Batch Chlorine Dioxide Production Using Solid Phase Acids
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Solution Overview
Problem
Current methods for generating chlorine dioxide solutions are unstable, pose safety concerns due to the use of liquid acids, and are not suitable for batch production, especially as they require expensive electrochemical processes or catalysts that degrade quickly.
Innovation Solution
A batch process involving the addition of a solid phase alkali metal chlorite salt, a solid phase oxidizing agent, and a solid phase acid with a pKa of less than 4.0 to an aqueous solution, generating chlorine dioxide without the need for liquid acids or electrochemical processes, ensuring stability and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If liquid phase strong acids are used to generate chlorine dioxide, then chlorine dioxide can be produced, but handling issues and safety concerns arise
Solution Approach 1:
The patent changes the physical state parameter of the acid from liquid to solid phase. Solid phase acids with pKa less than 4.0 are used instead of liquid phase strong acids, maintaining the necessary acidity for chlorine dioxide generation while eliminating the handling issues and safety concerns associated with liquid acids.
Solution Approach 2:
The patent uses solid phase acids that can be easily handled and disposed of. These solid acids serve their purpose in generating chlorine dioxide and can be managed more safely than liquid acids, effectively replacing hazardous liquid reagents with more manageable solid alternatives.
2Productivity
If electrochemical processes are used to generate chlorine dioxide, then continuous generation is achieved, but expensive equipment and large footprint are required
Solution Approach 1:
The patent replaces the electrochemical system with a chemical reaction system using solid phase reagents. Instead of using electricity and electrochemical cells, the system uses chemical reactions between solid phase alkali metal chlorite, solid phase oxidizing agent, and solid phase acid to generate chlorine dioxide, eliminating the need for expensive electrochemical equipment.
Solution Approach 2:
The patent extracts and eliminates the electrochemical apparatus from the system. By removing the need for power sources, electrochemical cells, and associated plumbing, the invention simplifies the system while maintaining chlorine dioxide generation capability through alternative chemical means.
3Productivity
If catalysts are used for continuous chlorine dioxide production, then generation is achieved, but catalyst support materials degrade quickly
Solution Approach 1:
The patent uses solid phase reagents that are consumed in the reaction rather than catalysts that degrade. The solid phase alkali metal chlorite, oxidizing agent, and acid are consumed reactants that can be replenished, avoiding the problem of degrading catalyst support materials while maintaining reliable chlorine dioxide generation.
4Ease of operation
If chlorine dioxide is stored in solution, then availability is improved, but shelf life becomes extremely short
Solution Approach 1:
The patent segments the chlorine dioxide generation system into separate solid phase components (alkali metal chlorite, oxidizing agent, and acid) that can be stored stably and individually. These components are mixed at the point of use to generate chlorine dioxide on demand, allowing long-term storage of stable solids while providing availability when needed.
Solution Approach 2:
The patent prepares stable solid phase precursors in advance that can be stored for extended periods. These pre-prepared solids are then combined at the point of use to generate chlorine dioxide, effectively preparing the system in advance while maintaining long shelf life of the individual components.
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 process produces a stable chlorine dioxide solution with a long shelf life, reducing safety concerns and operational costs, and is effective for batch production without the need for expensive equipment or catalysts that degrade quickly.
Implementation Method 1
adding a solid phase alkali metal chlorite salt, a solid phase oxidizing agent and a solid phase acid to an aqueous solution, wherein the solid phase acid has a pKa of less than 4.0; and generating chlorine dioxide in the aqueous solution
Implementation Method 2
adding a solid phase alkali metal chlorite salt, a solid phase oxidizing agent and a solid phase acid to an aqueous solution
Data Source
AI summary
A process for generating aqueous chlorine dioxide solutions includes adding a solid phase alkali metal chlorite, a solid phase acid, and a solid phase oxidizing agent to an aqueous solution, wherein the solid phase acid ahs a pKa less than 4. Also disclosed are compositions for producing chlorine dioxide solutions.