Continuous Chlorine Dioxide Generation via UV Photo-oxidation
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Solution Overview
Problem
Existing methods for producing chlorine dioxide, such as batch processes, are inefficient, costly, and pose safety hazards due to the need for handling concentrated solutions and high UV exposure, which leads to photolysis and side reactions, increasing the risk of exceeding atmospheric toxicology thresholds.
Innovation Solution
A continuous process that generates low concentrations of chlorine dioxide using a UV lamp in a circulation tube with controlled flow rates and chlorite concentrations, monitored by an inline sensor, reducing photolysis and side reactions, and allowing direct application without dilution, utilizing specific water quality parameters to achieve low conversion efficiency and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If batch processes are used to generate chlorine dioxide, then higher concentrations can be produced, but safety hazards increase due to handling concentrated solutions and risk of exceeding atmospheric toxicology thresholds
Solution Approach 1:
The patent implements a continuous generation process where chlorine dioxide is produced continuously at low concentrations directly in the water stream, eliminating the need to handle concentrated solutions. The system maintains a steady state where chlorite is continuously converted to chlorine dioxide at controlled low levels, ensuring safety while maintaining effectiveness.
Solution Approach 2:
The patent changes the concentration parameter from high (batch process) to low (continuous process), and adjusts the generation rate to maintain optimal levels. By controlling the flow rate and UV irradiation intensity, the system maintains chlorine dioxide concentrations below toxicological thresholds while still achieving effective disinfection.
2Productivity
If high UV exposure is used to generate chlorine dioxide from chlorite, then generation efficiency improves, but photolysis and side reactions increase, reducing process reliability
Solution Approach 1:
The patent applies partial UV irradiation rather than maximum UV exposure. The UV dose is carefully controlled to achieve sufficient conversion of chlorite to chlorine dioxide without causing excessive photolysis or unwanted side reactions. This optimized UV exposure level balances generation efficiency with process stability.
Solution Approach 2:
The system uses inline sensors to monitor chlorine dioxide concentration and adjusts UV irradiation and flow rate accordingly. This feedback control ensures that the UV exposure remains within the optimal range for efficient generation while preventing conditions that lead to photolysis and side reactions.
3Device complexity
If batch processes are used, then equipment complexity is reduced, but manufacturing cost and time increase due to inefficient generation and required dilution
Solution Approach 1:
The continuous generation process eliminates idle time between batch cycles and maintains constant production. The system processes water continuously through the UV irradiation zone, converting chlorite to chlorine dioxide on-the-fly, which significantly improves throughput and reduces operational costs compared to intermittent batch processing.
Solution Approach 2:
The patent uses chlorite as an intermediary substance that is converted to chlorine dioxide in-situ. This approach eliminates the need for complex storage and handling equipment for concentrated chlorine dioxide, simplifying the overall system while maintaining continuous efficient generation.
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 continuous process produces a safe and reliable low-concentration chlorine dioxide stream suitable for direct use, reducing handling risks and costs, while maintaining sufficient disinfection efficacy, suitable for applications where higher concentrations are hazardous.
Implementation Method 1
The sodium chlorite is photochemically oxidized to chlorine dioxide
Implementation Method 2
a circulation tube proximate to the light for circulating the aqueous chlorite in contact with the lamp radiation
Data Source
AI summary
Provided are methods and systems for continuously producing low concentrations of chlorine dioxide from dilute solutions of sodium chlorite. The low concentrations of chlorine dioxide produced allow for reduced exposure risk with direct application of the chlorine dioxide stream. The incorporation of a suitable chlorine dioxide detector permits continuous monitoring and control of chlorine dioxide production ensuring that the process stays within regulatory guidelines. Pretreatment of reaction water is preferred for achieving suitable conversion rates of the low concentrations of chlorite to chlorine dioxide.