CIP Chlorine Concentration Control Across Broad pH Ranges
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Solution Overview
Problem
Existing chlorine monitors are not sensitive enough to accurately measure chlorine concentrations in electrolyzed water solutions used for clean-in-place (CIP) applications, particularly across broad pH ranges, due to their design for lower chlorine levels and pH variability in water supplies.
Innovation Solution
A control system that includes a chlorine sensor and a pH modifier to accurately measure chlorine oxyanion concentrations from 10 ppm to 1000 ppm, allowing for automated and hands-free adjustment of chlorine levels in CIP systems, using electrolytically-generated chlorine oxyanions such as hypochlorite, chlorite, chlorate, and perchlorate anions, and incorporating a feedback loop for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If commercially-available chlorine monitors are used, then they are designed for detecting lower chlorine levels (0.5-3 ppm), but they cannot accurately measure higher chlorine concentrations (10-1000 ppm) in electrolyzed water solutions
Solution Approach 1:
The patent modifies the operational parameters of chlorine monitors by adjusting pH levels and introducing pH modifiers to enable accurate measurement across a broad chlorine concentration range (10-1000 ppm). This resolves the contradiction by changing the measurement conditions rather than replacing the entire monitoring system.
Solution Approach 2:
The patent introduces pH modifiers as intermediary substances that facilitate accurate chlorine measurement by adjusting the pH of electrolyzed water solutions to optimal levels. This mediator enables standard chlorine monitors to function accurately in previously unsuitable high-concentration environments.
2Measurement precision
If pH variability in water supply is present, then it affects the accuracy of chlorine measurement, but adjusting pH for accurate measurement may alter the effectiveness of the electrolyzed water solution
Solution Approach 1:
The patent divides the water treatment process into separate stages: pH adjustment occurs in a dedicated conditioning system before the water enters the electrolytic cell, while the electrolyzed water maintains its sanitizing properties in the application system. This segmentation allows pH optimization for measurement without compromising sanitizing effectiveness.
Solution Approach 2:
pH modifiers serve as intermediaries that temporarily adjust pH for accurate measurement purposes, with the system designed to maintain the original electrolyzed water properties for sanitizing. The pH adjustment is controlled and reversible, acting as a temporary mediator rather than a permanent alteration.
3Productivity
If electrolyzed water solutions are used for CIP applications, then high and variable chlorine concentrations are generated for effective cleaning, but this creates corrosive levels that can damage CIP systems
Solution Approach 1:
The patent implements feedback control systems with chlorine monitors that continuously measure chlorine concentration and provide real-time data to control the electrolysis process. This feedback mechanism prevents chlorine concentrations from reaching corrosive levels by automatically adjusting electrolysis parameters, thus maintaining cleaning effectiveness while preventing system damage.
Solution Approach 2:
The system dynamically adjusts electrolysis parameters based on real-time chlorine concentration measurements, allowing the chlorine level to be optimized for cleaning effectiveness while automatically reducing levels when approaching corrosive thresholds. This dynamic control resolves the contradiction between maintaining high cleaning performance and preventing system corrosion.
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
Enables consistent and accurate chlorine concentration control across a broad pH range, overcoming sensor limitations and ensuring effective sanitizing and cleaning without corrosive levels, suitable for various industrial applications like food and beverage processing.
Implementation Method 1
Onsite chemistry production can be achieved through electrolysis of water and electrolytes to produce alkaline detergent solutions of sodium hydroxide (NaOH), hypochlorite solutions or chlorine for use as detergent, bleach, surface sanitizers and other disinfectant purposes.
Implementation Method 2
a pH modifier in fluid communication with the first portion of electrolysis solution to enable accurate measurement of chlorine oxyanion concentration from approximately 10 ppm to 1000 ppm
Implementation Method 3
a chlorine sensor in fluid communication with a first portion of the electrolysis solution
Data Source
AI summary
Control systems for use of electrolysis solutions for automated recirculating or single-pass cleaning systems, such as clean-in-place (CIP) applications are disclosed. Control systems and methods for using automated chlorine output solutions for various cleaning applications are measurable over broad pH ranges. The control systems generate consistent and predictable electrolytic solutions and include a measurement system that identifies chlorine oxyanion concentration across broad ranges of pH, overcoming the sensitivity of chlorine monitors to pH and permitting use of the control systems to control cleaning systems.