Brine Tank Electrolysis for Microbial Control and Salt Dissolution
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Solution Overview
Problem
Brine tanks used in water softening systems are prone to microbiological contamination due to high salinity, leading to extended saturation times and increased tank sizing requirements, which can result in contaminated ion-exchange materials and softened water.
Innovation Solution
A brine tank design featuring a first compartment for solid salt, a second compartment for brine storage separated by a salt-proof membrane, with a circulation system and an electrolyzer cell in the return line to oxidize chloride ions and maintain chlorine levels, enhancing microbiological control and dissolution rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brine tank stores water between regenerations, then brine can be prepared for ion-exchange material regeneration, but microbiological growth occurs in the high salinity environment
Solution Approach 1:
The patent extracts the harmful microbiological aspect by introducing an electrolysis system that generates chlorine from the brine itself. The electrolysis cell converts chloride ions in the brine to chlorine, which then acts as a biocide to eliminate microbiological contamination. This transforms the brine from a medium susceptible to contamination into its own disinfectant source.
Solution Approach 2:
The patent changes the chemical parameters of the brine by electrolyzing it to generate chlorine. The electrolysis process alters the brine's composition by converting chloride ions (Cl-) into chlorine (Cl2), which dissolves in water to form hypochlorous acid (HOCl). This parameter change fundamentally alters the biological properties of the brine, making it hostile to microorganisms.
2Manufacturing precision
If saturated brine is formed before regeneration, then complete salt dissolution is achieved, but minimum three hours waiting time is required
Solution Approach 1:
The patent applies preliminary action by continuously electrolyzing the brine in advance of regeneration. The electrolysis process is activated before regeneration occurs, maintaining chlorine levels and preparing the brine for immediate use. This eliminates the waiting time that would otherwise be required for salt dissolution and saturation, as the brine is continuously prepared and maintained in a ready state.
Solution Approach 2:
The patent ensures continuity of useful action by maintaining continuous electrolysis of the brine. Rather than allowing the brine to sit passively between regenerations, the electrolysis system operates continuously or periodically to maintain chlorine concentration and brine saturation. This continuous action eliminates idle time and ensures the brine is always ready for regeneration.
3Duration of action of stationary object
If ion-exchange material capacity is increased to maintain operational capacity during saturation period, then device can operate during brine formation time, but tank size must be increased
Solution Approach 1:
The patent applies self-service by enabling the brine to disinfect itself through electrolysis. The brine tank becomes self-sufficient in maintaining its own quality by generating chlorine from its own chloride content. This eliminates the need for larger ion-exchange material capacity or larger tank sizes to compensate for contamination issues, as the brine automatically maintains its own suitability for regeneration.
4Productivity
If brine circulation is implemented in brine tank, then salt dissolution rate is increased, but energy consumption increases
Solution Approach 1:
The patent merges two functions into one system: brine circulation and electrolysis. The electrolysis cell is positioned in the return line of the circulation system, so that the circulation pump serves both to circulate brine (enhancing dissolution) and to pass brine through the electrolysis cell (generating chlorine). This combination eliminates the need for separate circulation and electrolysis systems, optimizing energy usage while achieving both dissolution enhancement and microbiological control.
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
This configuration reduces tank size, increases regeneration frequency, and minimizes microbiological contamination by maintaining chlorine levels, ensuring consistent and efficient brine production for ion-exchange material regeneration.
Implementation Method 1
an electrolyzer cell (107) which is capable of applying a current to brine passed through the return line (106) to oxidize chloride ions in the brine
Implementation Method 2
a salt grid (101) which separates a first compartment (103) containing solid salt from a second compartment (102) for storing brine, the salt grid (101) allowing water and brine to pass through but preventing passage of solid salt
Implementation Method 3
the brine formed in the first compartment is able to sink through the openings of the separation element into the second compartment
Data Source
Figure 1
AI summary
A brine tank (100), a method to provide brine for regenerating an ion-exchange material and a water softening method are described. The brine tank (100) comprises a first compartment or top area (103) containing a solid salt, a second compartment or bottom area (102) for storing brine, and a separation element (101) between the two compartments. The separation element (101) contains openings which allow water and brine to pass therethrough but prevent passage of the solid salt. The brine tank further comprises an inlet (105) to feed water into the tank, an outlet (105) to discharge brine from the tank, and a water level control device (not shown) and/or at least one volume meter configured to measure the volume of brine discharged from the tank and/or the volume of water fed into the tank. The water level control device and/or the at least one volume meter are configured to adjust a water level in the tank that allows a portion of the salt contained in the first compartment to be in contact with water fed into the tank such that salt is caused to dissolve in the water and form brine. The first compartment, the second compartment and the separation element are arranged such that the brine formed in the first compartment (103) is able to sink through the openings of the separation element (101) into the second compartment (102). The second compartment is connected to the first compartment by a return line (106) through which brine is to be transferred from the second compartment (102) into the first compartment (103), thereby establishing a brine circulation that results in a much faster dissolution of solid salt in the first compartment. In addition to this, it is possible to chlorinate the brine with the help of an electrolyzer cell (107) positioned in the return line (106). The described water softening method comprises a regeneration step in which the brine generated in the brine tank is used.