Liquid Acid Concentrate Manufacturing via Solid Dissolution
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Solution Overview
Problem
Existing manufacturing facilities for liquid acid concentrate used in hemodialysis machines face challenges in ensuring precise composition, stability of components, and cost-effective transportation and storage, particularly due to the instability of glucose with acids and the need for complex monitoring systems.
Innovation Solution
A compact facility and method for manufacturing liquid acid concentrate that uses interchangeable tanks containing solid components, with a mixing tank equipped with scales, stirrers, and conductivity/density meters for precise monitoring and homogenization, allowing for the use of stable electrolyte mixtures and separate introduction of sodium chloride and acid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If liquid acid concentrate is manufactured on site from dry concentrates or precursor formulations, then transportation costs of water are avoided and local production is enabled, but the volume and weight of components requiring transport and storage increase significantly
Solution Approach 1:
The invention changes the physical state parameter of the concentrate components from liquid to solid form. By providing dry concentrates in interchangeable containers instead of liquid concentrates, the system reduces transportation volume and weight while enabling on-site manufacturing. The solid dry concentrates are transported efficiently and then dissolved on-site to produce the required liquid acid concentrate, resolving the contradiction between transportation efficiency and local production capability.
2Adaptability or versatility
If pre-dosed bags of solid components are used for on-site mixing, then manufacturing flexibility is improved, but the potential for confusion increases and analytical monitoring of every batch becomes necessary
Solution Approach 1:
The invention merges all concentrate components (sodium chloride, sugar, and electrolytes) into a single pre-mixed dry concentrate formulation contained in interchangeable containers. This eliminates the confusion associated with multiple separate pre-dosed bags while maintaining manufacturing flexibility. The single integrated container ensures accurate composition without requiring analytical monitoring of every batch, as the pre-mixed formulation guarantees consistent electrolyte concentrations.
Solution Approach 2:
The interchangeable container acts as an intermediary device that delivers pre-mixed dry concentrate from the manufacturing facility to the on-site production location. This intermediary solution transfers the precision of centralized manufacturing to distributed on-site production, ensuring composition accuracy without requiring complex monitoring systems at each location.
3Manufacturing precision
If complex monitoring systems are implemented to ensure correct composition during on-site manufacturing, then quality control is improved, but device complexity and personnel expenses increase
Solution Approach 1:
The invention performs the critical mixing and composition control actions in advance at the centralized manufacturing facility, where precision equipment and quality control systems are available. The pre-mixed dry concentrates are prepared with exact compositions before distribution. This preliminary action transfers the complexity of precise composition control to the manufacturing facility, allowing simple on-site dissolution processes that require minimal monitoring equipment and personnel expertise.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of stable liquid acid concentrate with precise composition, reducing transportation and storage costs by using mostly solid components, and simplifying monitoring processes without the need for sophisticated instruments, thus ensuring high-quality dialysate production.
Implementation Method 1
The water is circulated from the bottom of the tank, through the interchangeable container and back to the top of the tank. The water circulating inside the container causes the dry concentrate to dissolve.
Implementation Method 2
The level sensor is also designed to act as a conductivity sensor. The liquid acid concentrate is ready when the conductivity of the solution reaches the desired value.
Data Source
AI summary
The invention relates to a method for manufacturing a liquid acid concentrate for hemodialysis machines, with the following steps. In a preliminary step a water source (120), an acid source (130), an electrolyte tank (140) containing a mixture of electrolytes in exactly the quantity needed for the manufacture of the liquid acid concentrate, and a sodium chloride source (150) are connected to a mixing tank (110). During Step a), the quantity of water needed for the manufacture of the batch of liquid acid concentrate is introduced into the mixing tank (110). At Step b), the quantity of acid needed for manufacture the liquid acid concentrate is introduced into the mixing tank (110), the solution is stirred until a homogeneous solution is obtained. Step c) is to repeat Sub-steps c1) and c2) until the electrolyte mixture contained in the electrolyte tank is completely dissolved. At Sub-step c1) part of the solution contained in the mixing tank (110) is transferred into the electrolyte tank (140) containing the electrolyte mixture, then at Sub-step c2) the solution contained in the electrolyte tank (140) is transferred into the mixing tank, leaving the still solid constituents in the electrolyte tank. At Step d) the quantity of sodium chloride needed to manufacture the liquid acid concentrate is introduced into the mixing tank (110). Finally, at Step e), the solution is stirred and recirculated by taking it from the bottom the mixing tank (110) and reintroducing it at the top of the mixing tank until a homogeneous liquid acid concentrate is obtained. Steps a) to d) can be performed in any order, Step a) preceding always Step c).