Dynamic Acid Molar Excess Control for Chlorine Dioxide Production
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Solution Overview
Problem
Conventional methods for generating chlorine dioxide using the chlorite-acid process incur high costs due to the requirement of a three-fold molar excess of acid, which is not optimized for varying reaction temperatures and times, leading to inefficient chemical usage in large-scale disinfection applications.
Innovation Solution
A method where the reaction temperature in a reactor is determined, and the molar excess of acid relative to chlorite is adjusted based on this temperature, reducing the acid requirement from three moles per mole of chlorite to two moles per mole, thereby reducing chemical costs while maintaining a yield of at least 85% chlorine dioxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a three-fold molar excess of acid is used relative to chlorite, then the yield of chlorine dioxide is ensured to be at least 85%, but the chemical costs increase significantly
Solution Approach 1:
The patent applies dynamics by making the molar excess of acid variable rather than fixed. The control unit adjusts the acid-to-chlorite ratio in real-time based on reaction conditions (temperature, reaction time, plant utilization), allowing the system to adapt and optimize chemical usage while maintaining the required 85% yield threshold.
Solution Approach 2:
The patent changes the parameter of acid molar excess from a static value (3-fold) to a dynamic parameter that varies with reaction temperature and time. By adjusting this parameter according to actual reaction conditions, the system achieves cost reduction while maintaining product yield within the required range.
2Ease of operation
If a fixed three-fold molar excess of acid is used, then the process is simple to operate, but chemical costs are unnecessarily high under varying reaction conditions
Solution Approach 1:
The patent implements feedback control where the control unit continuously monitors reaction conditions (temperature, reaction time) and adjusts the acid dosing accordingly. This closed-loop system maintains operational simplicity through automated control while optimizing chemical consumption based on actual process conditions.
Solution Approach 2:
The system performs self-adjustment by automatically modifying the acid-to-chlorite ratio based on monitored reaction parameters. The control unit independently optimizes chemical usage without requiring manual intervention, making the process both operationally simple and chemically efficient.
3Quantity of substance
If the molar excess of acid is reduced below three-fold, then chemical costs decrease, but the yield of chlorine dioxide may fall below the required 85%
Solution Approach 1:
The system dynamically adjusts the acid molar excess based on reaction temperature and time, ensuring the yield remains at or above 85% while minimizing acid consumption. The control unit calculates the optimal ratio in real-time, preventing yield degradation even when using less than the conventional three-fold excess.
Solution Approach 2:
By changing the acid molar excess parameter from a fixed low value to a dynamically optimized value, the system achieves both cost reduction and yield assurance. The parameter is adjusted according to reaction conditions to maintain the 85% yield threshold while reducing overall acid consumption.
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 approach reduces chemical costs by approximately €40,000 per year without compromising the target yield, ensuring reliable disinfection in industrial and municipal water treatments by optimizing acid usage with varying reaction conditions.
Implementation Method 1
an acid, a chlorite and optionally water are introduced into a reactor... in which an acid reacts with a chlorite to form chlorine dioxide (ClO2) and a chloride
Data Source
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AI summary
To provide a method that significantly reduces the costs associated with conventional chlorine dioxide production processes using the chlorite-acid method, the invention proposes a process in which an acid, a chlorite, and optionally water are introduced into a reactor. In this process, the reaction temperature in the reactor is determined, and the amount of acid, chlorite, and/or water introduced into the reactor is selected such that the acid is introduced with a molar excess relative to the chlorite introduced into the reactor. The magnitude of this molar excess is varied according to the determined reaction temperature. Furthermore, the present invention relates to an apparatus suitable for carrying out the process according to the invention.