CIP Chlorine Control Across Broad pH Ranges
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Solution Overview
Problem
Existing CIP systems face challenges in maintaining consistent and accurate chlorine concentrations across a broad pH range due to variability in water quality and pH, which affects the sensitivity and accuracy of chlorine sensors, making it difficult to use electrolytic solutions effectively for cleaning and sanitizing without causing corrosion.
Innovation Solution
A control system that includes an electrochemical cell for in situ production of electrolyzed solution concentrate, a sensing cell with a chlorine sensor and pH probe for measuring and adjusting chlorine oxyanion concentration, and a feedback loop mechanism to maintain chlorine levels between 10 ppm to 1000 ppm and pH between 5.5 and 7.5, ensuring accurate and reproducible chlorine output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrolysis solutions are used for CIP applications to achieve high chlorine concentrations for effective cleaning and sanitizing, then cleaning and sanitizing efficacy is improved, but chlorine levels become corrosive to CIP systems and sensor accuracy deteriorates
Solution Approach 1:
The system dynamically adjusts the pH parameter of the electrolysis solution to optimize the chlorine sensor's operating range. By controlling pH levels, the system maintains accurate chlorine measurements while preserving the high chlorine concentrations necessary for effective cleaning and sanitizing, thereby preventing corrosion and ensuring reliable operation
Solution Approach 2:
The system employs a feedback mechanism where the chlorine sensor continuously monitors chlorine levels and the pH controller adjusts pH based on sensor readings and setpoint comparisons. This closed-loop control ensures that chlorine concentrations remain within the optimal range for both cleaning efficacy and sensor accuracy, preventing harmful corrosion effects
2Adaptability or versatility
If pH variability in water supply and dilution water is allowed, then system flexibility is maintained, but chlorine measurement accuracy deteriorates
Solution Approach 1:
The pH controller uses feedback from pH sensors to continuously adjust and stabilize pH levels within the optimal range for chlorine measurement. This feedback mechanism maintains measurement accuracy despite variations in water supply pH, while the system remains flexible in accepting different water sources
Solution Approach 2:
The system dynamically adjusts the pH parameter counteracting variations from water supply and dilution water. By actively controlling pH within the sensor's optimal range, the system maintains measurement accuracy while preserving flexibility in water source selection through automated compensation
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 system provides consistent and accurate control of chlorine oxyanion concentrations, enabling effective use of electrolyzed water solutions for CIP applications by stabilizing pH and adjusting chlorine levels, thus enhancing cleaning and sanitizing efficacy while preventing corrosion of CIP systems.
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
The sensing cell (14) comprises a chlorine sensor to measure chlorine oxyanion concentration of the portion of the electrolysis solution in the sensing cell (14)
Implementation Method 3
a pH probe to determine the pH of the portion of electrolysis solution in the sensing cell (14) that is measured by the chlorine sensor
Implementation Method 4
a sensing cell signal feedback (18) in communication with the sensing cell (14) and the electrolyzed concentrate control (24) and the dilution water control (26) to control the electrolyzed solution concentrate (10) and the dilution water (28)
Data Source
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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.