Chlorine Dioxide Generator Turn-Down Ratio
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Solution Overview
Problem
Existing chlorine dioxide generators face safety concerns due to potential explosions from highly concentrated chlorine dioxide and are limited in variability to treat applications with fluctuating process flow rates, such as oil and gas operations, where rapid changes in chlorine dioxide demand occur.
Innovation Solution
An automated process that adjusts the mass flow rate of dilute chlorine dioxide solution within a wide range (1:200 to 1:500) by controlling the feed rate of chemical pumps and motive water flow, ensuring at least 80% conversion of chlorite anion to chlorine dioxide without forming explosive concentrations, using a Programmable Logic Controller (PLC) and flow sensors to manage the generation and dilution process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If eductor based apparatus are used to generate chlorine dioxide, then concentrated chlorine dioxide can be produced, but safety risks increase due to potential explosions from highly concentrated chlorine dioxide
Solution Approach 1:
The patent extracts only the necessary portion of concentrated chlorine dioxide and immediately dilutes it with water to achieve the desired treatment concentration. The system generates concentrated chlorine dioxide but rapidly mixes it with dilution water to maintain safe concentrations in the treatment stream, thereby extracting the active ingredient while eliminating the harmful concentrated form.
Solution Approach 2:
The patent introduces water as an intermediary substance that mediates between the concentrated chlorine dioxide generation and the final application. The water acts as a diluent and safety buffer, transforming the hazardous concentrated chlorine dioxide into a safe dilute solution for treatment applications.
2Productivity
If variable dilution water flow rates are used to adjust chlorine dioxide output, then mass flow rate can be controlled, but the ability to treat process streams with large flow rate variances is limited
Solution Approach 1:
The patent employs dynamic control where both the chemical feed rate and dilution water flow rate are continuously adjusted based on real-time process conditions. The system responds dynamically to changing treatment demands by modulating pump speeds and flow rates, enabling rapid adaptation to process stream variations with a turn-down turn-up ratio of at least 1:200.
Solution Approach 2:
The patent changes multiple parameters simultaneously - both the feed rate of chemical reagents and the flow rate of dilution water - to achieve the desired chlorine dioxide mass flow rate while maintaining safe concentrations. This dual-parameter control provides flexibility to handle widely varying treatment demands.
3Device complexity
If fixed concentration of chlorine dioxide is generated, then generation process is simplified, but flexibility to meet varying treatment demands is reduced
Solution Approach 1:
The patent maintains relatively simple generation chemistry while introducing flexible parameter control through variable speed pumps and flow meters. By controlling the feed rate of chemical reagents and the dilution water flow rate independently, the system can adjust output concentration and mass flow rate to match varying treatment demands without complicating the core generation process.
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 solution provides safe and efficient generation of chlorine dioxide with high variability, meeting the demands of oil and gas applications by maintaining a safe concentration range (50-5000 ppm) and ensuring efficient operation across varying flow rates, enhancing treatment flexibility and safety.
Implementation Method 1
ensuring at least 80% conversion of chlorite anion to chlorine dioxide
Implementation Method 2
Generators that use chlorite, hypochlorite, and acid often comprise an eductor to form a vacuum to extract a highly concentrated stream of chlorine dioxide gas
Data Source
AI summary
Disclosed is a process for the safe and efficient generation of chlorine dioxide while achieving a variable chlorine dioxide mass flow rate with a turn-down to turn-up ratio of at least 1 to 200. The process allows for a single chlorine dioxide generating system to safely provide variable mass flow rate of chlorine dioxide to applications that have wide ranging chlorine dioxide demand, like those experienced in oil and gas applications.