reactor with or without the intensified reactor may be at least 100 meters below the processing rig, such as at least 150 meters below the processing rig, e.g. at least 250 meters below the processing rig, such as at least 500 meters below the processing rig, e.g. at least 750 meters TVD below the processing rig, such as at least 1000 meters TVD below the processing rig, e.g. at least 1500 meters TVD below the processing rig, such as at least 2000 meters TVD below the processing rig, e.g. at least 2500 meters TVD below the processing rig, such as at least 5000 meters TVD below the processing rig, e.g. at least 7500 meters TVD below the processing rig, such as at least 10,000 meters TVD below the processing rig, e.g. at least 12,500 meters TVD below the processing rig, such as at least 15,000 meters TVD below the processing rig. Carbon capture according to the present invention may relate to the process of capturing carbon monoxide (CO) and/or the carbon dioxide (CO₂) before the carbon monoxide (CO) and/or the carbon dioxide (CO₂) originally present in the hydrocarbon composition or the carbon monoxide (CO) and/or the carbon dioxide (CO₂) produced during the conversion of the hydrocarbon composition (or parts hereof) into the hydrogen composition, enters the atmosphere.

Carbon capture may include carbon monoxide (CO) and/or the carbon dioxide (CO₂) also provided from an externally supplied source where carbon monoxide (CO) and/or the carbon dioxide (CO₂) may not be originating from the reservoir or the hydrocarbon composition, but may be provided from above surface, e.g. from the atmosphere, by above surface carbon capture or from any external CO₂ market source or industrial supply.

It may be operationally or commercially advantageous to inject the waste gases (e.g., CO₂ or CO) into an adjacent geological reservoir or formation (or vertically below or above the hydrocarbon reservoir) within the same or different well or wellbores.

The electrochemical reactor according to the present invention may be used in a geothermal process, wherein a hydrocarbon composition may be injected from surface.

Preferably, the carbon monoxide (CO) and/or carbon dioxide (CO₂) originally present in the hydrocarbon composition or produced during the conversion of the hydrocarbon composition (or parts hereof), or provided from an externally supplied source may be transported to and stored in the same reservoir as the reservoir the gasified hydrocarbon composition was obtained, or it may be transported and stored in a different reservoir or geological formation, via the same or different wells or wellbores. Preferably, the carbon dioxide (CO₂) originally present in the hydrocarbon composition or produced during the conversion of the hydrocarbon composition (or parts hereof) or provided from an externally supplied source may be stored in the same reservoir via the same or different wellbore.

In a preferred embodiment of the present invention the electrochemical reactor with the electrochemical membrane may, during operation, be placed sub-surface. Preferably, the electrochemical reactor with the electrochemical membrane may be placed sub-surface within the wellbore. Preferably, the electrochemical reactor with the electrochemical membrane may not be placed within the reservoir, with the exception that it remains within the wellbore, which is drilled within, along or through the reservoir, and is placed at an equivalent vertical depth of the reservoir. Preferably, sub-surface relates to a depth of the reactor below the surface of the earth, and at sea below the seabed.

The position of the reactor may preferably be at least 100 meters TVD sub-surface, such as at least 150 meters TVD sub-surface, e.g. at least 250 meters TVD sub-surface, such as at least 500 meters TVD sub-surface, e.g. at least 750 meters TVD sub-surface, such as at least 1000 meters TVD sub-surface, e.g. at least 1500 meters TVD sub-surface, such as at least 2000 meters TVD sub-surface, e.g. at least 2500 meters TVD sub-surface, such as at least 5000 meters TVD sub-surface, e.g. at least 7500 meters TVD sub-surface, such as at least 10,000 meters TVD sub-surface, e.g. at least 12,500 meters TVD sub-surface, such as at least 15,000 meters TVD sub-surface.

Preferably, the sub-surface may relate to hydrocarbon drilling or geothermal drilling.

In an embodiment of the present invention the chemical reaction of the hydrocarbon composition to produce the composition comprising hydrogen (H₂) may include gasification of the hydrocarbon composition at elevated temperatures.

Dependent on the vertical depth of the electrochemical reactor placed within the wellbore some or all fluids and gasses may naturally enter their supercritical fluids phases due to the hydrostatic or geothermal temperature and pressure present within the wellbore. The supercritical phase of a fluid may enhance the gasification process further, and reduce the energy required to process the hydrocarbon composition.

At shallower depths, supercritical conditions may also be induced or artificially created within the tool through techniques whereby the internal pressure within the tool may be increased either via applied surface pressure, flow restrictions causing back-pressure, weighted annular fluids or a combination of these.

The chemical reaction of the hydrocarbon composition to produce the composition comprising hydrogen (H₂), e.g. the gasification process, may require a significant amount of heat.

In an embodiment of the present invention a conversion of a fuel, when provided to the fuel-chamber, to hydrogen (H₂), at the product chamber, may include at least a gasification process. The gasification process may be an initial gasification process, preferably within the intensified reactor e.g., Taylor-Couette Reactor (TCR). This gasification process is also known as Indirect Internal Reforming (HR) prior to the reaction products entering the electrochemical reactor. The continuous electrochemical reactions may transfer hydrogen from the reaction product concentration within the flow path out to the product chamber and dynamically reduce the concentration of hydrogen in the flow path. This simultaneous and spontaneous transfer and removal of hydrogen may reduce the hydrogen concentration along the flow path which may then bias the chemical equilibrium of the gasification chemical reactions to produce more hydrogen in the flow path concentration, increasing the production and cumulative transfer of hydrogen to the product chamber.

The electrochemical reactor according to the present invention may convert a fuel, when provided to the fuel-chamber, into a composition comprising carbon dioxide (CO₂) or carbon monoxide (CO). This composition comprising carbon dioxide (CO₂) or carbon monoxide (CO) may generate a revenue stream and storage, for collection and capture at the waste outlet. Initiation of the composition comprising carbon dioxide (CO₂) or carbon monoxide (CO) may include at least a gasification process, preferably from within an intensified reactor.

The transfer of hydrogen via electrochemical membrane to the product chamber away from the gasification reaction products, e.g. within the spiral shaped electrochemical membrane pathway may increase waste concentrations within the pathway. Water and waste gases like CO₂ or CO may therefore be obtained at increased concentration at the at least one waste material outlet allowing excretion or collection of concentrated waste gases, like CO₂ or CO for the purpose of a revenue stream or capture. The flow streams of product (hydrogen) and waste (e.g., CO₂ & CO) may also be swapped or interchanged if operational optimisations dictate.

A significant amount of heat may be necessary to drive the chemical reaction of the hydrocarbon composition to produce the composition comprising hydrogen (H₂), e.g. the gasification process, may be above the minimum chemical reaction activation energy, and may be in the range of 100-1200°C, e.g. in the range of 500-1000°C, such as in the range of 650-850°C, such as in the range of 675-775°C, e.g. about 700°C.

Any residual fuel and gasification reaction products may also be subject to Direct Internal Reforming (DIR) or further gasification to produce hydrogen (H₂), within the electrochemical reactor.

In an embodiment of the present invention the electrochemical reactor performance may be further improved by the wellbore pressure which may be dependent on various parameters like, the depth of the wellbore (or the depth of the reactor in the wellbore), on the particular sub-surface reservoir, the location of the sub-surface reservoir; the different rock types surrounding the sub-surface reservoir and/or the wellbore, the different fluid/gas content, the geological structure, and/or formation thickness, etc.

Geothermal heating and/or geological pore pressure may be used as an energy source, or as a significant energy contribution, to heat up and accelerate the chemical reaction of the hydrocarbon composition to the composition comprising hydrogen (H₂), e.g., the gasification process, resulting in a significant reduction in production energy costs. The geological temperature and pore pressure may also be used to as an energy source to turn parts of the reaction compositions supercritical (e.g., CO₂, H₂ and H₂O), enhancing the speed, energy and efficiency of the reaction.

The geothermal heating and/or geological pore pressure may come from geothermal energy and is energy from the interior of the earth. The geothermal energy is considered to originate from the formation of the planet and from radioactive decay of materials. The high temperature and pressure in Earth's interior may cause some rock to melt and solid mantle to behave plastically, resulting in parts of the mantle convecting upward since it is lighter than the surrounding rock and temperatures at the core-mantle boundary can reach over 4000 °C.

Geothermal heating and/or geological pore pressure, for example using water from hot springs has been used for bathing since Palaeolithic times and for space heating since ancient Roman times, however more recently geothermal power, the term used for generation of electricity from geothermal energy, has gained in importance. It is estimated that the earth's geothermal resources are theoretically more than adequate to supply humanity's energy needs, although only a very small fraction is currently being profitably exploited, often in areas near tectonic plate boundaries.

When recovering water from water reservoirs, hydrocarbons compositions from gas reservoirs or from oil reservoirs, the depth of the reservoir may determine the temperature, pressure and the geothermal energy. Generally, the deeper the reservoir is located below the earth surface, the higher the geothermal energy and the higher the temperature, although geological anomalies do exist where higher temperatures and pressures are found at shallower depths than normal geological gradients predict.

Thus, the inventor of the present invention surprisingly found a way to exploit the geothermal energy in the generating of a composition comprising hydrogen (H₂). The generation of the composition comprising hydrogen (H₂) may preferably be provided together with a reduced discharge or emission of potent greenhouse gasses (GHG) like carbon dioxide (CO₂) and/or methane (CH₄). This may be further improved with the addition of the surface injection of methane (CH₄) (e.g., Biogas or Bio-methane), carbon monoxide (CO) and/or carbon dioxide (CO₂) from external supplied sources.

This improvement may be accomplished by the electrochemical reactor with or without (preferably with) the intensified reactor according to the present invention.

In an embodiment of the present invention the sub-surface reservoir may be a liquid hydrocarbon reservoir, e.g., an oil reservoir (a sub-surface oil reservoir), a gaseous hydrocarbon reservoir, e.g., a gas or condensate reservoir (a sub-surface gas reservoir), or a geothermal reservoir (a sub-surface geothermal reservoir).

Preferably, the electrochemical reactor with/without the intensified reactor according to the present invention may be suitable for recovering a product, in particular a hydrogen composition (H₂-composition), utilising a sub-surface reservoir. Preferably, the sub-surface reservoir may be a liquid hydrocarbon reservoir, e.g., an oil reservoir (a sub-surface oil reservoir), a gaseous hydrocarbon reservoir, e.g., a gas or condensate reservoir (a subsurface gas reservoir), or a geothermal reservoir (a sub-surface geothermal reservoir).

The intensified reactor according to the present invention may comprise a rotating energy unit. The rotating unit may preferably be rotating around the centre axis of the reactor. In an embodiment of the present invention the electrochemical reactor may comprise an intensified reactor, e.g., a Taylor-Couette Reactor (TCR).

The energy unit may supply to the intensified reactor, e.g. the Taylor-Couette Reactor (TCR), and/or to the electrochemical membrane of the present invention.

In an embodiment of the present invention the intensified reactor, e.g. a Taylor-Couette Reactor (TCR), may provide a rotation in the range of 100-30,000 rpm, such as in the range of 500-8,000 rpm; e.g. in the range of 1,000-6,000 rpm; such as in the range of 1500-5,000 rpm; e.g. in the range of 2,000-4,000 rpm; such as in the range of 2500- 3,500 rpm; e.g. about 3,000 rpm.

The inventor of the present invention found that scalability, serviceability, maintenance, sustainability and/or costs may be significantly improved by providing the electrochemical reactor according to the present invention as a cartridge comprising one or more cartridge elements according to the present invention. The cartridge construction may allow sequential/sectional repairments or replacement, on-site repairment or replacement resulting in less down time, less material waste and higher productivity. A preferred embodiment of the present invention relates to a cartridge comprising one or more cartridge elements, wherein the one or more cartridge element comprises a electrochemical reactor, the electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 present invention relates to a cartridge comprising one or more cartridge elements, wherein the one or more cartridge element comprises an electrochemical reactor, the electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 electrochemical reactor 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, membrane separating the fuel chamber and the product chamber may comprise at least one electrochemical reactor layer.

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

In the context of the present invention the term "cartridge" may relate to a container or a cassette holding the electrochemical membrane according to the present invention in the electrochemical membrane shape and/or electrochemical membrane structure providing a fuel chamber and ready to receive an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), and then ready to be used.

In an embodiment of the present invention the one or more cartridge elements may be one or more doughnut shaped cylindrical cartridge elements.

The cartridge according to the present invention may comprise multiple cartridge elements, such as 2 or more cartridge elements, e.g. 3 or more cartridge elements, such as 5 or more cartridge elements, e.g. 7 or more cartridge elements, such as 10 or more cartridge elements, e.g. 12 or more cartridge elements, such as 15 or more cartridge elements, e.g. 20 or more cartridge elements, such as 25 or more cartridge elements, e.g.

50 or more cartridge elements, such as 75 or more cartridge elements, e.g. 100 or more cartridge elements.

In an embodiment of the present invention the one or more doughnut shaped cylindrical cartridges may be provided with a central hole for receiving an intensified reactor, e.g., a Taylor-Couette Reactor (TCR).

In a further embodiment of the present invention the fuel chamber may be formed between the inner space formed between the cartridge and the intensified reactor, e.g., a Taylor-Couette Reactor (TCR).

When the cartridge comprises multiple cartridge elements the cartridge elements may be stacked on top of each other providing a central hole through the cartridge comprising multiple cartridge elements.

The central hole of the cartridge or the one or more doughnut shaped cylindrical cartridge elements may form the intensified reactor chamber and may allow insertion of the intensified reactor, e.g., a Taylor-Couette Reactor (TCR). When the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), may be inserted into the central hole of the doughnut shaped cylindrical cartridge the fuel chamber may be formed between the outer surface of the intensified reactor, e.g., a Taylor-Couette Reactor (TCR), and the inner annulus of the electrochemical membrane.

The intensified reactor may be a fluidic oscillator.

The fluidic oscillator may be based on Coanda and/or Bernoulli effects.

Preferably the fluidic oscillator may be selected from oscillatory baffled reactors, jetting devices to cause hydrodynamic cavitation or allowing pulsating flows by ultrasound or mechanical vibration, static mixer reactors, microreactors, ejector loop reactors, or reactors based on the Taylor-Couette flow (e.g., Taylor-Couette reactors, TCRs). Preferably, the intensified reactor or a fluidic oscillator may be a reactor based on the Taylor-Couette flow (in particular Taylor-Couette reactors, TCRs).

In an embodiment of the present invention the at least one electrochemical membrane of the doughnut shaped cylindrical cartridge may comprise a spiral shaped membrane structure, a corrugated membrane structure, a concentric radial membrane structure, a radial star membrane structure, or a disc membrane structure. The doughnut shaped cylindrical cartridge may comprise a spiral shaped 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 doughnut shaped cylindrical cartridge may comprise a single electrochemical membrane or multiple electrochemical membranes, where multiple electrochemical membranes may be provided with one electrochemical membrane around the another with an increasing radius from the centre of the doughnut shaped cylindrical cartridge.

In an embodiment of the present invention the electrochemical membrane of the doughnut shaped cylindrical cartridge may comprise spiral shaped membrane structure where the radius of the electrochemical membrane (relative to the centre of the electrochemical membrane) is continuously increasing when moving along the electrochemical membrane when formed around a centre of the doughnut shaped cylindrical cartridge.

In another embodiment of the present invention the electrochemical membrane of the doughnut shaped cylindrical cartridge may comprise a concentric radial membrane structures, where cylindrical shaped membranes with constant but increasing radius (relative to the centre of the electrochemical membrane) may be placed around each other with the concentric radial membrane structure having the smallest radius closest to the centre of the doughnut shaped cylindrical cartridge and the concentric radial membranes having the larger radius provided around as the radius increases.

The radial star electrochemical membrane structure may comprise several electrochemical membranes according to the present invention, preferably the multiple individual electrochemical membranes held by radial flow spacer strips the multiple individual electrochemical membranes may be provided in various sizes to increase the total electrochemical membrane surface area as the radius increases from the centre of the cartridge. Preferably the radial star electrochemical membrane structure is not provided as a doughnut shaped cartridge element. Although, for ease of use and handling, the assembled star structure may be contained within an outer doughnut shaped cartridge body shell. Figure 9 demonstrates an example of a radial star electrochemical membrane structure.

The disc electrochemical membrane structure may allow easy replacement of cylindrical discs, for easy up- or down-scaling together with the ease of 3D printing of complex shapes during manufacturing. The electrochemical disc membrane structure may comprise electrochemical membranes according to the present invention. Flow path dimensions of the disc electrochemical membrane structure may be varied by height (straight, converging, diverging, wavy), width (straight, converging, diverging, or wavy), obstacles in channel (baffles, traps, pin-fins, or the like), direction (spirals, straight, star, zig-zig, leaf shape, or the like), cross-sectional shape (circular, semi-circular, rectangle, or triangle), cross-sectional shape (with or without sub-channels), number of flow path outlets (or dead ends) vs. inlets, even number of Archimedean spirals to offset the cathodes & anodes opposite each, suitable for adjusting the residence time (e.g. for providing long, medium or very short residence times for the membrane). A disc reactor may comprise multiple disc membranes stacked to a required axial length. Figure 10 demonstrates an example of a disc membrane structure. Construction using 3D printing may be used to print the above complex flow paths.

The electrochemical membrane may preferably be surrounding the fuel chamber of the electrochemical reactor.

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

The invention will now be described in further details in the following detailed description of the figures.

Fig ures la shows the radial view of the spiral shaped membrane (1) according to the present invention and figure lb show a longitudinal view of the spiral shaped electrochemical membrane (1) as shown in figure la.

Figures la and lb shows an example of the spiral shaped electrochemical membrane (1) installed around a rotating intensified reactor, e.g. a Taylor-Couette Reactor (TCR), (2) located in the centre of the spiral - in an intensified reaction chamber (24). The spiral shaped electrochemical membrane (1) comprises a fuel chamber (3). The fuel chamber (3) may extend from the inner annulus (4) to the outer annulus (5) along the flow path (6) created by the spiral shaped electrochemical membrane (1). The inner annulus (4) contains both the fuel, such as a hydrocarbon composition, and reaction products from its' gasification reactions within the inner annulus (4). As any remaining fuel, such as a hydrocarbon composition, and the gasification gases move from the inner annulus (4) along the flow path (6) of the spiral shaped electrochemical membrane (1) towards the outer annulus (5). The fuel, e.g., the hydrocarbon composition, may further react to produce hydrogen ions (H⁺) and gasification gases. The hydrogen, contained within the gasification reaction products, reacts with the electrochemical membrane and is removed from the hydrocarbon composition's stream flow path (6). The longer the hydrocarbon composition and gasification reaction products move along the flow path (6), the lower the concentration of hydrocarbons and the higher the concentration of remaining gasification gases in the flow path (6), and the higher the concentration of hydrogen (H₂) formed within the product chamber (10). Preferably, water and waste gases like CO₂ or CO may be obtained at the outer annulus (5). At least one waste material outlet (not shown) may be provided in fluid connection with the outer annulus (5) allowing excretion or collection of waste gases, like CO₂ or CO.

As the fuel (the hydrocarbon composition) and gasification reaction products move from the inner annulus (4) along the flow path (6) the anodes (8) provided on the outer surface of the spiral shaped electrochemical membrane (1) (and also as the outer surface of the corrugation layers (18)) enable the development of hydrogen ions (protons, H⁺) which move through the electrolyte (7) within the corrugation layer (18) to the cathode (9) (the inner surface of the corrugation layers (18), which also acts as the product chamber (10) surface) where it receives an electron and re-forms as a hydrogen atom, which then recombines with another hydrogen atom (H) and creates hydrogen gas (H₂) in the product chamber (10).

Non-conducting radial flow spacer strips (15) are provided circumferentially (at intervals longitudinally) along the spiral length of the electrochemical membrane (1) to keep the electrochemical membrane from contacting from itself and to provide a flow path (6) for the fuel, such as a hydrocarbon composition, and gasification reaction products as they travel from the inner annulus (4) to the outer annulus (5).

The spiral shaped electrochemical membrane (1) demonstrated in figure 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 double corrugated layer, e.g. a triple corrugated layer, such as a quadruple corrugated layer.

Figure 2: Figure 2a shows an electrochemical membrane (1) for a electrochemical reactor according to the present invention having two corrugated layers (18) as well as a view (figure 2b) on how the membrane may be spiralled to form the spiral shaped electrochemical membrane (1) according to the present invention with a centrally placed intensified reactor, e.g. a Taylor-Couette Reactor (TCR), placed in the intensified reaction chamber (24). The corrugated layers (18) are provided with several anodes (8) facing the fuel chamber (3) and cathodes (9) facing the product chamber (10). Between the anode (8) and the cathode (9) an electrolyte (7) may be placed. Hydrogen (H₂) may be produced as described above and stored in the product chamber (10). Fuel may be provided to the fuel chamber (3) e.g. via fuel permeable liners (11) assisting with the structure of the electrochemical membrane (1). The liners (11) may function as plies of the corrugated layer (18) of the electrochemical membrane (1). The liners ( 1 l)/plies are provided with anodes (8) which are connected to the corrugated layers (18) at the fuel chamber side of the electrochemical membrane (1). The corrugated layers (18) are also provided with cathodes (9) which are connected to a gas permeable liner (13) at the product chamber side of the electrochemical membrane (1). Flow paths (6) are formed on one or both sides of the electrochemical membrane (1).

Figure 3 shows a 3 layers electrochemical membrane (1) where two layers (12) (the top layer and the bottom layer) are straight and one corrugated layer (18) are provided with anodes (8), electrolyte (7) and cathodes (9) to promote hydrogen (H₂) formation as described previously. The fuel chamber may be the area outside the top layer (12) and bottom layer (12). Between the layers (12) and corrugated layers (18) product chambers (10) are formed. Fuel may be provided to the fuel chamber (3) surrounding the top layer (12) and bottom layer (12) and flow paths (6) are formed on one or both sides of the electrochemical membrane (1).

Figure 4 shows a 4 layered electrochemical membrane (1) where two layers (12) (the top layer (12) and the bottom layer (12)) are straight and two corrugated layers (18) are provided in between the straight layers (12). The fuel chamber (3) may be the area outside the top layer (12) and bottom layer (12), and between the layers (12) and corrugated layers (18) product chambers (10) are formed. The two corrugated layers may be separated by a gas permeable liner (13) allowing transfer of hydrogen (H₂) from one product chamber (10) to another. The layers (12) and corrugated layers (18) may be provided with anodes (8), electrolytes (7) and cathodes (9) to promote hydrogen (H₂) formation as described previously. Flow paths (6) are formed on one or both sides of the electrochemical membrane (1)

Figure 5 shows a 4 layered electrochemical membrane as described in figure 4 and illustrates the advantage of multiple layers (12/18) in the electrochemical membrane as a significant reduction in vulnerability to consequential damage due to the formation of hotspot holes (14) or tares in a layer (12) of the electrochemical membrane (1), e.g. due to local heat damages on the electrochemical membrane (1). These hot-spots (14) may cause mixing of fuel and product, whereby the product stream may be contaminated. However, when working with e.g. 3 or 4 layers electrochemical membranes a hot spot (14) in one layer may allow the hydrogen (H₂) product to move into adjacent product chambers (10). This therefore provides a deliberate built-in redundancy for durability, reliability, longevity and productivity, while improving mechanical strength and robustness to reduce the probability of incidents of tool failure.

Figure 6 illustrates the spiral structures according to the present invention to be used in a electrochemical membrane. Figure 6a shows a single spiral, preferably a single Archimedean spiral. To increase volume through-put of fuel and gasification gases in the electrochemical membrane, the number of flow paths (6) for fuel and gasification gases may be increased and multi-spirals may be used, where each spiral used provides a separate flow path (6). Preferably, the multi-spirals may be Archimedean multi-spirals, with separate spirals each starting at intervals of X deg of arc [Figure 6b]- depending on the number of spirals included. An advantage of using multi-spirals may be to reduce the measured length of each spiral (per cross-sectional area) and thus the gas residence time (per spiral). Furthermore, the use of multi-spirals may increase gas rate through-put since, as each spiral flow path (6) is shorter, it provides a lower pressure loss and the total cross- sectional area available to flow is increased, (i.e. from one flow path (6) to many flow paths (6) open to flow from the inner annulus (4) to the outer annulus (5)).

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

This flow path permits the electrochemical membrane to perform the electrochemical sieving of the valuable gasification reaction products from the intensified reactor, e.g. a Taylor-Couette Reactor (TCR), into separate flow streams for sale or capture.

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

Archimedean spirals permit the simultaneous initiation of multiple spirals from the central annulus of the intensified reactor, e.g. a Taylor-Couette Reactor (TCR), increasing volume throughput and reducing residence times and pressure drop within the spiral where necessary. The number of spirals is customized to optimize the process.

Figure 7 shows an example of the construction of an electrochemical membrane (1) to be installed around an intensified reactor, e.g. a Taylor-Couette Reactor (TCR), (2) in the centre of the spiral. In step I the cathode (9) may be prepared from a cathode material as a range of capillary tubes creating the product chamber (10) and the capillary tubes may be connected to from a string of product chambers. These capillary tubes act like a pseudo-corrugation.

In step II an electrolyte (7), e.g. 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) comprising a string of capillary tubes having 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), where the cathode (9) and the anode (8) are separated by the electrolyte (7) and flexible insulators (16).

The electrochemical membrane (1) provided may be installed e.g., within a doughnut shaped cylindrical cartridge and placed around an intensified reactor, e.g., a Taylor-Couette Reactor (TCR), (2) placed in the centre providing a spiral shaped electrochemical membrane (1) surrounding the intensified reactor, e.g., a Taylor-Couette Reactor (TCR). The spiral shaped electrochemical membrane (1) comprises a fuel chamber (3). The fuel chamber (3) may extend from the inner annulus (4) to the outer annulus (5) along the flow path (6) created by the spiral shaped electrochemical membrane (1).

Figure 8 shows an example of the construction of a spiral shaped electrochemical membrane (1), with internal corrugations (18), to be printed around an intensified reactor, e.g. a Taylor-Couette Reactor (TCR) (2) at the centre of the spiral. The anode (8), electrolyte (7) and cathode (9) layers may be simultaneously 3D printed onto a liner (11) in a corrugated build-on pattern using multi-headed printers (17), each with its' own specific 'ink' (e.g., of metal, electrolyte and insulator) to deposit. Radial flow spacer strips (15) of insulating material are printed at intervals on the liner, circumferentially and perpendicular to the longitudinal product chambers (10) to maintain flow paths between the individual spiral electrochemical membrane (1) wraps. The printing continues until the desired outer diameter is reached. The space inside two corrugated layers (18) may form a product chamber (10) and on the outside of the two corrugated layers (18) the fuel chamber (3) is provided. Between the two corrugated layers (18) a gas permeable liner (13) may be provided.

Figure 9 shows a cartridge (19) in form of a radial star reactor (20) comprising multiple radial star membrane structures (21) comprising electrochemical membranes according to the present invention. The multiple radial star membrane structures (21) are individual electrochemical membranes held by radial flow spacer strips (15). In figure 9 the multiple radial star membrane structures (21) is provided in various sizes to increase the total electrochemical membrane surface area as the radius increases from the centre of the cartridge (19). The cartridge (19) is provided with a central hole for receiving an intensified reactor in form of a Taylor-Couette Reactor (TCR) (2).

Figure 10 shows a cartridge (19) in form of a cylindrical disc reactor (22) which may comprise multiple disc membranes (23) stacked to a required axial length. The disc membrane structures (23) may preferably comprise electrochemical membranes according to the present invention. The cartridge (19) is provided with a central hole for receiving an intensified reactor in form of a Taylor-Couette Reactor (TCR) (2).

References

1) Electrochemical Reactor

2) Intensified reactor, e.g. a Taylor-Couette Reactor (TCR),

3) Fuel chamber

4) Inner annulus

5) Outer annulus

6) Flow path

7) Electrolyte

8) Anode

9) Cathode

10) Product chamber

11) liner/ply

12) Electrochemical membrane Layer (comprising an anode, electrolyte and cathode)

13) Gas permeable liner

14) Hot spot

15) Radial flow spacer strips

16) Flexible insulator

17) 3D printer heads (containing various materials)

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

19) Cartridge

20) A radial star reactor

21) Radial star membrane structures

22) A disc reactor

23) disc membrane structures

24) Intensified reaction chamber

Claims

1. An electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 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. The 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 paths (6) and/or wherein the electrochemical membrane is provided with a cathode surface (9) facing the product chamber.

3. The electrochemical reactor according to anyone of the preceding claims wherein the electrochemical membrane is a proton-conducting electrochemical membrane.

4. The electrochemical reactor according to anyone of the preceding claims wherein the at least one electrochemical membrane between the fuel chamber and/or the product chamber may comprise at least one layer, wherein at least one layer may be a corrugated layer.

5. The electrochemical reactor according to anyone of the preceding claims, wherein the centre of the electrochemical reactor comprises an intensified reactor or part hereof, e.g. a Taylor-Couette Reactor (TCR) or part hereof.

6. The electrochemical reactor according to anyone of the preceding claims, wherein a conversion of a fuel, when provided to the fuel-chamber, to hydrogen (H₂), at the product chamber, includes at least a gasification process.

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

8. The electrochemical reactor according to anyone of the preceding claims, wherein the electrochemical reactor comprises means for supplying energy or power to the electrochemical reactor.

9. A cartridge comprising one or more cartridge elements, wherein the one or more cartridge element comprises an electrochemical reactor, the electrochemical reactor comprising at least one fuel inlet in fluid connection to 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 electrochemical reactor the at least one electrochemical membrane comprises at least one high temperature proton exchange membrane.

10. The cartridge according to claim 9, wherein the one or more cartridge element is one or more doughnut shaped cylindrical cartridge elements.

11. The cartridge according to anyone of claims 9-10, wherein the cartridge, in particular the one or more doughnut shaped cylindrical cartridge elements, is provided with a central hole for receiving an intensified reactor.

12. The cartridge according to claim 11, wherein the fuel chamber is formed between the inner space formed between the cartridge and the intensified reactor.

13. An intensified reactor, e.g. a Taylor-Couette Reactor (TCR), comprising an intensified reaction chamber surrounded by an electrochemical reactor jacket, said intensified reaction chamber comprises at least one fuel-inlet, and at least one hydrogen-outlet (H₂-outlet); and an energy unit, 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 a least one fuel inlet in fluid connection to a fuel chamber located inside the electrochemical reactor and spiral flow paths (6), at least one product outlet in fluid connection with a product chamber located inside the electrochemical reactor, wherein a fuel provided to the fuel chamber moves substantially in the radial direction relative to the longitudinal direction of the electrochemical membrane and/or wherein the product moves substantially in the longitudinal direction of 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.

15. Use of the electrochemical reactor according to anyone of claims 1-8, or claim 14, or the cartridge according to anyone of claims 9-1211-1, or an intensified reactor, e.g. a Taylor-Couette Reactor (TCR), according to claim 13, for converting a hydrocarbon composition at least partly into a composition comprising hydrogen (H₂).