Investigation of the flash vaporization technique as a novel anolyte separation method in a copper-chlorine thermochemical cycle for sustainable hydrogen production

• Development of a novel experimental setup to examine the flash vaporization process. • Development of an empirical model for prediction of the separated anolyte solution. • Comparative evaluation of two flash chamber designs based on geometric differences. • Separated solution’s volume comparison between experimental results & empirical model. Thermochemical water-splitting processes are a promising alternative to the conventional hydrogen production technologies. In this regard, the thermochemical copper-chlorine cycle is amongst the clean hydrogen production processes that have shown immense promise to achieve commercialization in the long term future through several investigations reported in the open literature. A primary reason for this is its moderate temperature requirements which can be harnessed through a wide variety of sources such as waste heat or solar thermal energy. More specifically, the four-step variant of the copper-chlorine cycle has exhibited the highest efficiencies compared to its three and five-step versions. However, certain aspects of the cycle need further attention. One such aspect is the fourth and the final step of the cycle – the anolyte separation step which ensures the complete replenishment of all chemical compounds within the cycle. The anolyte is a homogeneous solution that constitutes water, hydrochloric acid, copper (II) chloride, and copper (I) chloride. The existing methodology for the separation of all these chemicals considers a multi-step drying process that takes place at ambient pressure and temperatures over 100 °C. These conditions have been concluded to contribute to lowering the energy efficiency and increasing the cost rate of hydrogen through various studies previously conducted and published by the authors. In this regard, the authors have investigated an alternative technique for the anolyte separation process – the flash vaporization method where the partial separation of various chemical species can be achieved under vacuum conditions resulting in lower required temperatures and ultimately making the anolyte separation process relatively less energy intensive. Thus, this paper develops a stand-alone experimental set-up to investigate the flash vaporization process on a lab scale to determine its feasibility and potential to be a replacement for the existing approach of anolyte separation in a four-step copper-chlorine thermochemical cycle. The experiments are conducted under a wide variety of conditions and the obtained results are quite promising. Further, this study also considers the development of an empirical model to enable an analytical quantitative prediction of the separated anolyte solution.