Electrolytic Sulfuric Acid Startup via Hydrogen Peroxide Addition
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Solution Overview
Problem
The existing system for manufacturing electrolytic sulfuric acid solutions requires a long time and high energy consumption to achieve the necessary persulfuric acid concentration for surface washing and modification processes, especially during startup or after shutdown, leading to inefficiencies in the production of plated components.
Innovation Solution
The method involves adding hydrogen peroxide water to the sulfuric acid solution to enhance oxidizing power, followed by electrolysis, which allows for rapid adjustment of persulfuric acid concentration and sulfuric acid concentration, reducing startup time and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrolysis is used to generate persulfuric acid from sulfuric acid solution, then the electrolytic sulfuric acid solution can be produced, but the startup time is long and energy consumption is high
Solution Approach 1:
The patent applies preliminary action by adding hydrogen peroxide to the sulfuric acid solution before electrolysis to pre-establish the necessary oxidizing environment. This preparatory step accelerates the generation of persulfuric acid during startup, reducing the time required to achieve the target concentration of 3 g/L or more while maintaining reliable etching performance.
2Reliability
If conventional electrolysis is used to generate persulfuric acid from sulfuric acid solution, then the electrolytic sulfuric acid solution can be produced, but energy consumption is high
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition parameters of the electrolyte through hydrogen peroxide addition. This changes the electrochemical environment to favor faster persulfuric acid generation, reducing the electrical energy required to achieve the target concentration during startup phases.
3Productivity
If the system is shut down and restarted, then production can resume, but the persulfuric acid concentration decreases requiring preparatory electrolysis
Solution Approach 1:
After system shutdown and restart, the patent applies preliminary action by adding hydrogen peroxide to rapidly replenish the persulfuric acid concentration that decreased during shutdown. This allows the system to resume production immediately with adequate etching capability, avoiding lengthy preparatory electrolysis periods.
4Loss of time
If hydrogen peroxide is added to enhance oxidizing power, then startup time is reduced, but additional material handling is required
Solution Approach 1:
The patent uses hydrogen peroxide as an intermediary substance to accelerate persulfuric acid generation during startup. While this requires additional material handling, the peroxide serves as a temporary catalyst that dramatically reduces electrolysis time, with the trade-off being justified by the significant productivity improvement during startup and restart operations.
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 significantly reduces the time and energy required to achieve the desired oxidizing solution concentrations, enabling quicker startup and more efficient production of electrolytic sulfuric acid solutions with enhanced oxidizing properties.
Implementation Method 1
adding hydrogen peroxide water to all or part of the solution composed mainly of a sulfuric acid component present in the system to adjust oxidizing power of the solution composed mainly of a sulfuric acid component to an enhanced state
Implementation Method 2
supplying the solution to an electrolytic cell to perform electrolysis
Data Source
AI summary
Hydrogen peroxide water and, if necessary, sulfuric acid and/or water, are added to a sulfuric acid solution in a storage tank of an electrolytic sulfuric acid solution manufacturing system to enhance the oxidizing power of the sulfuric acid solution supplied to an electrolytic cell to perform electrolysis. The manufacturing system starts up during an initial operation after completion of the system, or after replacement of a sulfuric acid-containing solution in the system, or during an operation after the concentration of a persulfuric acid component in the sulfuric acid solution stored in the system decreases due to shutdown of the system, or other similar situations. By starting up the manufacturing system in this manner, the startup of the system, which manufactures an electrolytic sulfuric acid solution containing a persulfuric acid component generated by electrolyzing sulfuric acid, can be completed in a short time, and the energy consumption can be reduced.