Catalyst Bed PAA Production With Just-in-Time Concentration Control

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Solution Overview

Problem

Peroxyacetic acid (PAA) solutions are unstable, pose health risks, and present handling and transportation hazards due to their volatility and concentration requirements, necessitating a method for stable and safe production and application in food processing industries.

Innovation Solution

An online production system that precisely mixes hydrogen peroxide and acetic acid solutions using a controlled mixing system and catalyst bed to produce PAA directly for application, eliminating the need for concentrated solutions and reducing transportation risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If concentrated PAA solutions are manufactured and stored, then antimicrobial effectiveness is improved, but stability and safety deteriorate due to volatility and decomposition

Engineering Contradiction:

Improveantimicrobial effectivenessVSAvoidPAA solution stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The system performs preliminary action by pre-positioning the precursor chemicals (acetic acid and hydrogen peroxide) in ready-to-use reservoirs, eliminating the need to pre-manufacture and store unstable concentrated PAA solutions. The PAA is generated just-in-time through automated mixing, maintaining both stability during storage and effectiveness during application.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces intermediary substances (acetic acid and hydrogen peroxide) that are stable during storage and can be safely transported. These intermediaries are then combined in a controlled manner to produce the active PAA solution, effectively mediating between stable storage requirements and effective application needs.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If concentrated PAA solutions are transported to processing plants, then immediate application capability is improved, but safety and exposure risks worsen

Engineering Contradiction:

Improveimmediate application capabilityVSAvoidexposure hazard to employees

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary action by pre-positioning stable precursor chemicals at the processing plant in ready-to-use reservoirs. This eliminates the need to transport hazardous concentrated PAA solutions while maintaining immediate application capability, as the precursors are simply mixed on-site when needed.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent converts the harmful property of PAA volatility and instability into a benefit by using these same properties to enable just-in-time generation of the chemical. The precursors are stable during transport and storage, but when mixed, they rapidly produce the active PAA that decomposes quickly after use, reducing overall exposure risk.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of operation

If stable PAA storage is attempted, then handling safety is improved, but concentration control and effectiveness worsen due to decomposition

Engineering Contradiction:

Improvehandling safetyVSAvoidconcentration control

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system employs feedback control through automated dosing equipment that precisely measures and controls the mixing ratios of precursors. Sensors and control systems monitor the mixing process in real-time, ensuring consistent PAA concentration without manual intervention, thereby maintaining both safety and precision.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent changes the fundamental parameter of how PAA is maintained - instead of storing finished PAA solutions and relying on their inherent (unstable) concentration, the system continuously generates PAA by controlling the mixing parameters of precursors. This transforms concentration control from a storage maintenance problem to a controlled generation process.

Inventive Principle:

Principle #35Parameter changes

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

Ensures stable and safe production of PAA with precise concentration control, reducing exposure hazards and environmental impact by generating PAA just in time for use, thereby maintaining antimicrobial effectiveness and avoiding the need for stabilizing compounds that contribute to environmental pollution.

Implementation Method 1

online production system that precisely mixes hydrogen peroxide and acetic acid solutions using a controlled mixing system and catalyst bed to produce PAA

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS11873273B2Online production of organic peroxide using a catalyst bed

Publication Date: 2024.01.16 SAFE FOODS CORP

AI summary

A method of producing an organic peroxide includes introducing an organic solution and a peroxide solution into a mixing tank to form a mixture. The method further includes circulating the mixture over a fixed catalyst bed to form the organic peroxide and measuring a concentration of the organic peroxide in the mixture. Further, the method includes removing at least a portion of the mixture when the concentration reaches a set value.