On-Site Performic Acid Generation via Continuous Flow Reactor
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Solution Overview
Problem
The instability and explosive nature of performic acid make it challenging to manufacture, store, and transport, necessitating on-site generation to avoid decomposition and safety issues.
Innovation Solution
A method and system for on-site generation of performic acid using a continuous flow reactor, where formic acid and an oxidizing agent are contacted in the presence of heat to form performic acid, eliminating the need for acid catalysts and stabilizing agents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If performic acid is manufactured and stored in concentrated form, then manufacturing efficiency is improved, but storage stability and safety deteriorate due to decomposition and explosive nature
Solution Approach 1:
The system segments the performic acid generation process into separate functional modules: a continuous flow reaction system for on-site generation, separate storage for stable reactants (formic acid and hydrogen peroxide), and dedicated dosing systems. This segmentation allows efficient manufacturing of stable reactants while generating unstable performic acid only when needed, eliminating storage stability issues.
Solution Approach 2:
The system performs preliminary action by pre-storing stable reactants (formic acid and hydrogen peroxide) in separate tanks and preparing them for on-demand reaction. The continuous flow reactor is pre-configured with heating elements and flow control systems, enabling immediate generation of performic acid when required, thus avoiding the need to store the unstable product.
2Stability of the object's composition
If performic acid is generated on-site, then storage stability is improved, but device complexity increases due to need for continuous flow reactor and control systems
Solution Approach 1:
The continuous flow reactor serves multiple functions: it acts as a reaction vessel, heating chamber, mixing device, and flow control system all in one integrated unit. The same reactor configuration can generate different peracid compositions by varying reactant flow rates and temperatures, providing versatility that reduces the need for multiple specialized devices.
Solution Approach 2:
The system introduces water as an intermediary medium to facilitate the reaction between formic acid and hydrogen peroxide. The aqueous solution serves as the reaction medium, allowing controlled generation of performic acid while managing heat and mass transfer, thus simplifying the overall system design compared to anhydrous methods.
3Speed
If acid catalysts and stabilizing agents are used in performic acid generation, then reaction rate is improved, but harmful factors increase due to decomposition and reactivity
Solution Approach 1:
The system replaces chemical catalysts with a continuous flow reactor equipped with heating elements and controlled flow rates. The reaction is driven by thermal energy and controlled mixing rather than chemical catalysts, eliminating the harmful effects of catalyst decomposition and reducing unwanted side reactions while maintaining efficient reaction rates.
Solution Approach 2:
The continuous flow reactor maintains continuous generation of performic acid through sustained reaction of formic acid and hydrogen peroxide. This continuous action prevents accumulation of unstable intermediates and ensures steady-state operation, reducing decomposition risks associated with batch processing and catalyst degradation.
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 system allows for variable rate generation of performic acid, enhancing stability and safety by avoiding transportation hazards and storage instability, while maintaining effective disinfection properties.
Implementation Method 1
contacting said formic acid source with an effective amount of said oxidizing agent within said length of pipe in the presence of a heating device to form a performic acid
Implementation Method 2
The formation of performic acid is achieved on-site by contacting an aqueous oxidizing agent and aqueous formic acid in liquid phase
Data Source
AI summary
Methods of generating performic acid by contacting aqueous oxidizing agent and aqueous formic acid source in liquid phase are disclosed. A system and apparatus for the in situ production of the performic acid chemistries is further disclosed. In particular, a continuous flow reactor is provided to generate performic acid at variable rates. Methods of employing the oxidizing biocide for various disinfection applications are also disclosed.