MATERIAL AND METHOD TO DISSOCIATE WATER

Abstract: Material and method for the decomposition/dissociation of water into hydrogen and oxygen. The material comprises an amalgam of an alkali metal, mercury, and aluminum combined with a catalytically effective amount of an alloy comprising nickel and at least one metal selected from the group consisting of germanium, antimony, gallium, thallium, indium and bismuth.

Description: MATERIAL AND METHOD TO DISSOCIATE WATER CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of Applica¬ tion Serial No. 902,705, entitled MATERIAL AND METHOD FOR OBTAINING HYDROGEN AND OXYGEN BY DISSOCIATION OF WATER, filed on May 4, 1978; of Application Serial No. 902,708, entitled MATERIAL AND METHOD FOR OBTAINING HYDROGEN AND OXYGEN BY DISSOCIATION OF WATER, filed on May 4, 1978; of Application Serial No. 06/068,749, entitled MATERIAL AND METHOD FOR OBTAINING HYDROGEN BY DISSOCIATION OF WATER, filed on August 23, 1979; and of an application having attorney's indicia AE-109,entitled MATERIAL AND METHOD TO DISSOCIATE WATER AT CONTROLLED RATES, filed on October 16, 1979; and is related to to an application having at¬ torney's indicia AE-106, entitled HYDROGEN GENERATING APPARATUS AND METHOD, filed on October 16, 1979; and to Application Serial No. 06/056,994, entitled FUEL SYSTEM AND METHOD, filed on July 12, 1979. BACKGROUND OF INVENTION Field of Invention This invention relates to a material for and method of effecting the decomposition/dissociation of water into hydrogen and oxygen. The water is reacted with an amalgam of sodium, alu- minun and mercury to form hydrogen and a metallic hy¬ droxide denoted by the formula Na3AL(OH)g is unstable at SUBSTITUTE SHEET the temperature of formation in the presence of a catalys comprising nickel and at least one element selected from the group consisting of germanium, antimony, gallium, thallium, indium, and bismuth and breaks down to form metallic sodium and aluminum thereby releasing oxygen and hydrogen. Description of the Prior Art It is well known in the prior art that the alkali metals react with water to form hydrogen and the stable alkali metal hydroxide. The foregoing reaction is rapid, the heat generated intense and explosion of hydrogen ordi arily occurs. The result is an unsatisfactory and danger ous method of generating hydrogen. It is also well know that alkali metal peroxides may be used for the generati of oxygen (see U. S. Patent 3,574,561) . Thermochemical cycles comprising metal-metaloid com¬ binations for the generating of both hydrogen and oxygen are disclosed in U. S. Patent 3,969,495. Closed cycle processes for dissociation of water into hydrogen and oxygen are disclosed in U. S. Patents 3,821,358, 3,928,549 and 4,011,305. Combinations of var¬ ious metals in multistep processes for dissociation of water are, therefore, well known; however, the simple and facile manner of producing hydrogen and oxygen utilizing an amalgam of alkali metal, aluminum and mercury combined with a catalytic alloy comprising nickel and at least one element selected from the group consisting of germanium, antimony, gallium, thallium, indium and bismuth has not been heretofore appreciated. DESCRIPTION OF THE INVENTION The material I have found to be suitable for the generation of hydrogen and oxygen from water without spon taneous combustion of the resultant evolved hydrogen and oxygen gases comprises an amalgam of (1) an alkali metal such as lithium, sodium, potassium, cesium, or combina¬ tions thereof, (2) aluminum and (3) mercury combined with a catalytic alloy comprising nickel and at least one element selected from the group consisting of germanium, antimony, gallium, thallium, indium and bismuth. The particle size of the sodium and aluminum is such as to enable formation of an amalgam and may fall within the range of from about 10 to about 100 mesh. Most pre- ferably, the particle size of the aluminum should be about 10 mesh. Alkali metal of 1/4" diameter is suitable. The particle size of either the alkali metal or aluminum is not critical since the foregoing metals and mercury readily intermix. The smaller the particle size, of course, the more rapid the mixing. The atomic weight ratio of alkali metal to mercury is from about 1:100 to about 100:1 and the atomic weight ratio of alkali metal to aluminum is from about 1:100 to about 100:1. Preferably, the atomic weight ratio of alkali metal to mercury is from about 3:1 to about 1:1.5 and the atomic weight ratio of alkali metal to aluminum is from about 1:1 to about 3:1. The amalgam of alkali metal, aluminum and mercury is combined with a catalytically active alloy which is present in a catalytically effective amount and, at the conditions of hydrogen generation, functions to regenerate amalgam to the active metallic state. The catalyst/alloy is nickel and at least one element selected from the group consisting of germanium, antimony, gallium, thallium, indium and bismuth. Preferably, the catalyst comprises nickel and at least one element selected from the group consisting of germanium, antimony, gallium, thallium, indium and bismuth. Catalytic activity is further enhanced by the addi- tion of minor amounts of zirconium and chromium. TE SHEET Silver and/or gold may be incorporated in the catal as an alloying element to lower the melting point of the alloy. The alloy and amalgam may be combined in weight rati of from about 1:1 to about 1:5 and preferably from about 1:2 to about 1:3. In combining the alloy and amalgam, they may be com¬ pounded with an extender. The extender functions both to dilute the amalgam-catalytic alloy combination and to provide a heat sump for heat generated during the dissoci tion of water by contact with the combined amalgam and catalytic alloy. The extender is preferably bismuth; however, admixtures of tin and bismuth or gallium may also function as extenders. The combination of amalgam and alloy or amalgam, alloy and extender is most suitably used in solid block form, hereinafter referred to as a reactor block. Where an extender is employed it may be present as a major con¬ stituent of the reactor block. Although not wishing to be bound by the following explanation, it is believed that the water reacts with the alkali metal, e.g., sodium, and the aluminum liberat¬ ing hydrogen and forming Na3AL(OH)5- The a3AL(OH)g is unstable, and in the presence of the alloy at the condi¬ tions of a3AL(OH)g formation, the foregoing composition decomposes to form H2, O2 and regenerated amalgam. The alloy apparently functions to catalyze the decomposition, and thereby extends the useful life of the amalgam. The process may be depicted as follows: 2 Na + 2 H2O »- 2 NaOH + H 2 6 H2O + 2 Al 6 NaOH »- 2 a3Al(OH) 6 + 3 H2 N a 3 Al (O H ) 6 cafcalytic alloy ' 3 Na + Al + 3H 2 + 30 2 SUBSTITUTE SHEET O • fa Wii - It is preferred to include chromium as an additional component of the alloy. The incorporation of chromium as a component of the alloy appears to lower the heat of reaction. The chromium is generally present in the alloy in an amount measured on a weight percent basis of said alloy of from about 0.7% to about 1.1% and preferably for about 0.8% to about 0.9%. Each of the components of the alloy may be present in amounts of from about 0.4% by weight to about 28 " .5% by weight based on the weight of the combined catalytic alloy and amalgam. The preferred alloy comprises (1) nickel present in an amount of from about 3.5 to about 6.5% by weight, (2) bismuth present in an amount of from about 40.1 to about 68.7% by weight, (3) antimony present in an amount of from about 25.-5 to about 42.5% by weight, (4) chromium present in an amount of from about 0.7 to about 1.1% by weight, (5) zirconium present in an amount of from about 4.1 to about 6.8% by weight and gold present in an amount of from about 1.1 0.6 to about 1.9% by weight. A specific example of said preferred alloy comprises about 4.5 weight percent nickel, about 53.7 weight percent bismuth, about 34.0 weight percent antimony, about 0.9 weight percent chromium, about 5.4 weight percent zirconium and about 1.5 weight percent gold. • The amalgam of sodium, aluminum and mercury is pre¬ pared utilizing any of the well known procedures with the added proviso that an inert atmosphere be employed. Amal¬ gamation may be facilitated by utilization of an elevated temperature, preferably around 200° C±10° C. The amalgam is preferably maintained at this elevated temperature for about 10 minutes where 100 grams.are being processed, and the time is extended about 1 minute for each additional 100 gram aliquot. SUBSTITUTE SHEET ( °™ The resulting amalgam is cooled, generally to room temperature, utilizing an inert atmosphere. For this purpose either helium or argon are satisfactory. Coolin is preferably effected in a desiccator to insure that no water contacts the amalgam. As in the preparation of the amalgam and all other steps in the method of manufacture of the various compos tions of this invention, precaution must be taken during preparation to avoid the presence of oxygen because it has been observed that oxygen operates to poison the res tant material. The preparation of the alloy selected may be in any well known manner having in mind the proviso that an ine atmosphere be maintained. The alloy, upon solidification, and as a practical matter, upon cooling is ground into a powder, preferably a fine powder of about 10 mesh or less. Cooling may be effected in a dessicator to insure the absence of oxygen and moisture, whose presence is detrimental during prepa ation. Grinding/pulverizing may be effected in any well known manner including use of a ball, hammer and/or stam mill. The objective in combining the alloy and amalgam is to intimately admix the two respective components. The specific manner of catalysis is not known, but generally catalysis is a surface phenomenon and consistent there¬ with in the instant invention it appears that the cata¬ lysis is related to both particle size and nature as wel as uniformity of mixture of the amalgam and catalytic alloy. The amalgam and catalytic alloy may be used (1) in particulate form such as a floating bed, or other inti¬ mate dispersion, (2) in the form of porous mass which ma be formed by compression or sintering or (3) as a solid mass by alloying of the amalgam and catalytic alloy. By SUBSTITUTE SHEET alloying, it is meant that the amalgam and catalytic alloy are combined to form an admixture and alloyed under inert conditions at a temperature above the melting point of said admixture. In either of the foregoing forms an extender, such as gallium, tin, bismuth, and preferably bismuth may be utilized. The extender functions to vary activity and as a heat sink to retain at least a portion of the heat of reaction of- sodium aluminum hydroxide formation, whereby catalysis of the unstable hydroxide to the metal and oxygen and hydrogen is enhanced. Admixture of extender with the amalgam and catalytic alloy is effected utilizing the extender in a particulate form of comparable size to the other components, which size is generally from about 10 to about 100 mesh. EXAMPLE I Preparation of Amalgam An amalgam comprising 35.144 parts by weight of sodium, 13.749 parts by weight of aluminum and 51.107 parts by weight of mercury is formed in a graphite crucible in an inert atmosphere of argon at an elevated temperature of 200° C. The resulting amalgam is cooled to room temperature in a dessicator in an inert argon atmosphere. There¬ after, the amalgam is formed into a fine powder of about 10 mesh utilizing a ball mill. Grinding is effected in an inert atmosphere of argon. It is important to prepare the amalgam in an inert gas atmosphere to prevent hydroxide formation. Preparation of Catalytic Alloy 53.7 parts by weight bismuth, 34.0 parts by weight antimony, 4.5 parts by weight nickel, 1.5parts by -weight gold, 5.4 parts by weight zirconium and 0.9 parts by weight chromium are introduced into a graphite crucible which is SUBSTITUTE SHEET thereafter placed in an oven and heated to melting in an inert atmosphere of helium to form an alloy of said meta The resulting alloy is cooled in a dessicator to about room temperature in an inert helium atmosphere. Thereafter the amalgam is formed into a fine powder of about 10 mesh or less utilizing a ball mill. Grinding i effected in an inert atmosphere of helium. The inert atmosphere is used to prevent oxidation o the alloy. Formation of Intimate Amalgam and Catalytic Alloy Admixture Three parts by weight of powdered amalgam is admixe with one part by weight powdered alloy in an inert atmos phere to obtain a uniform mixture of the amalgam and cat lytic alloy. The admixture may be utilized by passing steam up¬ wardly therethrough whereby steam is dissociated into hydrogen and oxygen. Formation of Reactor Block Comprising Amalgam and Catalytic Alloy Three parts by weight of powdered amalgam is admixe with one part by weight powdered alloy. The weighing an blending is effected in an inert atmosphere. After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per squar inch in a graphite mold conforming to the desired shape of the finished product. The mold utilized produces a cubical block. The resulting block is heated to an elevated temper ature of about 10° C above the melting point of the mass and maintained at said temperature for about lO±l minutes. In the oven utilized for heating, an inert at- " osphere, is maintained. Thereafter the mass comprised of amalgam and alloy is transferred to a dessicator where¬ in an inert atmosphere is maintained and the mass is allowed to cool. Upon cooling the resulting block is ready for use. The entire foregoing procedure should be carried out in an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic com¬ ponents and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. Formation of Reactor Block Comprising Amalgam, Catalytic Alloy and Extender The amalgam and alloy prepared above and an extender of gallium are admixed in the following proportions: 21.775 parts by weight amalgam. 9.225 parts by weight alloy. 69.0 parts by weight gallium. The weighing and blending of the foregoing metallic compounds should be done in an inert atmosphere. After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per square inch in a graphite mold conforming to the desired shape of the finished product. The compressed mass in a cru¬ cible conforming to the shape thereof is heated to an elevated temperature of about 10° C. above the melting point of the mass and this temperature is maintained for about 10JI1 minutes. In the oven utilized for heating, an inert atmosphere is maintained. Thereafter the crucible SUBSTITUTE SHEET and its contents are transferred to a desiccator wherein an inert atmosphere is maintained. Upon cooling the re- suiting block is ready for use. The entire foregoing procedure should be carried ou under an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic components and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. The reactor blocks are contacted with a fine spray of water at about room temperature in an atmospheric en¬ vironment. The gaseous effluent from said contact com- prises hydrogen and oxygen and burns when subjected to electrical sparking. The volume of gas evolved is depen¬ dent on reactor block surface area and the volume of wate impinging thereon. Generally a 2.5 square cm surface will react with 0.10 gallons of water per minute. EXAMPLE II Preparation of Amalgam An amalgam comprising 37.688 parts by weight of alu¬ minum, 32.112 parts by weight sodium and 30.2 parts by weight mercury is formed in a graphite crucible in an inert atmosphere of argon at an elevated temperature of 200° C. The resulting amalgam is cooled to room temperature in a dessicator in an inert argon atmosphere. There¬ after, the amalgam is formed into a fine powder of about 10 mesh utilizing a ball mill. Grinding is effected in an inert atmosphere of argon. It is important to prepare the amalgam in an inert gas atmosphere to prevent hydroxide formation. SUBSTITUTE SHEET f 0M Preparation of Catalytic Alloy 57.5 parts by weight bismuth, 4.0 parts by weight nickel and 38.5 parts by weight germanium are introduced into a graphite crucible which is thereafter placed in an oven and heated to melting in an inert atmosphere of heliuπ. to form an alloy of said metals. The resulting alloy is cooled in a desiccator to about room temperature in an inert helium atmosphere. Thereafter the amalgam is formed into a fine powder of about 10 mesh or less utilizing a ball mill. Grinding is effected in an inert atmosphere of helium. The inert atmosphere is used to prevent oxidation of the alloy. Formation of Intimate Amalgam and Catalytic Alloy Admixture Three parts by weight of powdered amalgam is admixed with one part by weight powdered alloy in an inert atmos¬ phere to obtain a uniform mixture of the amalgam and cata- lytic alloy. The admixture may be utilized by passing steam up¬ wardly therethrough whereby steam is dissociated into hydrogen and oxygen. Formation of Reactor Block Comprising Amalgam and Catalytic Alloy Three parts by weight of powdered amalgam is admixed with one part by weight powdered alloy. The weighing and blending is effected in an inert atmosphere. After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per square inch in a graphite mold conforming to the desired shape of the finished product. The mold utilized produces a cubical block. SUBSTITUTE SHEET The resulting block is heated to an elevated temper ature of about 10° C above the melting point of the mass and maintained at said temperature for about 10±1 minutes. In the oven utilized for heating, an inert at- mosphere is maintained. Thereafter the mass comprised o amalgam and alloy is transferred to a dessicator wherein an inert atmosphere is maintained and the mass is allowe to cool. Upon cooling the resultant block is ready for use. The entire foregoing procedure should be carried ou in an inert atmosphere such as helium or argon and in th absence of contaminants. Oxidation of the metallic com¬ ponents and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. Formation of Reactor Block Comprising Amalgam, Catalytic Alloy and Extender The amalgam and alloy prepared above and an extende of gallium are admixed in the following proportions: 21.775 parts by weight amalgam. 9.225 parts by weight alloy. 69.0 parts by weight gallium. The weighing and blending of the foregoing metallic compounds should be done in an inert atmosphere. After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per squar inch in a graphite mold conforming to the desired shape of the finished product. The compressed mass in a crucible conforming to the shape thereof is heated to an elevated temperature of about 10°C above the melting point of the mass and this temperature is maintained for about 10+1 minutes. In th SUBSTITUTE SHEET oven utilized for heating, an inert atmosphere is main¬ tained. Thereafter the crucible and its contents are transferred to a desiccator wherein an inert atmosphere is maintained. Upon cooling the resultant block is ready for use. The entire foregoing procedure should be carried out under an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic components and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. The reactor blocks are contacted with a fine spray of water at about room temperature in an atmospheric en¬ vironment. The. gaseous effluent from said contact com¬ prises hydrogen and oxygen and burns when subjected to electrical sparking. The volume of gas evolved is depen¬ dent on the reactor block surface area and the volume of water impinging thereon. Generally a 2.5 square cm sur¬ face will react with 0.14 gallons of water per minute. EXAMPLE III Preparation of Amalgam An amalgam comprising 22.947 parts by weight of alu- minum, 18.391 parts by weight sodium and 58.662 parts by weight mercury is formed in a graphite crucible in an inert atmosphere of argon at an elevated temperature of 200°C. The resulting amalgam is cooled to room temperature in a dessicator in an inert argon atmosphere. There¬ after, the amalgam is formed into a fine powder of about 10 mesh utilizing a ball mill. Grinding is effected in an inert atmosphere of argon. It is important to prepare the amalgam in an inert gas atmosphere to prevent hydroxide formation. Preparation of Catalytic Alloy 61.264 parts by weight bismuth, 2.25 parts by weigh nickel, 36.036 parts by weight antimony and 0.45 parts b weight germanium are introduced into a graphite crucible which is thereafter placed in an oven and heated to melt in an inert atmosphere of helium to form an alloy of sai metals. The resulting alloy is cooled in a desiccator to about room temperature in an inert helium atmosphere. Thereafter the amalgam is formed into a fine powder of . about 10 mesh or less utilizing a ball mill. Grinding i effected in an inert atmosphere of helium. The inert atmosphere is used to prevent oxidation o the alloy. - Formation of Intimate Amalgam and - Catalytic Alloy Admixture Three parts by weight of powdered amalgam is admixe with one part by weight powdered alloy in an inert atmos phere to obtain a uniform mixture of the amalgam and cat lytic alloy. The admixture may be utilized by immmersion in wate whereby water is dissociated into hydrogen and oxygen. Formation of Reactor Block Comprising Amalgam and Catalytic Alloy Three parts by weight of powdered amalgam is admixe with one part by weight powdered alloy. The weighing an blending is effected in inert atmosphere. After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per square inch in a graphite mold conforming to the desired shape of the finished product. The mold utilized pro¬ duces a cubical block. SUBSTITUTE SHEET - The resulting block is heated to an elevated temper¬ ature of about 10°C above the melting point of the mass and maintained at said temperature for about lO±l minutes. In the oven utilized for heating, an inert atmosphere is mainta ned. Thereafter, the mass com¬ prised of amalgam and alloy is transferred to a desic¬ cator wherein an inert atmosphere is maintained and the mass is allowed to cool. Upon cooling, the resul¬ tant block is ready for use. 0 The entire foregoing procedure should be carried out in an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic components and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. Formation of Reactor Block Comprising 0 Amalgam, Catalytic Alloy and Extender The amalgam and alloy prepared above and a powdered extender comprising 50 weight percent tin and 50 weight percent bismuth of about 10 mesh are admixed in the following proportions: 5 21.775 parts by weight amalgam. 9.225 parts by weight alloy. 69.0 parts by weight extender. The weighing and blending of the foregoing metal¬ lic compounds should be done in an inert atmosphere. 0 After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per square inch in a graphite mold conforming to the desired shape of the finished product. The compressed mass in a crucible conforming to the shape thereof is heated to an elevated temperature of about 10°C above the melting point of the mass and this temperature is maintained for about lO±l minutes. In th oven utilized for heating, an inert atmosphere is main¬ tained. Thereafter the crucible and its contents are transferred to a desiccator wherein an inert atmosphere is maintained. Upon cooling the resultant block is read for use. The entire foregoing procedure should be carried ou under an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic components and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. The reactor blocks are contacted with a fine spray of water at about room temperature in an atmospheric en- viron ent. The gaseous effluent from said contact com¬ prises hydrogen and oxygen and burns when subjected to electrical sparking. The volume of gas evolved is depen dent on the reactor block surface area and the volume of water impinging thereon. Generally a 2.5 square cm sur- face-will react with 0.08 gallons of water per minute. EXAMPLE IV Preparation of Amalgam An amalgam comprising 19.383 parts by weight alumin 31.068 parts by weight potassium and 49.549 parts by wei mercury is formed in a graphite crucible in an inert atm phere of argon at an elevated temperature of 200°C. The resulting amalgam is cooled to room temperature in a desiccator in an inert argon atmosphere. There- SUBSTITUTE SHEET after, the amalgam is formed into a fine powder of about 10 mesh utilizing a ball mill. Grinding is effected in an inert atmosphere of argon. It is important to prepare the amalgam in an inert gas atmosphere to prevent hydroxide formation. Preparation of Catalytic Alloy 33.131 parts by weight bismuth, 12.145 parts by weight nickel, 42.847 parts by weight antimony , 2.429 parts by weight cadmium and 9.448 parts by weight zirconium are introduced into a graphite crucible which is thereafter placed in an oven and heated to melting in an inert atmos¬ phere of helium to form an alloy of said metals. The resulting alloy is cooled in a desiccator to about room temperature in an inert helium atmosphere. Thereafter the amalgam is formed into a fine powder of about 10 mesh or less utilizing a ball mill. Grinding is effected in an inert atmosphere of helium. The inert atmosphere is used to prevent oxidation of the alloy. Formation of Intimate Amalgam and Catalytic Alloy Admixture Three parts by weight of powdered amalgam is admixed with one part by weight powdered alloy in an inert atmos¬ phere to obtain a uniform mixture of the amalgam and cata¬ lytic alloy. The admixture may be utilized by spraying water on the admixture whereby water is dissociated into hydrogen and oxygen. Formation of Reactor Block Comprising Amalgam and Catalytic Alloy Three parts by weight of powdered amalgam is admixed with one part by weight powdered alloy. The weighing and blending is effected in an inert atmosphere. SUBSTITUTE SHEET OΛ'.PI <fr Vf.P0 After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per square inch in a graphite mold conforming to the desired shape of the finished product. The mold utilized pro¬ duces a cubical block. The resulting block is heated to an elevated tem¬ perature of about 10°C above the melting point of the mass and- maintained at said temperature for about lO±l minutes. In the oven utilized for heating, an inert atmosphere is maintained. Thereafter, the mass com¬ prised of amalgam and alloy is transferred to a desic¬ cator wherein an inert atmosphere is maintained and the mass is allowed to cool. Upon cooling, the resul- tant block is ready for use. The entire foregoing procedure should be carried out in an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic components and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. Formation of Reactor Block Comprising Amalgam, Catalytic Alloy and Extender The amalgam and alloy prepared above and an ex¬ tender of gallium are admixed in the following propor¬ tions: 21.775 parts by weight amalgam. 9.225 parts by weight alloy. 69.0 parts by weight gallium. The weighing and blending of the foregoing metallic compounds should be done in an inert atmosphere. SUBSTITUTE SHEET After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per square inch in a graphite mold conforming to the desired shape of the finished product. The compressed mass in a crucible conforming to the shape thereof is heated to an elevated temperature of about 10°C above the melting point of the mass and this temperature is maintained for about lO±l minutes. In the oven utilized for heating, an inert atmosphere is main- tained. Thereafter, the crucible and its contents are transferred to a desiccator wherein an inert atmosphere is maintained. Upon cooling the resultant block is ready for use. The entire foregoing procedure should be carried out under an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic components and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. The reactor blocks are contacted with a fine spray of water at about room temperature in an atmospheric en¬ vironment. The gaseous effluent from said contact co - prises hydrogen and oxygen and burns when subjected to electrical sparking. The volume of gas evolved is depen¬ dent on the reactor block surface area and the volume of water impinging thereon. Generally a 2.5 square cm sur¬ face will react with 0.10 gallons of water per minute. EXAMPLE V Preparation of Amalgam An amalgam comprising 37.688 parts by weight aluminum, 32.112 parts by weight cesium and 30.2 parts by weight S UBSTITUTE SHEET mercury is formed in a graphite crucible in an inert atm phere of argon at an elevated temperature of 200°C The resulting amalgam is cooled to room temperature in a desiccator in an inert argon atmosphere. There- after, the amalgam is formed into a fine powder of about 10 mesh utilizing a ball mill. Grinding is effected in an inert atmosphere of argon. It is important to prepare the amalgam in an inert gas atmosphere to prevent hydroxide formation. Preparation of Catalytic Alloy 57.5 parts by weight bismuth, 4.0 parts by weight nickel and 38.5 parts by weight germanium are introduced into a graphite crucible which is thereafter placed in a oven and heated to melting in an inert atmosphere of hel to form an alloy of said metals. The resulting alloy is cooled in a desiccator to about room temperature in an inert helium atmosphere. Thereafter the amalgam is formed into a fine powder of about 10 mesh or less utilizing a ball mill. Grinding i effected in an inert atmosphere of helium. The inert atmosphere is used to prevent oxidation o the alloy. Formation of Intimate Amalgam and Catalytic Alloy Admixture Three parts by weight of powdered amalgam is admixe with one part by weight powdered alloy in an inert atmos phere to obtain a uniform mixture of the amalgam and cat lytic alloy. . The admixture may be utilized by steam upwardly the through whereby steam is dissociated into hydrogen and oxygen. Formation of Reactor Block Comprising Amalgam and Catalytic Alloy SUBSTI TUTE SHEE T Three parts by weight of powdered amalgam is admixed with one part by weight powdered alloy. The weighing and blending is effected in inert atmosphere. After blending to provide a uniform mixture, the resultant mixture is compressed to. form a solid mass by application of pressure of about 40,000 pounds per square inch in a graphite mold conforming to the desired shape of the finished product. The mold utilized pro¬ duces a cubical block. The resulting block is heated to an elevated temper¬ ature of about 10°C above the melting point of the mass and maintained at said temperature for about lO±l minutes. In the oven utilized for heating, an inert atmosphere is maintained. Thereafter ' , the mass com- prised of amalgam and alloy is transferred to a desic¬ cator wherein an inert atmosphere is maintained and the mass is allowed to cool. Upon cooling, the resul¬ tant block is ready for use. The entire foregoing procedure should be carried out in an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic components and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. Formation of Reactor Block Comprising Amalgam, Catalytic Alloy and Extender The amalgam and alloy prepared above and an ex¬ tender of powdered tin of about 10 mesh are admixed in the following proportions: 21.775 parts by weight amalgam. 9.225 parts by weight alloy. 69.0 parts by weight tin. SUBSTITUTE SHEET The weighing and blending of the foregoing metal¬ lic compounds should be done in an inert atmosphere. After blending to provide a uniform mixture, the resultant mixture is compressed to form a solid mass by application of pressure of about 40,000 pounds per squar inch in a graphite mold conforming to the desired shape of the finished product. The compressed mass in a crucible conforming to the shape thereof is heated to an elevated temperature of about 10°C above the melting point of the mass and this temperature is maintained for about lO±l minutes. In th oven utilized for heating, an inert atmosphere is main¬ tained. Thereafter the crucible and its contents are trandferred to a desiccator wherein an inert atmosphere is maintained. Upon cooling the resultant block is read for use. The entire foregoing procedure should be carried ou under an inert atmosphere such as helium or argon and in the absence of contaminants. Oxidation of the metallic components and/or hydroxide formation will "poison" the resulting reactor block and reduce the activity thereof. Moreover, during the steps of the process operated at elevated temperature, the presence of any oxygen will cause the mass to ignite. The reactor blocks are contacted with a fine spray of water at about room temperature in an atmospheric en¬ vironment. The gaseous effluent from said contact com¬ prises hydrogen and oxygen and burns when subjected to electrical sparking. The volume of gas evolved is depen dent on the reactor block surface area and the volume of water impinging thereon. Generally a 2.5 square cm sur¬ face will react with 0.14 gallons of water per minute. Although the invention has been described in detail with respect to specific examples, it will be appreciate TITUTE SHEET ~ τ that various changes and modifications can be made by those skilled in the art within the scope of the invention as I have expressed in the following claims. SUBSTITUTE SHEET

Claims: I claim: 1. A material for the generation of hydrogen and oxygen from water which comprises an amalgam of an alkal metal, mercury and aluminum combined with an alloy of nickel and at least one element selected from the group consisting of germanium, antimony, gallium, thallium, indium and bismuth. 2. The material of Claim 1 further characterized i that the alkali metal is sodium or potassium. 3. The material of Claim 1 further characterized i that the alloy comprises nickel and at least one metal selected from the group consisting of germanium, antimon gallium, thallium, indium and bismuth and the alkali met of the amalgam is sodium. 4. The material of Claim 3 further characterized i that the alloy comprises nickel and thallium. 5. The material of Claim 3 further characterized i that the alloy comprises nickel and germanium. 6. The material of Claim 3further characterized in that the alloy also contains a metal selected from the group consisting of zirconium, chromium and mixtures the 7. The material of Claim 3 further characterized i that the alloy also contains a metal selected from the group consisting of silver, gold and mixtures thereof. C. SUBSTITUTE SHEET fry* V»' 8. The material of Claim 3 further comprising galliuu. 9. The material of Claim 3 further characterized in that the ratio of alkali metal to mercury is from about 3:1 to about 1:1.5 and the atomic weight ratio of alkali metal to aluminum is from about 1:1 to about 3:1. 10. The material of Claim 3 further characterized in that the ratio, by weight, of alloy to amalgam is from about 1:1 to about 1:5. 11. The material of Claim 10 further characterized in that the ratio, by weight, of alloy to amalgam is about 1:1 to about 1:3. 12. The material of Claim 6 further characterized in that that alloy contains from about 0.7% to about 1:1% by weight chromium. 13. The material of Claim 3 further characterized in that each of the metallic components of the alloy present in said material is present in an amount of from about 0.4 to about 28.5 weight percent based upon the weight of alloy and amalgam combined. SUBSTITUTE SHEET 14. The material of Claim 1 further characterized in that said alloy comprises nickel present in an amount of from about 3.5 to about 6.5% by weight, bismuth present in an amount of from about 40.1 to about 68.7% by weight, antimony present in an amount of from about 25.5 to about 42.5% by weight, chromium present in an amount of from about 0.7 to about 1.1% by weight, zirconium present in an amount of from about 4.1 to about 6.8% by weight and gold present in an amount of from about 1.1 to about 1.9% by weight. 15. The material of Claim 14 further characterized in that said alloy comprises about 4.5 weight percent nickel, about 53.7 weight percent bismuth, about 34.0 weight percent antimony, about 0.9 weight percent chromiu about ' 5.4 weight percent zirconium and about 1.5 weight percent gold. 16. The process for the generation of hydrogen and oxygen from water which comprises contacting water with an amalgam of an alkali metal, mercury and aluminum combi with a nickel containing alloy. 17. The process of Claim 16 further characterized in that the alkali metal is sodium, potassium or mixtures thereof. 18. The process of Claim 17 further characterized in that the alloy comprises nickel and at least one metal selected from the group consisting of germanium, antimony gallium, thallium, indium and bismuth. SUBSTITUTE SHEET 19. The process of Claim 16 further characterized in that the alloy comprises nickel and at least one metal selected from the group consisting of germanium, antimony, gallium, thallium, indium and bismuth and the alkali metal of the amalgam is sodium. 20. The process of Claim 19 further characterized in that the alloy comprises nickel and thallium. 21. The process of Claim 19 further characterized in that the alloy comprises nickel and germanium. 22. The process of Claim 19 further characterized in that the alloy also contains a metal selected from the group consisting of zirconium, chromium and mixtures thereof. 23. The process of Claim 19 further characterized in that the alloy also contains a metal selected from the group consisting of silver, gold and mixtures thereof. 24. The process of Claim 19 further comprising gallium. 25. The process of Claim 19 further characterized in that the atomic weight ratio of alkali metal -to mercury is from about 3:1 to about 1:1.5 and the atomic weight ratio of alkali metal to aluminum is from about 1:1 to about 3:1. 26. The process of Claim 19 further characterized in that the ratio, by weight, of alloy to amalgam is from about 1:1 to about 1:5. SUBSTITUTE SHEET

Inventors: ANDERSON E
Applicants: HORIZON MFG CORP
Application year: 1981
Main classification: C01B13
IPC codes: C01B3, C01B13, C22C7