Devices for urea electrolysis and methods of using same

• US 10,391,222 B2
• Filed: 03/18/2016
• Issued: 08/27/2019
• Est. Priority Date: 12/31/2015
• Status: Active Grant

• Current Assignee: Baxter Healthcare SA (Baxter International Inc.), Baxter International Inc.
• Original Assignee: Baxter International Inc.
• Inventors: Ding, Yuanpang Samuel, Menzel Bueno, Cristian Adolfo, Yeh, Rosa
• Primary Examiner(s): Jain, Salil
• Application Number:
  US15/074,388
• Publication Number:
  US 20170189594A1
• Time in Patent Office: 1,257 Days
• CPC Class Codes: A61M 1/1672 using membrane filters, e.g. for sterilising the dialysate
• CPC Class Codes: A61M 1/169 using chemical substances
• CPC Class Codes: A61M 1/1696 with dialysate regeneration
• CPC Class Codes: B01D 61/42 Electrodialysis; Electro-osmosis ; Electro-ultrafiltration; Membrane capacitive deionization
• CPC Class Codes: B01D 61/422 Electrodialysis
• CPC Class Codes: B01D 61/423 comprising multiple electrodialysis steps
• CPC Class Codes: B01D 61/445 with bipolar membranes; Water splitting
• CPC Class Codes: B01D 61/46 Apparatus therefor
• CPC Class Codes: B01D 61/463 comprising the membrane sequence AC or CA, where C is a cation exchange membrane
• CPC Class Codes: B01D 61/465 comprising the membrane sequence AB or BA, where B is a bipolar membrane
• CPC Class Codes: B01D 61/466 comprising the membrane sequence BC or CB
• CPC Class Codes: C02F 1/46104 Devices therefor; Their operating or servicing
• CPC Class Codes: C02F 1/4672 by electrooxydation
• CPC Class Codes: C02F 1/469 by electrochemical separation, e.g. by electro-osmosis, electrodialysis, electrophoresis
• CPC Class Codes: C02F 1/4693 electrodialysis
• CPC Class Codes: C02F 2001/46133 characterised by the material
• CPC Class Codes: C02F 2101/16 Nitrogen compounds, e.g. ammonia
• CPC Class Codes: C25B 3/23 Oxidation halogenation C25B3/27
• CPC Class Codes: C25B 9/17 Cells comprising dimensionally-stable non-movable electrodes; Assemblies of constructional parts thereof

Abstract

The present disclosure provides devices and methods of using same for cleansing a solution (e.g., a salt solution) of urea via electrooxidation, and more specifically to cleansing a renal therapy solution/dialysis solution of urea via electrooxidation so that the renal therapy solution/dialysis solution can be used or reused for treatment of a patient. In an embodiment, a device for the removal of urea from a fluid having urea to produce a cleansed fluid includes a urea decomposition unit and an electrodialysis unit.

Claims

1. A device for the removal of urea from a fluid having urea to produce a cleansed fluid, the device comprising:

a urea decomposition unit comprising an inlet for entry of the fluid having urea and an outlet for removal of the cleansed fluid, and one or more sets of electrodes each having an anode and a cathode, wherein the anode of the one or more sets of electrodes is provided with an electrocatalytic surface for decomposition of urea via electrooxidation; and

an electrodialysis unit comprising

a bipolar membrane;

at least two ion exchange membranes; and

a set of electrodes having an anode and a cathode for separation of the fluid having urea via electrodialysis, where the fluid having urea is separated into an acid stream and a basic stream,

wherein the basic stream of the electrodialysis unit is placed in fluid communication with the inlet of the urea decomposition unit, wherein the basic stream of the electrodialysis unit is oxidized by the one or more set of electrodes, and wherein the acid stream separated from the fluid having urea is placed in fluid communication with the basic stream oxidized by the one or more set of electrodes of the urea decomposition unit to produce a neutralized, cleansed fluid.

2. The device of claim 1, wherein the electrodialysis unit comprises a first cell comprising the bipolar membrane, a first ion exchange membrane, and a second ion exchange membrane, wherein the first ion exchange membrane is positioned next to one side of the bipolar membrane and the second ion exchange membrane is positioned next to an opposite side of the bipolar membrane, thereby forming (i) a first compartment between the bipolar membrane and the first ion exchange membrane and (ii) a second compartment between the bipolar membrane and the second ion exchange membrane.

3. The device of claim 2, wherein the first ion exchange membrane is an anion exchange membrane or a cation exchange membrane.

4. The device of claim 2, wherein the second ion exchange membrane is an anion exchange membrane or a cation exchange membrane.

5. The device of claim 2, wherein the bipolar membrane is a first bipolar membrane, wherein the electrodialysis unit further comprises a second cell including a second bipolar membrane and a third ion exchange membrane, wherein the second cell is positioned next to the first cell, and wherein the second bipolar membrane is positioned between the second ion exchange membrane of the first cell and the third ion exchange membrane, thereby forming a third compartment between the second bipolar membrane and the third ion exchange membrane.

6. The device of claim 5, wherein each of the first, second, and third ion exchange membranes are cation exchange membranes, or wherein each of the first, second, and third ion exchange membranes are anion exchange membranes.

7. The device of claim 1, wherein the bipolar membrane is a first bipolar membrane, wherein the electrodialysis unit comprises a cell including the first bipolar membrane, a second bipolar membrane, a first ion exchange membrane, and a second ion exchange membrane, and wherein the first ion exchange membrane and the second ion exchange membrane are positioned between the first bipolar membrane and the second bipolar membrane, thereby forming a first compartment between the first bipolar membrane and the first ion exchange membrane, a second compartment between the first ion exchange membrane and the second ion exchange membrane, and a third compartment between the second ion exchange membrane and the second bipolar membrane.

8. The device of claim 7, wherein the first ion exchange membrane is a cation exchange membrane and the second ion exchange membrane is an anion exchange membrane.

9. The device of claim 1, wherein a power source in the urea decomposition unit provides the electrodes with an electrical charge to activate the electrocatalytic surface of the electrodes.

10. The device of claim 1, wherein a power source in the electrodialysis unit provides the electrodes with an electrical charge to split water in the bipolar membrane into H⁺ and OH⁻

.

11. The device of claim 1, wherein the electrodialysis unit separates the fluid having urea via bipolar membrane electrodialysis.

12. The device of claim 1, wherein the fluid having urea is a dialysis fluid.

13. The device of claim 12, wherein the dialysis fluid includes one or more substance selected from the group consisting of:

a sodium salt, a magnesium salt, a calcium salt, lactate, carbonate, acetate, citrate, and phosphate.

14. The device of claim 1 further comprising a tank for the fluid having urea.

15. The device of claim 1, wherein the basic stream includes NaOH.

16. The device of claim 1, wherein the acid stream includes HCl.

17. The device of claim 1, wherein the electrocatalytic surface for decomposition of urea comprises a transition metal and/or mixtures thereof and/or alloys thereof.

18. The device of claim 17, wherein the transition metal is cobalt, copper, iron, nickel, platinum, palladium, iridium, ruthenium, or rhodium.

19. The device of claim 17, wherein the anode in the urea decomposition unit comprises nickel, nickel oxide, nickel hydroxide or nickel oxide hydroxide (NiOOH).

20. The device of claim 1, wherein the urea decomposition unit includes an alkaline polymeric gel.

21. The device of claim 1, wherein the fluid having urea is a dialysis fluid contaminated with urea.

22. The device of claim 1, wherein a voltage difference applied across the cathode and the anode in the urea decomposition unit is sufficient to produce nitrogen gas, carbon dioxide gas, and water.

23. A renal replacement therapy system comprising:

a dialysis fluid circuit, wherein the dialysis fluid circuit comprises a device for the removal of urea from a dialysis fluid having urea to produce a cleansed dialysis fluid, the device comprising;

a urea decomposition unit comprising an inlet for entry of the dialysis fluid having urea and an outlet for removal of the cleansed dialysis fluid, and a set of electrodes having an anode and a cathode, wherein the anode of the set of electrodes is provided with an electrocatalytic surface for decomposition of urea via electrooxidation; and

an electrodialysis unit comprising

a bipolar membrane;

at least two ion exchange membranes; and

a set of electrodes having an anode and a cathode for separation of the dialysis fluid having urea via electrodialysis, where the dialysis fluid having urea is separated into an acid stream and a basic stream,

wherein the basic stream of the electrodialysis unit is placed in fluid communication with the inlet of the urea decomposition unit, wherein the basic stream of the electrodialysis unit is oxidized by the one or more set of electrodes, and wherein the acid stream separated from the dialysis fluid having urea is placed in fluid communication with the basic stream oxidized by the set of electrodes of the urea decomposition unit to produce a neutralized, cleansed fluid.

24. The renal replacement therapy system of claim 23, wherein the cleansed dialysis fluid recirculates through the dialysis fluid circuit.

25. The renal replacement therapy system of claim 23, wherein the electrodialysis unit comprises a first cell including the bipolar membrane, a first ion exchange membrane, and a second ion exchange membrane, wherein the first ion exchange membrane is positioned next to one side of the bipolar membrane and the second ion exchange membrane is positioned next to an opposite side of the bipolar membrane, thereby forming a first compartment between the bipolar membrane and the first ion exchange membrane and a second compartment between the bipolar membrane and the second ion exchange membrane.

26. The renal replacement therapy system of claim 25, wherein the first ion exchange membrane is an anion exchange membrane or a cation exchange membrane.

27. The renal replacement therapy system of claim 25, wherein the second ion exchange membrane is an anion exchange membrane or a cation exchange membrane.

28. The renal replacement therapy system of claim 25, wherein the bipolar membrane is a first bipolar membrane, wherein the electrodialysis unit further comprises a second cell including a second bipolar membrane and a third ion exchange membrane, wherein the second cell is positioned next to the first cell, and wherein the second bipolar membrane is positioned between the second ion exchange membrane of the first cell and the third ion exchange membrane, thereby forming a third compartment between the second bipolar membrane and the third ion exchange membrane.

29. The renal replacement therapy system of claim 28, wherein each of the first, second, and third ion exchange membranes are cation exchange membranes or wherein each of the first, second, and third ion exchange membranes are anion exchange membranes.

30. The renal replacement therapy system of claim 23, wherein the bipolar membrane is a first bipolar membrane, wherein the electrodialysis unit comprises a cell including the first bipolar membrane, a second bipolar membrane, a first ion exchange membrane, and a second ion exchange membrane, and wherein the first ion exchange membrane and the second ion exchange membrane are positioned between the first bipolar membrane and the second bipolar membrane, thereby forming a first compartment between the first bipolar membrane and the first ion exchange membrane, a second compartment between the first ion exchange membrane and the second ion exchange membrane, and a third compartment between the second ion exchange membrane and the second bipolar membrane.

31. The renal replacement therapy system of claim 30, wherein the first ion exchange membrane is a cation exchange membrane and the second ion exchange membrane is an anion exchange membrane.

32. The renal replacement therapy system of claim 23, wherein a power source in the urea decomposition unit provides the electrodes with an electrical charge to activate the electrocatalytic surface of the electrodes.

33. The renal replacement therapy system of claim 23, wherein a power source in the electrodialysis unit provides the electrodes with an electrical charge to split water in the bipolar membrane into H⁺ and OH⁻

.

34. The renal replacement therapy system of claim 23, wherein the electrodialysis unit separates the dialysis fluid having urea via bipolar membrane electrodialysis.

35. The renal replacement therapy system of claim 23, wherein the dialysis fluid includes one or more substance selected from the group consisting of:

a sodium salt, a magnesium salt, a calcium salt, lactate, carbonate, acetate, citrate, and phosphate.

36. The renal replacement therapy system of claim 23, further comprising a tank for the dialysis fluid having urea.

37. The renal replacement therapy system of claim 23, wherein the basic stream includes NaOH.

38. The renal replacement therapy system of claim 23, wherein the acid stream includes HCl.

39. The renal replacement therapy system of claim 23, wherein the electrocatalytic surface for decomposition of urea comprises a transition metal and/or mixtures thereof and/or alloys thereof.

40. The renal replacement therapy system of claim 39, wherein the transition metal is cobalt, copper, iron, nickel, platinum, palladium, iridium, ruthenium, or rhodium.

41. The renal replacement therapy system of claim 39, wherein the anode in the urea decomposition unit comprises nickel, nickel oxide, nickel hydroxide or nickel oxide hydroxide (NiOOH).

42. The renal replacement therapy system of claim 23, wherein the urea decomposition unit includes an alkaline polymeric gel.

43. The renal replacement therapy system of claim 23, wherein a voltage difference applied across the cathode and the anode in the urea decomposition unit is sufficient to produce nitrogen gas, carbon dioxide gas, and water.