Electrocoagulation System for Dissolved Metal Removal

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Solution Overview

Problem

Conventional electrocoagulation (EC) processes are ineffective in treating wastewater with dissolved metal contaminants due to insufficient residence time for chemical reactions to complete, and they struggle with low electrical conductivity and scalability issues.

Innovation Solution

A system comprising an electrocoagulation (EC) cell and a reactor, where the EC cell generates in-situ coagulants to alter the chemical characteristics of the water, and the reactor provides a predetermined residence time for the completion of chemical reactions, enabling effective precipitation and separation of dissolved metal contaminants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If conventional EC process is used, then treatment process is simple, but residence time is insufficient for chemical reactions to complete

Engineering Contradiction:

Improvetreatment process complexityVSAvoidresidence time

Core Design Contradiction:

Device complexityVSDuration of action of moving object

Solution Approach 1:

The treatment system is divided into two distinct segments: an EC cell for electrochemical reactions and a reactor for chemical reactions. This segmentation allows each component to be optimized for its specific function, with the EC cell providing coagulants and the reactor providing sufficient residence time for precipitation, thereby resolving the contradiction between process simplicity and adequate reaction time.

Inventive Principle:

Principle #1Segmentation

2Reliability

If chemical precipitation is used, then dissolved metal contaminants can be precipitated, but large amounts of reagents are required which increases cost

Engineering Contradiction:

Improveprecipitation effectivenessVSAvoidreagent quantity

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The EC cell generates coagulants in-situ through electrochemical dissolution of sacrificial anodes, eliminating the need for external reagent addition. This self-service mechanism reduces reagent quantity and associated costs while maintaining reliable precipitation effectiveness for dissolved metal contaminants.

Inventive Principle:

Principle #25Self-service

3Reliability

If lime is used as precipitating agent, then metal contaminants can be precipitated, but lime handling and equipment fouling become difficult

Engineering Contradiction:

Improveprecipitation effectivenessVSAvoidhandling and operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The mechanical handling system for solid lime is replaced with an electrochemical system where coagulants are generated in-situ through electrode dissolution. This substitution eliminates the need for lime storage, slurry preparation, and pumping equipment, thereby resolving handling and operation difficulties while maintaining precipitation effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If multiple stages of chemical precipitation are used, then all dissolved metal contaminants can be removed, but process complexity and cost increase

Engineering Contradiction:

Improvecontaminant removal completenessVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The EC cell with appropriately selected sacrificial anodes can simultaneously target multiple dissolved metal contaminants through electrochemical dissolution and coagulation. The reactor then provides a unified environment for precipitation of all metal contaminants, replacing multiple specialized chemical precipitation stages with a single integrated process, thereby reducing complexity while maintaining removal completeness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively converts dissolved metal contaminants into an insoluble form, allowing for easy separation and reducing the volume of by-products, thus improving treatment efficiency and reducing operational costs.

Implementation Method 1

electrocoagulation (EC) cell having at least an electrode assembly... adapted to receive the water stream and change the first set of chemical characteristics of the water stream to a second set of chemical characteristics to enable precipitation of the first set of dissolved metal contaminants

Methodology Applied

Scientific EffectElectrocoagulation: Electrolysis

Implementation Method 2

provide a pre-determined residence time to the intermediate water stream to facilitate completion of the precipitation of the first set of dissolved metal contaminants and formation of flocs of a desired density and size

Methodology Applied

Scientific EffectPrecipitation: Precipitation

Data Source

PatentUS20250136482A1Process and System for Treatment of Water Containing Dissolved Metals

Publication Date: 2025.05.01 WATERSTRIDER TREATMENT INC

AI summary

A process and system for effective treatment of a water stream containing dissolved metal contaminants. The process and system employ the electrocoagulation principle to enable precipitation of the dissolved metal contaminants and provide sufficient residence time for completion of the precipitation process so that flocs of the dissolved metal contaminants that can be easily separated are generated thereby resulting in effective treatment of the water stream.