Electrocoagulation Unit with Tapered Tank and Cleaning Cycle
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Solution Overview
Problem
Current wastewater treatment methods, such as reverse osmosis and distillation, are expensive and time-consuming, especially when dealing with high contaminant levels, necessitating an improved filtration system for safe and reliable wastewater processing.
Innovation Solution
An electrocoagulation (EC) unit with a reaction tank made of non-conductive material, featuring charge plates and intermediate plates, and a controller that initiates a cleaning cycle by draining wastewater and filling the tank with a cleansing solution, such as hydrochloric acid, to maintain efficiency and prevent scaling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reverse osmosis filtering process is used to treat wastewater, then contaminants are removed, but the process becomes expensive and time-consuming
Solution Approach 1:
The patent replaces the mechanical reverse osmosis filtering process with an electrochemical process. Electrically charged plates generate electrical fields that cause contaminants to coagulate and settle, eliminating the need for high-pressure mechanical filtration and enabling faster treatment without sacrificing contaminant removal effectiveness.
Solution Approach 2:
The patent changes the fundamental treatment parameter from mechanical pressure-driven filtration to electrical field-driven coagulation. By applying electrical charges to plates in the wastewater stream, contaminants are attracted and coagulated, dramatically reducing treatment time while maintaining reliable contaminant removal.
2Reliability
If distillation process is used to treat wastewater, then contaminants are removed, but the process becomes expensive and time-consuming
Solution Approach 1:
The patent substitutes the thermal distillation process with an electrochemical coagulation process. Instead of heating wastewater to evaporate and condense water molecules, electrically charged plates induce contaminant coagulation and settling, achieving effective contaminant removal with minimal energy input and without time-consuming phase changes.
3Reliability
If chemical processes are used to treat wastewater, then contaminants are removed, but additional processes are needed to return wastewater to safe levels
Solution Approach 1:
The patent implements a self-service system where electrically charged plates automatically coagulate contaminants and enable their removal through settling. The process inherently returns wastewater to safe levels without requiring additional treatment stages, as the electrochemical coagulation directly precipitates contaminants for easy separation.
4Productivity
If electrocoagulation unit operates continuously, then wastewater treatment is maintained, but oxide buildup on plates reduces efficiency
Solution Approach 1:
The patent implements periodic cleaning cycles where the electrocoagulation unit alternates between treatment mode and cleaning mode. During cleaning cycles, acidic solutions are introduced to dissolve oxide buildup on the charged plates, restoring their electrical charge and treatment efficiency. This periodic maintenance enables sustained continuous operation without permanent efficiency loss.
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 EC unit effectively removes contaminants from wastewater, reduces operational costs, and ensures reliable operation by periodically cleaning the system to prevent oxide buildup and maintain efficiency.
Implementation Method 1
electrocoagulation (EC) systems
Implementation Method 2
charge plates within the reaction tank that are spaced at a distance
Implementation Method 3
The bottom of the reaction tank tapers toward one or more ports on the bottom of the reaction tank. Due to the tapered bottom, the reaction tank may be completely emptied or drained of liquids when desired
Data Source
AI summary
An electrocoagulation (EC) unit that performs an electrocoagulation process on wastewater or the like. In one embodiment, the EC unit includes a reaction tank formed from a non-conductive material, charge plates within the reaction tank that are spaced at a distance, intermediate plates disposed within the reaction tank between the charge plates, and plate conductors configured to electrically couple the charge plates to a power source. The bottom of the reaction tank tapers toward one or more ports which act as an ingress and egress point for the EC unit.