Hypochlorite Electrolysis Flow Control for Stable On-Site Disinfection
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Solution Overview
Problem
Existing systems for producing alkali metal hypochlorite solutions, such as sodium hypochlorite, face challenges including instability due to UV light and high storage temperatures, require large and impractical setups, and suffer from maintenance issues with PLC control systems, leading to inefficiencies and environmental pollution during transport.
Innovation Solution
A device and method for producing alkali metal hypochlorite solutions with a minimal, pressure-independent, and low-maintenance design, utilizing outlet valves and a pump to control the flow of brine and water to maintain constant concentration, incorporating IoT technology for remote monitoring and modular components for easy assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ready-made sodium hypochlorite solutions are transported to disaster areas, then disinfection can be provided, but the solutions are unstable to UV light and sensitive to high storage temperatures, requiring special storage conditions and resulting in environmental pollution during transport
Solution Approach 1:
The system prepares stable precursor solutions (brine and water) in advance that can be stored without special conditions, and only performs the electrolysis conversion to hypochlorite immediately before use at the disaster site, eliminating the need to transport unstable hypochlorite solutions while ensuring disinfection capability is ready when needed
2Productivity
If large systems are used for water chlorination in cities and municipalities, then effective disinfection is achieved, but the systems are not suitable for mobile use in remote locations
Solution Approach 1:
The system is divided into separate functional modules: a brine tank, a water supply system, an electrolysis cell, and a control unit. This modular segmentation allows the disinfection system to be compact and mobile while maintaining effective productivity, enabling deployment in remote disaster areas unlike large fixed municipal systems
3Manufacturing precision
If PLC control systems with sensors are used to control brine concentration, then precise control is achieved, but regular maintenance is required making the system impractical for remote and disaster areas
Solution Approach 1:
The control unit uses simple, robust sensors that require minimal maintenance and can operate reliably in remote conditions. The system performs self-monitoring of brine concentration and automatically adjusts operation, reducing the need for external maintenance intervention and making it practical for deployment in disaster areas where maintenance resources are limited
4Productivity
If metering pumps are used to supply brine and water to the electrolysis cell, then flow rate control is achieved, but the system lacks the ability to regulate flow rates independently
Solution Approach 1:
The system uses controllable metering pumps that can dynamically adjust their flow rates independently based on real-time feedback from sensors monitoring brine concentration and electrolysis cell conditions. This dynamic control allows optimization of electrolysis efficiency while providing operational flexibility to adapt to different discharge requirements and maintain precise concentration control
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
Ensures a constant concentration of alkali metal hypochlorite solution production, reduces energy consumption, and allows for continuous operation with minimal maintenance, suitable for mobile use in disaster areas and developing countries.
Implementation Method 1
water and a saturated brine solution are supplied to an electrolysis cell and converted into alkali metal hypochlorite solution
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
Device for producing an alkali metal hypochlorite solution comprising a housing (1), a brine container (3) for a saturated brine solution, a water supply (2), an electrolysis cell (7) and a power connection (8) for transmitting a current through the electrolysis cell (7), wherein the brine container (3) and the water supply (2) are coupled to the electrolysis cell (7) via a pump (16), characterized in that the brine container (3) and the water supply (2) each have an outlet valve (14, 15), wherein a predefined current through the electrolysis cell (7) can be set by controlling the opening times of the outlet valves (14, 15) and the volume flow through the pump (16), which is connected downstream of the outlet valves (14, 15).