Chlorous Acid Manufacturing via In-Situ Electrolysis and Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing chlorous acid aqueous solutions using chlorate as a raw material are costly, unstable, and pose handling risks due to the hazardous nature of chlorate, while also generating carcinogenic byproducts and requiring additional safety measures.
Innovation Solution
A method involving the electrolysis of sodium chloride to produce chlorate, followed by reduction with acidic thiosulfuric acid or dithionous acid, using hydrogen peroxide, to generate chlorous acid, which is then neutralized to produce a stable chlorous acid aqueous solution with enhanced antimicrobial, sterilizing, and antiviral properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods using chlorate as raw material are used, then manufacturing cost is reduced, but safety and stability deteriorate due to hazardous nature of chlorate
Solution Approach 1:
The patent applies preliminary action by performing electrolysis of sodium chloride in advance to generate sodium chlorate in situ, which is then immediately reduced to chlorous acid. This eliminates the need to handle, store, and transport hazardous chlorate materials, thereby reducing manufacturing costs while improving safety and stability.
Solution Approach 2:
The patent uses electrolysis as an intermediary process that converts safe, stable sodium chloride into sodium chlorate, which is then immediately converted to chlorous acid. This intermediary electrolysis step allows the system to benefit from chlorate's reactivity without exposing operators to its hazards, resolving the contradiction between cost and safety.
2Device complexity
If conventional methods using chlorate are used, then manufacturing process is simpler, but harmful byproducts increase due to carcinogenic substances
Solution Approach 1:
The patent changes the chemical parameters of the reaction system by using electrolysis to generate chlorate in situ at controlled concentrations, followed by immediate reduction. This parameter change (from batch chlorate addition to continuous in-situ generation) reduces harmful byproducts while maintaining process simplicity.
Solution Approach 2:
The patent converts the potentially harmful high concentration chlorate into beneficial low concentration chlorous acid through controlled electrolysis and immediate reduction. The electrolysis process generates chlorate at controlled rates that are immediately consumed, converting what would be a harmful intermediate into a beneficial product with minimal harmful byproducts.
3Reliability
If additional electrolysis step is added, then reactivity and antimicrobial power are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the electrolysis step with the chlorous acid generation step into a single integrated process. The electrolysis cell directly generates chlorous acid in the reaction medium, combining what would otherwise be separate operations (electrolysis to make chlorate, then reduction to make chlorous acid). This maintains high reactivity and antimicrobial power while minimizing manufacturing complexity.
Solution Approach 2:
The electrolysis process is self-regulating, generating chlorate and chlorous acid at rates determined by the applied current. The system automatically adjusts production based on electrical input without requiring complex control mechanisms, thereby improving reactivity and antimicrobial power while keeping the manufacturing process relatively simple.
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 method produces a chlorous acid aqueous solution that is safer, more cost-effective, and has improved reactivity and stability, with reduced generation of carcinogenic byproducts, maintaining antimicrobial and antiviral effectiveness over a longer period.
Implementation Method 1
electrolyzing a salt to obtain a chlorate or an aqueous solution
Implementation Method 2
reducing the chlorate or the aqueous solution thereof to obtain an aqueous solution including a chlorous acid
Data Source
AI summary
The present invention provides a method for manufacturing a chlorous acid aqueous solution using salt as a raw material. The present invention provides a method for manufacturing a chlorous acid aqueous solution, the method including 1) a step for electrolyzing salt and obtaining a chlorate or an aqueous solution thereof, and 2) a step for reducing the chlorate or aqueous solution thereof and manufacturing an aqueous solution including chlorous acid. The method for manufacturing a chlorous acid aqueous solution includes a step for mixing an inorganic acid or an inorganic acid salt as a simple substance or two or more types thereof with the aqueous solution including chlorous acid, and then mixing any of an inorganic acid, an inorganic acid salt, an organic acid, or an organic acid salt as a simple substance or two or more types thereof.