Fixed Flow Restrictor Control of HOCl pH and FAC
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Solution Overview
Problem
Existing systems for producing electrochemically activated (ECA) solutions, particularly hypochlorous acid (HOCl) and hydroxide solutions, face challenges in maintaining consistent pH and free available chlorine (FAC) levels, leading to ineffective cleaning and disinfecting due to imprecise control of water flow, electrolyte concentration, and electric current, and are prone to technician errors and increased complexity and cost.
Innovation Solution
A system utilizing a fixed flow restrictor (FFR) to control the pH and FAC of HOCl solutions by recirculating hydroxide back through the electrolysis cell, eliminating the need for needle valves or electronic controls, and integrating current-sensing and flow-sensing technologies for self-balancing the electrolysis process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional needle valves or electronic controls are used to control pH and FAC levels, then precise control can be achieved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the complex needle valves and electronic controls from the system, replacing them with a simple fixed flow restrictor that passively controls flow rates based on pressure differentials, thereby reducing device complexity while maintaining control precision
Solution Approach 2:
The fixed flow restrictor creates a self-regulating system where the pressure differential automatically controls the flow rates of water and brine into the electrolysis cell, eliminating the need for external control mechanisms and reducing system complexity
2Measurement precision
If traditional needle valves or electronic controls are used to control pH and FAC levels, then precise control can be achieved, but cost and maintenance increase
Solution Approach 1:
The patent removes expensive needle valves and electronic control components, replacing them with a simple fixed flow restrictor made from basic materials, thereby reducing manufacturing cost and maintenance requirements while preserving control precision
Solution Approach 2:
The fixed flow restrictor is designed as a simple, inexpensive component that can be easily replaced if needed, reducing overall system cost and maintenance burden compared to expensive electronic controls
3Device complexity
If imprecise control of water flow, electrolyte concentration, and electric current is used, then device complexity is reduced, but pH and FAC levels become inconsistent leading to ineffective cleaning and disinfecting
Solution Approach 1:
The patent implements passive feedback control where the fixed flow restrictor creates pressure differentials that automatically adjust flow rates in response to changes in system conditions, ensuring consistent pH and FAC levels without complex control systems
Solution Approach 2:
The system self-regulates through the fixed flow restrictor, which automatically balances the flow of water and brine based on pressure differentials, maintaining reliable and consistent pH and FAC levels without external intervention
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 ensures consistent and effective production of HOCl and hydroxide solutions with precise pH and FAC control, reducing complexity, cost, and maintenance while enhancing reliability and safety, ensuring effective cleaning and disinfecting capabilities.
Implementation Method 1
an electrolysis cell operable for producing a hypochlorous acid (HOCl) solution and a hydroxide solution from water, salt and electricity
Implementation Method 2
A system utilizing a fixed flow restrictor (FFR) to control the pH and FAC of HOCl solutions by recirculating hydroxide back through the electrolysis cell
Data Source
AI summary
A system and apparatus operable for producing the HOCl and hydroxide solutions utilizing electricity and a mixture of water and brine in an electrolysis cell includes a fixed flow restrictor (FFR) operable for controlling at least one of a pH of the HOCl solution and a free available chlorine (FAC) in the HOCl solution. The FFR includes an insert having a fluid passageway with an inner diameter and length selected to control the pH and/or the FAC of the HOCl solution. A plurality of interchangeable FFRs or a multiple FFR manifold is provided so that the pH of the HOCl solution and/or the FAC of the HOCl solution can be precisely controlled. A self-balancing system and method optimizes the electrochemical production of HOCl and hydroxide solutions by the precise management and control of the water flow, electrolyte concentration and electric current variables in an EAW process.