External Electromagnetic Mixing for Corrosive Acid Dissolution
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Solution Overview
Problem
The preparation of ferrous chloride solutions for iron redox flow batteries is hindered by the corrosive nature of concentrated hydrochloric acid, leading to rapid degradation of equipment and safety hazards due to emitted fumes, and inefficient heating in tanks made of materials with low thermal conductivity.
Innovation Solution
An external electromagnetic mixing system using a plurality of electromagnets positioned around a production tank to mix and heat ferromagnetic solids within the hydrochloric acid without direct contact, increasing equipment lifespan and reducing exposure to hazardous fumes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If immersion heaters are used to heat the hydrochloric acid solution, then heating efficiency is improved, but component lifespan deteriorates due to corrosive degradation
Solution Approach 1:
The patent introduces an electromagnetic field as an intermediary to transfer energy to the ferromagnetic solid particles in the solution. The electromagnets positioned around the tank exterior generate alternating magnetic fields that induce eddy currents and hysteresis heating in the ferromagnetic particles, which then heat the surrounding hydrochloric acid solution through thermal conduction, without any heater component needing to contact the corrosive solution
2Stability of the object's composition
If manual mixing is performed to mix the solution, then mixing effectiveness is improved, but safety deteriorates due to exposure to harmful fumes
Solution Approach 1:
The patent replaces manual mechanical stirring with an electromagnetic mixing system. Electromagnets positioned around the tank exterior generate alternating magnetic fields that attract and move ferromagnetic solid particles throughout the solution, creating effective mixing through magnetic forces rather than mechanical contact, thereby eliminating operator exposure to harmful fumes
3Stability of the object's composition
If pumps and fittings are used to circulate the hydrochloric acid, then mixing is improved, but reliability deteriorates due to rapid degradation from prolonged exposure
Solution Approach 1:
The patent replaces mechanical pumping and circulation systems with an electromagnetic mixing system. Electromagnets positioned around the tank exterior generate alternating magnetic fields that directly move ferromagnetic solid particles and drive convection currents in the solution, achieving thorough mixing without any mechanical components that would contact and degrade from prolonged exposure to the corrosive hydrochloric acid
4Reliability
If plastic or stainless steel tanks are used to contain the hydrochloric acid, then corrosion resistance is improved, but heating efficiency deteriorates due to low thermal conductivity
Solution Approach 1:
The patent replaces conventional conductive heating through tank walls with electromagnetic heating. Electromagnets positioned around the tank exterior generate alternating magnetic fields that directly induce heating in ferromagnetic solid particles suspended in the solution, bypassing the need for thermal conduction through the plastic or stainless steel tank walls and achieving efficient heating while maintaining corrosion resistance
Solution Approach 2:
The alternating magnetic field causes ferromagnetic particles to undergo repeated magnetization and demagnetization cycles, generating heat through hysteresis losses and eddy currents. This internal heat generation within the particles directly heats the surrounding solution, overcoming the low thermal conductivity barrier of plastic or stainless steel tank materials
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 approach extends the useful life of components, enhances safety by minimizing exposure to corrosive fumes, and improves heating efficiency by using the magnetic field to heat the metallic iron pieces, thus accelerating the dissolution process without the need for direct immersion heaters.
Implementation Method 1
a plurality of electromagnets spaced externally around a production tank, wherein the production tank contains a liquid and a ferromagnetic and/or ferrimagnetic solid, and wherein the plurality of electromagnets are configured to move the ferromagnetic and/or ferrimagnetic solid within the liquid
Implementation Method 2
the reaction may be heated during preparation to increase a rate at which the iron metal reacts (e.g., dissolves into the hydrochloric acid). Heating may be accomplished by immersion heaters placed within the preparation tank or external heaters positioned around an external wall of the preparation tank
Data Source
AI summary
Systems and methods are provided for an external electromagnetic mixing system. The external electromagnetic mixing system includes a plurality of electromagnetics spaced externally around a production tank which contains a liquid and a ferromagnetic and/or ferrimagnetic solid. The plurality of electromagnets are configured to move the ferromagnetic and/or ferrimagnetic solid within the liquid.