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ENCYCLOPEDIA OF RADIO ELECTRONICS AND ELECTRICAL ENGINEERING electrolysis welding. Encyclopedia of radio electronics and electrical engineering
Encyclopedia of radio electronics and electrical engineering / welding equipment A water decomposition welding machine is more expensive than a conventional one. Maybe it will be possible to make electrolytic welding easier? This article contains guidelines for designing an electrolyser, as well as tips for using it. The electrolytic cell described in the article is bipolar, it has 110 electrolytic cells connected in series in the DC circuit. Each electrode, with the exception of the two extreme ones, works as a cathode on one side, and as an anode on the other. This electrolyzer differs from those described earlier [1,2, 1] in the absence of a step-down transformer, which made it possible to reduce the cost of manufacturing the apparatus and its weight. It is possible to regulate the performance easier (Fig. 245), but such a need did not arise. Bridge diodes (four D1A) were used without radiators, since the power of the device is about XNUMX kW.
In total, we built three electrolyzers, which gave a very valuable experience. Consider the latest, most successful design, as well as ideas for its improvement. Let's start with metal plates that simultaneously play the role of both electrodes and air cooling fins. Steel 3, steel 45 and stainless steel were used as the material, we did not notice any difference. Since the thickness of the plates does not play any role, very thin iron was used in the latest model, which made it possible to drastically reduce the length and weight of the cell. For a transformerless electrolyzer with a power of about 1 kW, 109 plates will have to be cut (Fig. 2). Their shape can be both octagonal and round (to facilitate the apparatus), but this will increase the cooling time of the electrolyzer.
It must be said that this electrolyzer is not suitable for long-term continuous operation, it can only be operated periodically. The reason is the gradual heating of the electrolyte to the formation of water vapor, which, once in the burner, cuts off (extinguishes) the flame. Control methods: cooling the electrolyzer, electrolyte and gas, increasing the amount of electrolyte (interelectrode distance). By the way, the efficiency of the electrolyser only increases with increasing temperature, and some industrial plants operate at an electrolyte temperature of up to 95°C! Please note that compared to [2], the number of drilled holes in the plates is reduced by 6 times. On the advice of the inventor R. Stasiv, only one hole was left in the plate, which completely eliminates parasitic heating of the electrolyte. The diameter of this hole determines the rate of filling the cell, but too large a hole will reduce the usable area of the electrodes or cause parasitic heating of the electrolyte. It is better if this hole does not have a round, but a figured shape (highlighted in Fig. 3 by a bold line).
During operation, the sides of the plates, which act as anodes, wear out (oxidize). In order not to clean them, industrial devices use anodes coated with sulfided or ordinary nickel. There is no need to be afraid that the iron plates will rust, since this does not happen in an alkaline environment. Alkali (KOH or NaOH) is part of the electrolyte. When buying, ask for caustic potassium or sodium, potassium or sodium hydroxide, caustic soda. The safety of the electrode plates, especially the anode, depends on the quality of the electrolyte. Alkali concentration - 5...30%. In industrial electrolyzers, KOH is predominantly used, in the absence of which we used NaOH. Alkali must be clean, not affected by contact with carbon dioxide in the air, on which it turns into potash (K2CO3) or soda (Na2CO3). During operation, the alkali does not decrease, only distilled water has to be added. If distilled water is not available, then prepare its amii using a still. If electrolyte gets into your eyes, rinse immediately with plenty of distilled water. It is better to work with the electrolyte in safety glasses, which can be easily and quickly made from a plastic bottle [3]. Rubber pads (Fig. 4) perform the function of electrolysis baths. In our case, it took 110 pieces. For the first electrolyzer cut with scissors. On a lathe cut (all at once) gaskets of the second cell. For the third, rings made by vulcanization were used - this is the most economical way. The capacity of the device, and hence the number of electrolyte refills, depends on the thickness of the gaskets. We tried the thickness of the rings from 2 to 5 mm, we did not notice much difference. The most economical are square gaskets, but we did not use them, because we wanted to achieve a high pressure of the exhaust gases. In industrial plants, in order to achieve high efficiency, the pressure is increased to 200 or more atmospheres, and at no additional cost, due to the energy of gas formation alone. More than once we have seen reports about the excess of the efficiency of electrolysis by modern methods over 100%.
The end electrodes are different from the rest. These are two thick (8 ... 10 mm) steel plates, which, with the help of a tie, hold all the plates and gaskets in one package. One of the plates serves only as a cathode, the other as an anode. A hole was drilled in one of the plates for mounting a universal tank (Fig. 5).
This tank is another feature of our electrolyzer (fig.6).
It plays the role of a filler neck, a gas receiver, a foam trap, and is simply necessary for the operation of the apparatus (Fig. 7), where a) electrolyte filling, water addition; b) draining the excess; c) concentration equalization; d) work; e) drain).
When turning off the electrolyzer operated with a bubbler, we advise you to immediately unscrew the tank lid, since the cooling gas will draw liquid from the bubbler (not shown in Fig. 7). During the operation of the electrolyzer, highly concentrated alkali is collected in the tank, which is safely dissolved with distilled water during topping up. It should be borne in mind that a transformerless electrolyzer is very dangerous, since it does not have galvanic isolation from the mains. The electrolytic screed consists of 4 studs and 8 nuts. You can also use 4 long bolts. We put PVC tubes on the studs, steel washers and engravers under the nuts. The length of the studs depends on the thickness of all gaskets and plates in the compressed state. Four insulating gaskets for nuts (Fig. 8) were made of durable plastic. They perform the function of eight legs, since in the process of servicing our device has to be turned over (Fig. 7).
When an unprotected electrolysis burner is switched off, a stoichiometric mixture of hydrogen and oxygen (2:1) explodes. It is recommended to extinguish the burner by dipping into water before switching off the apparatus, since under water the oxy-fuel flame burns only in the presence of hot carbon (graphite). Flame arresters inside the burner often do not work, since the ignition energy (heat) of hydrogen is 15 times less, and the flame front propagation speed is 8 times greater than that of conventional combustible gases. Since the radiation of the hydrogen flame is 10 times less, and the ignition temperature (not to be confused with heat) is greater, flame arresters must be a powerful heat sink. Such a flame arrester can be made from thin copper wire (without varnish), which is tightly stuffed with a hammer into the metal body of the burner using a conical striker. They also use hydraulic seals (bubblers) filled with water or kerosene, as well as shutting off the gas pipeline. The best gas pipeline is a transparent tube from a medical dropper. Spargers are made from plastic bottles (Fig. 9) with a capacity of 0,5 liters.
If you want more electrolysis gases, increase the total area of the electrodes, not the voltage. The voltage of the best electrolyzers is in the range of 1,7 ... 2,6 V per cell. If you can't make a large electrolyser, then make two or more small ones and connect them in parallel to work together. At first, our electrolyzer was intended only for demonstration on republican television (1991) of an internal combustion steam engine. An experienced gas welder was entrusted to investigate the welding abilities of a water-oxygen flame. Without restraining his enthusiasm, the specialist immediately determined that the device was producing too much oxygen and required the addition of hydrocarbon fuels: combustible gases, such as propane, or vapors of combustible liquids. At the same time, free hydrogen greatly accelerates the combustion process, which increases the temperature of the flame. One of the potential customers of the electrolyser (jeweler M. Kanaev) reported that his senior colleagues pass the gas of the electrolyzer through methyl alcohol, gasoline or gasoline and keep this technology in the strictest confidence. There are rumors among the people about gas welding, which does not require carbide and oxygen cylinders. In all likelihood, this legendary gas welding is electrolysis with the addition of hydrocarbon fuels. Once, before the widespread introduction of electric arc welding, electrolytic welding completely satisfied industrialists. Today, when extracting old tanks from rivers and swamps, most of all they are surprised by the shiny even seams against the background of rusty iron - this is the work of the electrolyzer. We have not yet met a person who is disappointed in the electrolyzer, so in conclusion a few words about the prospects. Obtaining hydrogen and oxygen using an electrolyzer is the most expensive today. But it is difficult to find a replacement for an electrolyzer where there is no gas equipment and where high quality welding work and special flame purity are required. Since in the technology of obtaining atomic hydrogen (H) and ozone (O3) are the same, an ozonator can be used to increase the energy of the burner. It is also possible to increase the temperature by increasing the pressure in the welding zone. Hydrogen and oxygen can be separated using a gas cyclone (vortex tube). For medicine, so-called plasma scalpels can be made. The sphere of use of "burning water" may turn out to be much wider than it can be imagined today, so we invite the readers of the magazine to experiment with the electrolyzer themselves and share their experience. References:
Authors: I.P. Oleinik, Yu.I. Bearded
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