EP-4739821-A1 - METHODS AND SYSTEMS OF CONTROLLING BIDIRECTIONAL OPERATION OF AN ELECTROWINNING PLANT

Abstract

Methods and systems of the present disclosure are generally directed to switching operation of one or more electrochemical cells of an electrowinning plant between a charge mode and a discharge mode. In the charge mode, the one or more electrochemical cells may reduce metal from an oxidized state to a zero valence state with a first electric current applied across the one or more electrochemical cells. In the discharge mode, the one or more electrochemical cells may oxidize at least some of the metal from the zero valence state to the oxidized state to generate a second electric current, oppositely charged relative to the first electric current, to generate electricity (e.g., for delivery to the grid). Operation of the one or more electrochemical cells of the electrowinning plant may be selectively changed between the charge mode and the discharge mode based on, for example, availability/cost of electricity from the grid.

Inventors

• SU, LIANG
• THOMAS-ALYEA, Karen
• RATHERT, Janna
• POIRIER, JEFFREY
• MANSER, Joseph Stephen

Assignees

• Form Energy, Inc.

Dates

Publication Date

20260513

Application Date

20240703

Claims (20)

1. 1. A method of controlling bidirectional operation of an electro winning plant, the method comprising: receiving a supply of metal in an oxidized state into at least one electrochemical cell; operating the at least one electrochemical cell in a charge mode in which a first electric current applied across the electrochemical cell reduces the metal from the oxidized state to a zero valence state in the electrochemical cell: operating the at least one electrochemical cell in a discharge mode in which oxidation of at least some of the metal from the zero valence state to the oxidized state in the electrochemical cell generates a second electric current oppositely charged relative to the first electric current; and selectively changing operation of the at least one electrochemical cell between the charge mode and the discharge mode.
2. 2. The method of claim 1, wherein the metal in the oxidized state includes metal ore.
3. 3. The method of any one of the preceding claims, wherein the metal includes one or more of iron, copper, zinc, nickel, manganese, lead, aluminum, or cobalt.
4. 4. The method of any one of the preceding claims, wherein operating the at least one electrochemical cell in the discharge mode includes inserting an additional amount of the metal in the zero valence state into the electrochemical cell.
5. 5. The method of any one of the preceding claims, wherein operating the at least one electrochemical cell in the charge mode includes receiving power from a power network to apply the first electric current across the electrochemical cell, and operating the at least one electrochemical cell in the discharge mode includes delivering, to the power network, at least some of the power generated by the electrochemical cell.
6. 6. The method of claim 5, wherein the power network is an electrical grid.
7. 7. The method of claim 6, wherein the electrical grid is a bulk grid or a micro-grid.
8. 8. The method of any one of the preceding claims, wherein operating the at least one electrochemical cell in the charge mode includes applying the first electric current across a negative electrode and at least one positive electrode, via an electrolyte therebetween, with the negative electrode including the metal in the oxidized state.
9. 9. The method of claim 8, wherein operating the at least one electrochemical cell in the discharge mode includes generating the second electric current across the negative electrode and the at least one positive electrode, via the electrolyte therebetween, with the negative electrode including metal in the zero valence state.
10. 10. The method of any one of claims 8 or 9, wherein receiving the supply of metal in the oxidized state into the at least one electrochemical cell includes dissolving the metal in the oxidized state in a solution with the electrolyte and pumping the solution into the at least one electrochemical cell.
11. 11. The method of any one of claims claim 8-10, wherein receiving the supply of metal in the oxidized state into the at least one electrochemical cell includes providing a solid form of metal ore to the negative electrode of the at least one electrochemical cell.
12. 12. The method of any one of claims 9-11, wherein the at least one positive electrode is a bifunctional oxygen electrode in electrical communication with the negative electrode in each of the charge mode and the discharge mode.
13. 13. The method of any one of claims 9-11, wherein the at least one positive electrode includes a charge positive electrode and a discharge positive electrode.
14. 14. The method of claim 13, wherein selectively changing operation of the at least one electrochemical cell between the charge mode and the discharge mode includes selective electrical isolation of the negative electrode from one of the charge positive electrode and the discharge positive electrode depending on operation mode of the at least one electrochemical cell.
15. 15. The method of claim 14, wherein selective electrical isolation of the negative electrode from one of the charge positive electrode and the discharge positive electrode includes interrupting electrical communication between the discharge positive electrode and the negative electrode as the charge positive electrode and the negative electrode are in electrical communication with one another in an electric circuit including the electrolyte.
16. 16. The method of claim 15, wherein the charge positive electrode has pores through which electrolyte is transportable from the negative electrode to the discharge positive electrode, and interrupting electrical communication between the discharge positive electrode and the negative electrode includes removing the discharge positive electrode from the electrolyte.
17. 17. The method of any one of claims 15 or 16, wherein the charge positive electrode is nonporous and interrupting electrical communication between the discharge positive electrode and the negative electrode includes positioning the charge positive electrode in the electrolyte, between the discharge positive electrode and the negative electrode.
18. 18. The method of claim 17, wherein the charge positive electrode positioned in the electrolyte, between the discharge positive electrode and the negative electrode, blocks substantially all transport of electrolyte to the discharge positive electrode.
19. 19. The method of any one of claims 15-18, wherein interrupting electrical communication between the discharge positive electrode and the negative electrode includes positioning a shield between the discharge positive electrode and the charge positive electrode in the electrolyte, and the shield is electrically insulating and fluid impermeable.
20. 20. The method of any one of claims 14-19, wherein selectively changing operation of the at least one electrochemical cell between the charge mode and the discharge mode includes removing the charge positive electrode from the electrolyte and placing the discharge positive electrode into the electrolyte for operation of the at least one electrochemical cell in the discharge mode, and removing the discharge positive electrode from the electrolyte and placing the charge positive electrode into the electrolyte for operation of the at least one electrochemical cell in the charge mode.

Description

METHODS AND SYSTEMS OF CONTROLLING BIDIRECTIONAL OPERATION OF AN ELECTROWINNING PLANT CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of priority to U.S. Provisional Patent Application 63/511,769, filed July 3, 2023, the entire contents of which are hereby incorporated herein by reference. BACKGROUND [0002] During charge operation, an electrowinning plant consumes electricity to produce a product metal from ore. However, markets for both metal and electricity are highly volatile. Metal prices are affected, for example, by demand for metal (e.g., varying as needs for construction materials change) and by supply from competing sources of product metal. Electricity markets typically vary according to factors such as time of day, season of the year, and weather conditions. For cost reasons, some electrowinning plants reduce electricity consumption, and thus production of product metal, when electricity prices are high (e.g., during hot afternoons). Further, given that high demand on the electricity grid may cause blackouts in some cases, grid utilities may offer electrowinning plants a fixed amount of money each month, in return for the plant committing to reducing consumption during times of high electricity prices. [0003] Accordingly, there remains a need for managing operation of electro winning plants to facilitate achieving robust cost-effectiveness and profitability through volatility associated with metal and electricity markets. SUMMARY [0004] Methods and systems of the present disclosure are generally directed to switching operation of one or more electrochemical cells of an electrowinning plant between a charge mode and a discharge mode. In the charge mode, the one or more electrochemical cells may reduce metal from an oxidized state to a zero valence state with a first electric current applied across the one or more electrochemical cells. In the discharge mode, the one or more electrochemical cells may oxidize at least some of the metal from the zero valence state to the oxidized state to generate a second electric current, oppositely charged relative to the first electric current, to generate electricity (e.g., for delivery to the grid). Operation of the one or more electrochemical cells of the electrowinning plant may be selectively changed between the charge mode and the discharge mode based on, for example, availability/cost of electricity from the grid. [0005] According to one aspect, a method of controlling bidirectional operation of an electrowinning plant may include receiving a supply of metal in an oxidized state into at least one electrochemical cell; operating the at least one electrochemical cell in a charge mode in which a first electric current applied across the electrochemical cell reduces the metal from the oxidized state to a zero valence state in the electrochemical cell; operating the at least one electrochemical cell in a discharge mode in which oxidation of at least some of the metal from the zero valence state to the oxidized state in the electrochemical cell generates a second electric current oppositely charged relative to the first electric current; and selectively changing operation of the at least one electrochemical cell between the charge mode and the discharge mode. [0006] In some implementations, metal in the oxidized state may include metal ore. [0007] In certain implementations, the metal may include one or more of iron, copper, zinc, nickel, manganese, lead, aluminum, or cobalt. [0008] In some implementations, operating the at least one electrochemical cell in the discharge mode may include inserting an additional amount of the metal in the zero valence state into the electrochemical cell. [0009] In certain implementations, operating the at least one electrochemical cell in the charge mode may include receiving power from a power network to apply the first electric current across the electrochemical cell, and operating the at least one electrochemical cell in the discharge mode includes delivering, to the power network, at least some of the power generated by the electrochemical cell. The power network may be an electrical grid. For example, the electrical grid may be a bulk grid or a micro-grid. [0010] In some implementations, operating the at least one electrochemical cell in the charge mode may include applying the first electric current across a negative electrode and at least one positive electrode, via an electrolyte therebetween, with the negative electrode including the metal in the oxidized state. Operating the at least one electrochemical cell in the discharge mode may include generating the second electric current across the negative electrode and the at least one positive electrode, via the electrolyte therebetween, with the negative electrode including metal in the zero valence state. Further, or instead, receiving the supply of metal in the oxidized state into the at least one electrochemical cell may include disso