Apparatus and System Design, Build & Modeling

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Explore our Electrochemical Apparatus and System Design, Build and Modeling Approaches

Faraday designs systems and creates models to improve product performance, reduce downtime and improve reproducibility. The following examples demonstrate some of the Electrochemical Models we have developed with our multi-physics platform and Electrochemical Systems that we have designed and built for our customers.

Faraday installs custom flexibility into many of our systems allowing developers and users to enhance operational control to achieve consistent performance. We also use multi-physics modeling to improve tool designs, enabling more controlled operations. Finally, we design flow manifolds and bipolar plates for improved plate and frame operations. 

These techniques have been proven to:

Click tab to see examples, publications, patents and awards

Plate and Frame Reactors

ECHANGE®

The FARADAYIC ® ECHANGE ® plate and frame reactor was designed and built to continuously remove metal containment from waste water

ElectroReactor®

The plate and frame electroreactors that Faraday has designed and built have been utilized for a wide range of applications include H2O2 production, CO2 conversion, water desalination, and electrochemical destruction

Patents:

Method of removing metal salts from solution by electrolysis an electrode closely associated with an ion exchange resin.” Chengdong Zhou, E. Jennings Taylor, Robert P. Renz, Eric C. Stortz, Jenny J. Sun

FARADAYIC® ElectroCell®

Faraday has designed, built, and installed the FARADAYIC® ElectroCell® platform at the bench-scale (15-20 L), alpha- to beta-scale (50 to 800 gallons) for panels up to 2′ x 2′, and full commercial scale (1200 to 1600 gallons) for simultaneous processing of multiple large panels.

Patents:

Electroplating cell with hydrodynamics facilitating more uniform deposition across a workpiece during plating.” Lawrence E. Gebhart, Jenny J. Sun, Phillip O. Miller, E. Jennings Taylor

Electroplating cell with hydrodynamics facilitating more uniform deposition across a workpiece during plating” Lawrence E. Gebhart, Jenny J. Sun, Phillip O. Miller, E. Jennings Taylor

Bench-Scale

Alpha- to Beta-Scale

Full Commercial Scale

Specialty Systems

Electrochemical Winning

Faraday designed and built a large working area electrochemical winning system to remove waste metals from plating, electrochemical machining, and pickling operations. This process reduced waste and improved the lifetime of the working solutions for their given applications.

Patents:

Electroplating cell with hydrodynamics facilitating more uniform deposition across a workpiece during plating” Lawrence E. Gebhart, Jenny J. Sun, Phillip O. Miller, E. Jennings Taylor

Reel to Reel Wire Polishing

Faraday designed and built a continuous feed reel-to-reel system to electropolish wire. This system is installed at Faraday and features controllable:

Nb Superconducting Radio Frequency Cavities

Faraday has scaled their Nb superconducting RF cavity electropolishing approach from single to nine-cell 1.3 GHz cavities as well as three-cell 805 MHz cavities.

KEK 9 - Cell Nb Superconducting Cavity Polishing
ORNL 3 - Cell Nb Superconducting Cavity Polishing

Electrochemical Modeling

Surface Finishing
Modeling Current Flow/Voltage Drops in an Anode Bussing Frame
Electrochemical Machining (ECM)
Time-Varying 3D ECM Part Shape Predictions
Corrosion
Corrosion Current Density Predictions for a Galvanic Fastener System

Faraday's Process Advantage

Model of Pulse Plating vs DC
Pulse Plating
DC

If you have an electrochemical engineering or scaling problem that needs a solution, call Faraday today!