Helical Separator for On-Site Chlorine Dioxide Generation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Chlorine dioxide, a potent microbiocide, has a short shelf life and is unstable in solution, making it difficult to produce in large quantities for industrial applications, and its generation often requires the use of hazardous liquid phase strong acids, posing handling and safety concerns.
Innovation Solution
A method of generating chlorine dioxide by mixing an acid solution with a chlorite or chlorate solution in a separator, where the reaction mixture is directed in a helical path to produce gaseous chlorine dioxide, which is then withdrawn and injected into process water, allowing for on-site production and reducing the need for hazardous acids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chlorine dioxide is generated by reacting metal chlorate or chlorite with liquid phase strong acid, then large quantities of chlorine dioxide can be produced, but handling and safety concerns arise due to the use of hazardous strong acids
Solution Approach 1:
The patent changes the physical state parameter of the acid from liquid phase to gas phase. By using gaseous acid (such as gaseous HCl or gaseous CO2) instead of liquid strong acids, the system maintains high chlorine dioxide production capability while eliminating the handling and safety concerns associated with corrosive liquid acids. The gaseous acid can be introduced into the reaction system in controlled amounts and does not pose the same handling risks.
Solution Approach 2:
The patent employs a disposable or easily replaceable acid source in the form of gas cartridges or gas cylinders. These contain pre-measured amounts of gaseous acid that can be consumed and replaced without requiring complex handling infrastructure. This approach allows continuous operation while minimizing safety risks, as each gas cartridge is a self-contained, easily managed unit that eliminates the need for large storage tanks of hazardous liquid acids.
2Ease of operation
If chlorine dioxide is stored in solution, then it is available for use, but it becomes unstable with extremely short shelf life and is only available in less than 3000 ppm concentration
Solution Approach 1:
The patent implements preliminary action by pre-mixing the acid and chlorate/chlorite solutions in separate storage containers before use. The gaseous acid is pre-loaded into gas cartridges, and the aqueous chlorate or chlorite solutions are prepared in advance and stored in separate, stable containers. This allows the system to generate fresh, high-concentration chlorine dioxide on-demand without requiring storage of unstable chlorine dioxide solutions. The reactants are stabilized in their separate forms and only combined at the moment of use.
Solution Approach 2:
The patent segments the chlorine dioxide generation system into separate functional modules: a gaseous acid source (in cartridges), an aqueous chlorate or chlorite solution reservoir, a mixing chamber, and a delivery system. This segmentation allows each component to be optimized independently - the acid source provides controlled gas delivery, the chlorate/chlorite solution remains stable in storage, and the mixing chamber generates fresh chlorine dioxide only when needed. This modular approach eliminates the need to store unstable chlorine dioxide solutions while ensuring continuous availability.
3Productivity
If chlorine dioxide is generated on-site by chemical reaction, then large quantities can be produced, but complex handling systems and safety measures are required
Solution Approach 1:
The patent employs disposable or easily replaceable acid sources in the form of pre-filled gas cartridges or gas cylinders. These contain pre-measured amounts of gaseous acid that can be consumed and replaced without requiring complex handling infrastructure. This approach allows continuous operation while minimizing safety risks, as each gas cartridge is a self-contained, easily managed unit that eliminates the need for large storage tanks of hazardous liquid acids and complex transfer systems.
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 method achieves high conversion efficiency of chlorine dioxide production, up to 90%, while minimizing safety risks and handling issues, enabling effective microbiocide treatment of process water across various industries.
Implementation Method 1
reacting the acid with the chlorite or the chlorate to produce chlorine dioxide in the separator
Implementation Method 2
directing the reaction mixture in a helical path through the separator
Implementation Method 3
producing gaseous chlorine dioxide within the separator; withdrawing the gaseous chlorine dioxide from the separator
Data Source
AI summary
A method of producing chlorine dioxide is disclosed. The method may include feeding a reaction mixture into a separator. The reaction mixture may follow a helical path through the separator and produce gaseous chlorine dioxide within the separator. Gaseous chlorine dioxide may be withdrawn from the separator and used to disinfect process water.