U.S. patent application number 10/495487 was filed with the patent office on 2005-02-10 for electrochemical activaton system suitable for producing electrochemically-activated solutions through use of an electrolytic cell exchange module.
Invention is credited to Rawhani, Suha, Viljoen, Jacobus Johannes.
Application Number | 20050029093 10/495487 |
Document ID | / |
Family ID | 27145597 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050029093 |
Kind Code |
A1 |
Rawhani, Suha ; et
al. |
February 10, 2005 |
Electrochemical activaton system suitable for producing
electrochemically-activated solutions through use of an
electrolytic cell exchange module
Abstract
This invention relates to an electrochemical activation system
adapted for production, and particularly on-site production, of
separable and both of an aqueous, mixed oxidant, predominantly
anion-containing solution and an aqueous, mixed reductant,
predominantly cation-containing solution. The ECA system is
characterised therein that it includes at least one electrolytic
cell exchange module designed for accommodating one or more
electrolytic cells therein, the electrolytic cell exchange module
being removably arranged within the ECA system and characterised in
either being disposable or reusable within the ECA system. The
invention also extends to an electrolytic cell exchange module
suitable for use within the system.
Inventors: |
Rawhani, Suha; (Roodepoort,
ZA) ; Viljoen, Jacobus Johannes; (Henley-on-Klip,
ZA) |
Correspondence
Address: |
NIXON & VANDERHYE, PC
1100 N GLEBE ROAD
8TH FLOOR
ARLINGTON
VA
22201-4714
US
|
Family ID: |
27145597 |
Appl. No.: |
10/495487 |
Filed: |
September 22, 2004 |
PCT Filed: |
November 13, 2002 |
PCT NO: |
PCT/ZA02/00176 |
Current U.S.
Class: |
204/242 ;
204/267 |
Current CPC
Class: |
C02F 2301/024 20130101;
C02F 2209/008 20130101; C02F 2209/05 20130101; C02F 2209/005
20130101; C02F 2201/4612 20130101; C02F 2201/46145 20130101; C02F
1/4618 20130101; C02F 2201/4616 20130101; C02F 2209/06 20130101;
C02F 2001/46119 20130101; C02F 2201/008 20130101; C02F 2209/42
20130101; C02F 1/46104 20130101; C02F 2209/04 20130101 |
Class at
Publication: |
204/242 ;
204/267 |
International
Class: |
C25C 007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 13, 2001 |
ZA |
01/9329 |
Nov 13, 2001 |
ZA |
01/9330 |
Claims
1. An electrochemical activation ("ECA") system adapted for
production, and particularly on-site production, of separable and
both of an aqueous, mixed oxidant, predominantly anion-containing
solution and an aqueous, mixed reductant, predominantly
cation-containing solution, the ECA system being characterised
therein that it includes at least one electrolytic cell exchange
module designed for accommodating one or more electrolytic cells
therein, the electrolytic cell exchange module being removably
arranged within the ECA system and characterised in either being
disposable or reusable within the ECA system.
2. The ECA system as claimed in claim 1 characterised therein that
it also includes a power supply unit ("PSU") suitable for providing
required levels of power to the system during operation of the
same, the PSU including an intelligent controller and either being
integrally located within the electrolytic cell exchange module or
being a removable PSU.
3. The ECA system as claimed in claim 2 characterised therein that
the PSU is adapted for the ECA system such that a power circuit
does not supply a steady DC signal to the system, but rather
converts a negative half of an AC cycle into a positive signal for
providing A sinoidal envelope with, for example, a 12V RMS voltage
with a frequency of approximately 110 to 120 Htz, depending on the
frequency of the mains electricity supply.
4. The ECA system as claimed in claim 2 characterised further
therein that the PSU is adapted to generate a high switching
frequency wave with a frequency of more than 1 kHtz, and preferably
between 45 and 95 kHtz, and most preferably at 70 kHtz, which is
superimposed on the sinoidal envelope, resulting in a signal that
vary, for the example in claim 3, between 0 and nearly 18 volts at
different points in the cycle.
5. The ECA system as claimed in claim 2 characterised therein that
all major heat generating components in the electronics circuitry
are positioned and assembled in such a way that the heat is safely
conducted away to a liquid medium being electrolysed for
maintaining the circuits at an optimum temperature during
operation.
6. The ECA system as claimed in claim 1 characterised therein that
the system includes an integral monitoring and control unit ("MCU")
that is operatively associated with the PSU and that is suitable
for monitoring power supply status throughout an activation cycle,
the MCU being characterised therein that upon occurrence of a fault
condition, it automatically switches off certain circuits within
the ECA system depending on the error condition.
7. The ECA system as claimed in claim 6 characterised therein that
the MCU is adapted particularly to monitor and control one or more
of the following variables, namely anolyte output flow rate;
catholyte output flow rate; total system flow rate; pump motor
current; PSU output; current drawn by each electrolytic cell; level
of anolyte in an anolyte holding tank and level of catholyte in a
catholyte holding tank; and wherein the MCU also provides user
control means for switching on and switching off of the ECA system,
as well as automatic shutdown capacity after completion of a
production cycle.
8. The ECA system as claimed in claim 1 characterised therein that
the system incorporates a feed preparation system arranged in fluid
communication with the electrolytic cell exchange module for
premixing a saline solution of fixed concentration so as to ensure
that a consistent feed solution is presented to the electrolytic
cells, the feed preparation system including at least one saline
storage container for storing the premixed saline solution and from
where the saline solution is fed directly into the electrolytic
cells of the electrolytic cell exchange module under a controlled
flow rate by means of pumping, gravity feeding, pressurised feeding
or the like.
9. The ECA system as claimed in claim 8 characterised therein that
only one premixed feed solution is used in the system and wherein
variations in the activated solutions are achieved, inter alia, by
varying the nature and concentration of the saline content of the
feed solution, flow rate or hydraulic scheme, or by varying voltage
applied to the electrolytic cells.
10. The ECA system as claimed in claim 1 characterised therein that
the electrolytic cell exchange module is dimensioned for
accommodating a series of electrolytic cells therein and, more
particularly, is modularised to incorporate different numbers of
electrolytic cells for different production volumes, and wherein
the electrolytic cells is interconnected in the electrolytic cell
exchange module electrically and/or hydraulically either in series
or in parallel.
11. The ECA system as claimed in claim 1 characterised therein that
the electrolytic cell exchange module includes pH control means,
ORP and conductivity sensors incorporated within the same.
12. The ECA system as claimed in claim 1 characterised therein that
the system also includes water softeners, which may be located in
the electrolytic cell exchange module, for reducing the need for
de-scaling of electrodes.
13. The ECA system as claimed in claim 1 characterised therein that
the electrolytic cell exchange module includes a housing for
protecting the enclosed electrolytic cells from impact and
mishandling.
14. The ECA system as claimed in claim 1 characterised therein that
the electrolytic cell exchange module includes at least one gas
separation device adapted for trapping gasses produced during an
electrolytic activation reaction.
15. The ECA system as claimed in claim 1 characterised therein that
the electrolytic cell exchange module is removably arranged within
the ECA system such that it can be taken off-site for de-scaling,
servicing and maintenance of the electrolytic cells and subsequent
reinstallation in the ECA system after reconditioning.
16. The ECA system as claimed in claim 1 characterised therein that
the electrolytic cell exchange module incorporates a programmable
logic controller ("PLC") or a central processing unit ("CPU") to
facilitate control and administration of the electrolytic cells,
wherein the PLC or CPU is adapted to control fluid flow through the
electrolytic cells, automatically switching off after a
predetermined volume of product has been generated and as such
obliging a user to dispose of or exchange the electrolytic cell
exchange module in order to maintain production efficiency and
product quality.
17. The ECA system as claimed in claim 1 characterised therein that
the electrolytic cell exchange module also incorporates electronic
identification and tracking means ("ITM") for uniquely identifying
and tracking various component parts within the module,
facilitating the use only of approved and authorised component
parts and for indicating unauthorised tampering with the
electrolytic cell exchange module.
18. The ECA system as claimed in claim 17 characterised therein
that the ITM is operatively associated with the MCU and includes a
micro-controller; a unique alphanumerical serial number; a secure
communications interface; and a non-volatile memory containing the
status and history log of each component part within the
electrolytic cell exchange module.
19. The ECA system as claimed in claim 17 characterised therein
that the ITM is integrated with each component part, e.g. in the
form of an electronic micro-chip, so as to render the component
part tamperproof, the arrangement being such that any attempt to
divorce the ITM from the component part renders the latter
inoperable.
20. The ECA system as claimed in claim 17 characterised therein
that the ITM is adapted to capture status information during normal
operation of the electrolytic cell exchange module and to keep
track of the remaining operational period, the arrangement being
such that when a pre-determined operating milestone is reached, the
ITM sends a signal to the MCU to shut down the system so as to
prevent further use of the electrolytic cell exchange module.
21. The ECA system as claimed in claim 18 characterised therein
that the unique alphanumerical serial number is verifiable by the
CPU and is correlated to one or more predetermined operational
parameters, such as operating hours, allocation to a specific
system at a particular site, or operating in conjunction with
another component equipped with a similar ITM, which operational
parameters is used to isolate specific identifying numbers to be
allocated for use by the ECA system at a time of manufacturing and
is decoded with an identical set of rules by the device performing
the validation during normal operation.
22. The ECA system as claimed in claim 18 characterised therein
that the secure communications interface is wired or wireless and
data is communicated by means of a secure communications
protocol.
23. The ECA system as claimed in claim 18 characterised therein
that the non-volatile memory contains current and/or history status
information pertaining to each component part, to the system AND/OR
the environment within which the component part is used, the
arrangement being such that measurements or observations are made
internally or externally to the component part and saved to the
non-volatile ITM memory.
24. The ECA system as claimed in claim 23 characterised therein
that the history status information includes details regarding
identity of a manufacturer; date of manufacture and production date
stamp; identity of respective users; identity and access history of
individual service technicians, number of de-scale cycles or
operation cycles of the electrolytic exchange module; the number of
conditionings and hours in service; number of service hours
remaining before a reconditioning cycle (default start value is
programmable); and the date of the last/previous conditioning.
25. The ECA system as claimed in claim 1 characterised therein that
each electrolytic cell arranged within the electrolytic cell
exchange module includes two c-axial cylindrical electrodes and a
cylindrical diaphragm located co-axially between the two electrodes
so as to separate an annular inter-electrode space into a co-axial,
annular catholytic and an annular anolytic chamber arrangement,
wherein the electrolytic cell has a relatively small, annular,
cross-sectional total open area for fluid flow for allowing
turbulent fluid flow there through so as to ensure maximum exposure
of the solutions to the electric field, and wherein the
electrolytic cell is adapted to produce an electrolytically,
electrically or electrochemically activated, aqueous solution by
means of electrolysis of a relatively low concentration aqueous
salt solution.
26. The ECA system as claimed in claim 25 characterised therein
that the electrolytically, electrically or electrochemically
activated, aqueous solution is prepared from any one of the
following solutions, namely an anion-containing solution; a
cation-containing solution; a mixture of an anion-containing
solution and a cation-containing solution; an anion-containing
solution having been prepared from an anion-containing solution, a
cation-containing solution or a mixture of an anion-containing
solution and a cation-containing solution; and a cation-containing
solution having been prepared from an anion-containing solution, a
cation-containing solution or a mixture of an anion-containing
solution and a cation-containing solution.
27. The ECA system as claimed in claim 25 characterised therein
that the electrolytic cell is operated under a relatively low
current, preferably of about 5 to 15 A, and a relatively high
voltage, preferably of about 6 to 48 V, and more preferably between
12V and 36 V, for providing a relatively high voltage gradient or
electric field intensity at the interface between the electrode
surface and electrolyte, estimated to be about 106 V/CM.
28. The ECA system as claimed in claim 25 characterised therein
that levels of saline concentration and mineral content of the feed
solution, as well as operational variables of the electrolytic
cell, such as flow rates, flow regimes, -paths, and-rates of
recycle, currents and potential differences, are all adjustable so
as to produce anolyte and catholyte with particular physical and
chemical characteristics, with specific conductivity, redox
potential and pH, concentration of "activated species" and other
characteristics, for different specific applications.
29. An ECA system adapted for producing separable and both of an
aqueous, mixed oxidant, predominantly anion-containing solution and
an aqueous, mixed reductant, predominantly cation-containing
solution, the ECA system being characterised therein that it
includes at least one through-flow electrolytic cell; feed
preparation means arranged in fluid communication with the
electrolytic cell for introducing into the same a premixed saline
solution of fixed concentration; distribution means, such as a
hydraulic manifold, for distributing feed solution in a parallel,
serial or hybrid manner, through the electrolytic cell; and
collection means for continuously collecting the predominantly
anion-containing and predominantly cation-containing solutions.
30. The ECA system as claimed in claim 29 characterised therein
that the hydraulic manifold incorporates an integral, alternatively
separate, means of gas/liquid separation for separating any gases
produced as a result of electrolysis and for preventing formation
of a gas or air lock in the hydraulic system.
31. An electrolytic cell exchange module characterised therein that
it is designed for accommodating a series of electrolytic cells
therein and, more particularly, is modularised to incorporate
different numbers of electrolytic cells for different production
volumes, and wherein the electrolytic cells is interconnected in
the electrolytic cell exchange module electrically and/or
hydraulically either in series or in parallel, and arranged in
fluid communication with a feed preparation system.
32. The electrolytic cell exchange module as claimed in claim 31
characterised therein that it is removably arranged within an ECA
system such that it can be taken off-site for de-scaling, servicing
and maintenance of the electrolytic cells and subsequent
reinstallation in the ECA system after reconditioning.
33. The electrolytic cell exchange module as claimed in claim 31
characterised therein that it incorporates a programmable logic
controller ("PLC") or a central processing unit ("CPU") to
facilitate control and administration of the electrolytic cells,
wherein the PLC or CPU is adapted to control fluid flow through the
electrolytic cells, automatically switching off after a
predetermined volume of product has been generated and as such
obliging a user to dispose of or exchange the electrolytic cell
exchange module in order to maintain production efficiency and
product quality.
34. The electrolytic cell exchange module as claimed in claim 31
characterised therein that it incorporates electronic
identification and tracking means ("ITM") for uniquely identifying
and tracking various component parts within the module,
facilitating the use only of approved and authorised component
parts and for indicating unauthorised tampering with the
electrolytic cell exchange module.
35. The electrolytic cell exchange module as claimed in claim 31
characterised therein that it includes pH control means, water
softeners, and at least one gas separation device adapted for
trapping gasses produced during an electrolytic activation
reaction.
36. An electrochemical activation management ("ECAM") system
characterised therein that it is adapted to cooperate with an ECA
system for managing removal, reconditioning and installation of
electrolytic cell exchange modules and electrolytic cells of the
ECA system, and which keeps track of movement and history of
individual electrolytic exchange modules.
37. The ECAM system as claimed in claim 36 characterised therein
that it is arranged in communication with one or more components of
the ECA system by means of a direct or remote network or modem
connection, the arrangement being such that data is collected from
these components at a remote database and communicated through to a
centralised master ECAM database for consolidation and
correlation.
38. The ECAM system as claimed in claim 36 characterised therein
that it correlates specific electrolytic cell exchange modules with
customer and service centre information, the arrangement being such
that information on the history of each of these is recorded in a
centralised master ECAM database, which enables a manufacturer to
manage and plan a manufacturing process better, schedule
maintenance and be prepared for receiving electrolytic cell
exchange modules that have reached the end of their life cycle.
39. The ECAM system as claimed in claim 36 characterised therein
that it includes a cleaning unit adapted for remote cleaning and
conditioning of the electrolytic cell exchange module, the cleaning
unit comprising its own power supply means, monitoring and control
unit, a cleaning solution dispenser, pump and an electrolytic cell
exchange module holder, the configuration of the cleaning unit
being such that it circulates cleaning solution through the
electrolytic cell exchange module a number of times before
disposing of the waste fluids, and wherein the final cycle of the
cleaning process is a rinse cycle, which is used to wash out the
electrolytic cell exchange module with clean water to remove final
traces of deposits, as well as traces of the cleaning solution.
40. The ECAM system as claimed in claim 39 characterised therein
that the cleaning process is performed without the need for manual
intervention and further characterised therein that the cleaning
unit includes its own ITM for saving operational information in its
own status and history log, and is also adapted to save specific
parameters onto the ITM of the electrolytic cell exchange module,
for example a unique identification and access code for the service
technician, the date of last conditioning, identification of the
cleaning unit used, and the number of conditionings and service
hours remaining.
41. The ECA system as claimed in claim 2 characterised therein that
each electrolytic cell is associated with at least one dedicated
in-line miniature field-effect transistor-based pH, ORP and
conductivity sensor, which is located in either the PSU of MCU, the
arrangement being such that each electrolytic cell constitutes a
modular and independent unit.
42-44. (canceled)
Description
TECHNICAL FIELD
[0001] This invention relates to an electrochemical activation
system, adapted for production of electrically, electronically
and/or electrochemically-activated solutions on a continuous and
industrial scale. It also includes an electrolytic cell exchange
module suitable for use within the system.
BACKGROUND ART
[0002] The use of electrolysis for the production of active
chemical species and radicals is well known in the art. However,
electrolysis cells cannot be used by themselves for producing
electrochemically-activa- ted preparations on a continuous and/or
industrial scale. In order to enable continuous and industrial
scale use, these electrolysis cells must be incorporated into
systems that support their functioning and allow them to operate
reliably by providing, for example, electricity and suitable feed
stock and continuously removing products and waste streams.
[0003] The truly continuous and uninterrupted operation of such
systems, or their apparently continuous and uninterrupted
operation, whether on a small or large scale and on a sustainable
and long-term basis, is generally not yet possible in the art,
since most presently available electrolytic activation or
electrochemical activation devices and associated systems suffer
from various disadvantages and shortcomings.
[0004] In conventional electrochemical activation systems,
electrolytic cells have a limited lifespan in that foreign matter
deposits on electrodes and membranes, eventually coating the
electrodes and blocking the membranes beyond operational limits.
These deposits are dissolved and cleaned from the electrodes a
number of times to extend the lifetime of the electrolytic cells
until the electrolytic cells are no longer able to produce
activated solutions with the required efficacy, at which time the
electrolytic cells are discarded. These deposits also form in other
parts of the system, such as connecting tubing and valves.
[0005] Electrode Cleaning: Acid Washing
[0006] Depending on the quality and chemical composition of a feed
stock, which is usually water or an aqueous solution of a salt, an
electrochemical activation operation is periodically interrupted at
relatively frequent intervals to clean the electrodes, particularly
the cathode, of scale and precipitates that accumulate and form a
deposit on it. This deposited scale or precipitate, which has
entirely different conductivity and dielectric and surface
characteristics to the clean, usually coated surface of the
electrode, behaves very differently to what was intended to be
achieved and prevents continued successful operation of the
electrolytic cell.
[0007] In an attempt to de-scale the electrodes, membrane and other
parts of the hydraulic system and to restore its original surfaces
and regain optimal operational efficiency, one practice at present
involves washing an affected surface with an appropriate solvent,
such as a dilute solution of an inorganic acid, e.g. 1% to 5%
hydrochloric acid. However, besides problems such as chemical and
biocompatibility, especially in sensitive applications such as in
food processing, or medical and dental applications, such solvents
often pose environmental pollution and disposal problems. The use
of acid is regarded as a risk in many markets and as such creates
problems in commercial exploitation of the technology. In addition,
the use of acid increases the general risks of operation, which iIn
turn causes increased difficulties in obtaining FDA and other
regulatory approvals.
[0008] Electrode Cleaning: Polarity Reversal
[0009] An alternative practice to de-scale the electrodes involves
periodic reversal of polarity between an anode and a cathode. This
is intended to help dissolve precipitated scale and remove it
particularly from the cathode surface, where it is mostly formed.
However, this practice suffers from the following
disadvantages.
[0010] Most salts that form scale crystals have a relatively low
solubility constant and, once precipitated from a solution, often
require more energy to re-dissolve than to precipitate in the first
place. Accordingly, in many cases polarity reversal is not possible
or energy efficient.
[0011] Many systems use a semi-permeable and/or ion exchange
membrane on and in which the scale forms and which is prone to
being severely affected by precipitated scale. However, not being
as electrically active as the electrodes during a forward or
reverse current, it is even more difficult to clean than the
electrodes.
[0012] In electrochemical and electrolytic processes, the anode is
prone to dissolution, while the cathode is not. Accordingly, in
order to prolong electrode life and avoid premature failure, the
anodes are often coated with platinum group metal oxides.
[0013] However, due to the high costs of such coatings, the
cathodes are generally not coated or if so, then normally with a
lighter or sub-standard grade coating compared to that of the
anode. For this reason many electrode manufacturers do not
recommend polarity reversal, as it could cause dissolution of the
cathode or deterioration in the quality of the cathode coating.
[0014] Operational Control
[0015] Another disadvantage associated with presently available
electrochemical activation devices and systems is a lack of
efficient control over the quality of solutions produced over time.
Deterioration of the membrane, electrodes and coatings can result
therein that sub-standard activated solutions are produced. Current
electrochemical activation devices require continuous adjustments
to control mechanisms of the device in order to generate solutions
of specific characteristics. The normal manner of using such
technology is to operate the device either manually or to use
automated devices.
[0016] Manual operation: Through manual operation a user normally
conducts a de-scaling operation on-site. Acid of various dilutions
(e.g. 3%) is run manually through the device and cells for
de-scaling purposes. Quality of the product(s) is monitored
manually and periodically and process variables are adjusted as
needed to maintain quality. The obvious disadvantage associated
with manual operation, other than the non-desirable use of acid, is
that it requires continuous on-site presence of trained
personnel.
[0017] Automated devices: Through automated devices de-scaling of
the cells and device is automated. Albeit that such automation
solves the problem of having to de-scale manually, such automated
devices are often too expensive for many markets. In addition,
automated de-scaling does not solve the problem of using acid in
the device. Another disadvantage of known automated devices is the
need to incorporate expensive in-line sensor technologies, such as
ORP and pH meters, for real time monitoring and control of the
quality of solutions and for ensuring that the solutions have been
adequately activated.
[0018] Feed Preparation
[0019] Saline intake is another area of potential problems
associated with currently available electrochemical activation
devices and systems. Two of these problems relate to control of
flow rate through the cells, and stabilisation of conductivity
levels of a saline feed solution. Electrochemical activation
devices are dependent on water supply and are normally connected to
a municipal supply or tap. Variations in hydraulic pressures, as
often occur in municipal and other water systems, cause variations
in flow rate of water through the cell(s), resulting in variations
in the quality and quantity of activated solutions generated. Also,
a saline solution is normally fed into incoming water by means of a
venturi. However, variations in water pressure also result in
variations in the performance of the venturi, the level of
conductivity and again in quality and quantity variations in the
activated solutions.
[0020] Power Supply Unit
[0021] A further disadvantage of known electrochemical activation
devices is that power supply units utilised in the same often
experience inefficiencies in power conversion and rectification;
which are generally manifested as heat. This inefficiency not only
wastes electricity, but also creates a further problem in that the
heat must be channelled away. Also, where two or more units are
used together, they have to be "balanced" against one another,
often due to slight variations in output voltage and current. This
is not always easy to achieve and differences between these units
often arise, which causes further heat generation and an associated
reduction in efficiency and reliability of the system as a
whole.
[0022] Complex Design and Cost Considerations
[0023] Many of the present electrochemical activation devices are
complex, suffering from having many components that are not built
for easy maintenance or replacement. This adds to increased
complexity and reduced reliability of these devices. In addition,
there is a real demand to reduce costs of these devices to within
affordable levels, particularly for industries such as water
treatment, food processing, and the medical and dental fraternity.
More particularly, there is a need to simplify the device, while at
the same time improving its reliability and without any
deterioration in the quality of activated solutions generated.
OBJECT OF THE INVENTION
[0024] It is an object of the present invention to provide an
electrochemical activation system that is adapted for on- or
off-site production of electrically, electronically and/or
electrochemically-activ- ated solutions, particularly on a
continuous and industrial scale, that will overcome or at least
minimise some of the disadvantages associated with currently
available electrochemical activation systems and devices.
[0025] It is a further object of the invention to provide an
electrolytic cell exchange module suitable for use within the
electrochemical activation system.
[0026] It is a further object of the invention to provide a method
for the management of an electrolytic cell exchange system.
DISCLOSURE OF THE INVENTION
[0027] For ease of reading, the following terminology is used
within this specification:
[0028] "Anion-containing solution" is also referred to as the
"anolyte solution" or "anolyte";
[0029] "Cation-containing solution" is also referred to as the
"catholyte solution" or "catholyte;
[0030] "ECA"=ElectroChemical Activation;
[0031] "ECAM"=ElectroChemical Activation Management;
[0032] "PSU"=Power Supply Unit;
[0033] "MCU"=Monitoring and Control unit;
[0034] "ORP"=Oxidation-Reduction Potential;
[0035] "PLC"=Programmable Logic Controller;
[0036] "CPU"=Central Processing Unit;
[0037] "ITM"=electronic Identification and Tracking Means; and
[0038] "RMS"=Root Mean Square
[0039] According to the invention there is provided an
electrochemical activation ("ECA") system adapted for production,
and particularly on-site production, of separable and both of an
aqueous, mixed oxidant, predominantly anion-containing solution and
an aqueous, mixed reductant, predominantly cation-containing
solution, the ECA system being characterised therein that it
includes at least one electrolytic cell exchange module designed
for accommodating one or more electrolytic cells therein, the
electrolytic cell exchange module being removably arranged within
the ECA system and characterised in either being disposable or
reusable within the ECA system.
[0040] The ECA system also may include a power supply unit ("PSU"),
suitable for providing required levels of power to the system
during operation of the same. The PSU may include an intelligent
controller and may either be integrally located within the
electrolytic cell exchange module or may be a removable PSU.
[0041] The PSU may be adapted for the ECA system such that a power
circuit does not supply a steady DC signal to the system, but
rather converts a negative half of an AC cycle into a positive
signal for providing a sinoidal envelope with, for example, a 12V
RMS voltage with a frequency of approximately 110 to 120 Htz,
depending on the frequency of the mains electricity supply. In
addition, the PSU may be adapted to generate a high switching
frequency wave with a frequency of more than 1 kHtz, and preferably
between 45 and 95 kHtz, and most preferably at 70 kHtz, which is
superimposed on the sinoidal envelope, resulting in a signal that
may vary, for the above example, between 0 and nearly 18 volts at
different points in the cycle.
[0042] The PSU of the ECA system may further be characterised
therein that all major heat generating components in the
electronics circuitry are positioned and assembled in such a way
that the heat is safely conducted away to a liquid medium being
electrolysed for always maintaining the circuits at an optimum
temperature during operation.
[0043] The ECA system further may Include an integral monitoring
and control unit ("MCU") that is operatively associated with the
PSU and suitable for monitoring power supply status throughout an
activation cycle, the MCU being characterised therein that upon
occurrence of a fault condition, it automatically switches off
certain circuits within the ECA system depending on the error
condition. Under these conditions a minimum number of circuits may
remain active so as to enable the ECA system to indicate the
presence of an error condition to an operator.
[0044] The MCU may be adapted particularly to monitor and control
one or more of the following variables, namely anolyte output flow
rate; catholyte output flow rate; total system flow rate; pump
motor current; PSU output; level of anolyte in an anolyte holding
tank and level of catholyte in a catholyte holding tank. In
addition, the MCU provides user control means for switching on and
switching off of the ECA system, as well as automatic shutdown
capacity after completion of a production cycle.
[0045] The ECA system also may include other disposable or
exchangeable components such as pump(s), valve(s), gas separation
unit(s), flow meter(s), and condition and quality monitoring
devices, including pH, ORP and conductivity meters.
[0046] The ECA system may be characterised therein that it is not
directly connected to a tap and as such operational efficiency is
not affected by pressure variations in external water supply
systems. More particularly, the ECA system of the invention may
incorporate a feed preparation system arranged in fluid
communication with the electrolytic cell exchange module for
premixing a saline solution of fixed concentration so as to ensure
that a consistent feed solution is presented to the electrolytic
cells. The feed preparation system may include at least one saline
storage container for storing the premixed saline solution and from
where the saline solution is fed directly into the electrolytic
cells of the electrolytic cell exchange module under a controlled
flow rate by means of pumping, gravity feeding, pressurised feeding
or the like.
[0047] With this invention, only one premixed feed solution is
used. Variations in the activated solutions produced may be
achieved, inter alia, by varying the nature and concentration of
the saline content of the feed solution, or by varying voltage
applied to the electrolytic cells. This arrangement improves
stability (in terms of pH, ORP, etc.) in the activated solutions
generated and eliminates the need for sophisticated electronic and
hydraulic controls, thereby reducing system costs and making it
more affordable to a larger section of the market, particularly
where small volumes of activated solutions are required, such as in
dental surgery.
[0048] Depending on the scale of operation and some site-dependant
logistics, the electrolytic cell exchange module, PSU, MCU and the
feed preparation system may all removably be arranged within a
single ECA device.
[0049] The electrolytic cell exchange module may be dimensioned for
accommodating a series of electrolytic cells therein and, more
particularly, may be modularised to incorporate different numbers
of electrolytic cells for different production volumes. The
electrolytic cells may be interconnected electrically and/or
hydraulically either in series or in parallel.
[0050] The electrolytic cell exchange module may be characterised
therein that it includes pH control means incorporated within the
same. The ECA system also may include water softeners, which may be
located in the electrolytic cell exchange module, for reducing the
need for de-scaling of electrodes.
[0051] The electrolytic cell exchange module also may include a
housing for protecting the enclosed electrolytic cells from impact
and mishandling.
[0052] The electrolytic cell exchange module also may include at
least one gas separation device adapted for trapping gasses that
may be produced during the electrolytic activation reaction.
[0053] The electrolytic cell exchange module may removably be
arranged within the ECA system such that it can be taken off-site
for de-scaling, servicing and maintenance of the electrolytic cells
and subsequent reinstallation in the ECA system after
reconditioning.
[0054] The electrolytic cell exchange module incorporates a
programmable logic controller ("PLC") or a central processing unit
("CPU") to facilitate control and administration of the
electrolytic cells. In particular, the PLC or CPU may be adapted to
control fluid flow through the electrolytic cells, automatically
switching off after a predetermined volume of product has been
generated and as such obliging a user to dispose of or exchange the
electrolytic cell exchange module in order to maintain production
efficiency and product quality.
[0055] The electrolytic cell exchange module also may incorporate
electronic identification and tracking means ("ITM") for uniquely
identifying and tracking various component parts within the module,
facilitating the use only of approved and authorised component
parts and for indicating unauthorised tampering with the
electrolytic cell exchange module. This would improve safety and
prevent the use of sub-standard, pirated or non-serviced component
parts or unauthorised components produced by an unlicensed
manufacturer.
[0056] The ITM may be operatively associated with the MCU and may
include a unique alphanumerical serial number; a secure
communications interface; and a non-volatile memory containing the
status and history log of each component part within the
electrolytic cell exchange module. The ITM also may include a
micro-controller. In one form of the invention the ITM is
integrated with each component part, e.g. in the form of an
electronic micro-chip, so as to render the component part
tamperproof, the arrangement being such that any attempt to divorce
the ITM from the component part renders the latter inoperable. The
ITM may be adapted to capture status information during normal
operation of the electrolytic cell exchange module and to keep
track of the remaining operational period, the arrangement being
such that when a pre-determined operating milestone is reached, the
ITM sends a signal to the MCU to shut down the system so as to
prevent further use of the electrolytic cell exchange module.
[0057] The unique alphanumerical serial number may be verifiable by
the CPU, and may be correlated to one or more predetermined
criteria such as operational parameters. One or more of these
pre-determined criteria or parameters, (e.g. operating hours,
allocation to a specific system at a particular site, operating in
conjunction with another component equipped with a similar ITM),
may be used to isolate specific identifying numbers to be allocated
for use by the ECA system at the time of manufacturing and decoded
with an identical set of rules by the device performing the
validation during normal operation. In this way, at the time of
manufacturing, or if required, subsequent servicing, specific
components, such as the electrolytic cells, or the PSU, may be
coded to operate only under certain desired and defined
conditions.
[0058] The secure communications interface may be wired or wireless
and data may be communicated by means of a secure communications
protocol. A physical interface may include one or more data lines
that may be driven serially or in parallel.
[0059] The non-volatile memory may contain current and/or history
status information pertaining to each component part, to the system
and/or the environment within which the component part is used.
Thus, measurements or observations may be made internally or
externally to the component part and saved to the ITM memory.
Specific conditions may apply with regard to the data written to or
changed on the non-volatile memory, such as the type of host device
interfacing to the component part and the type of status change
occurring.
[0060] The history status information stored in the non-volatile
ITM memory may be used to provide information to a service centre
when performing repairs. Without limiting the scope thereof, the
history status information may include details regarding identity
of a manufacturer; date of manufacture and production date stamp;
identity of respective users; identity and access history of
individual service technicians, number of de-scale cycles or
operation cycles of the electrolytic exchange module; the number of
conditionings and hours in service; number of service hours
remaining before a reconditioning cycle (default start value is
programmable); and the date of the last/previous conditioning.
[0061] Other interface lines to the ITM may include electrical
power supply as well as additional control lines to control either
the ITM as a whole or one or more of its component parts or both.
"Intelligent ITM's" (i.e. an ITM including an on-board
micro-controller) may generate some or all of these control lines
internally, whereas "dumb ITM's" (i.e. an ITM excluding an on-board
micro-controller) may utilise such control lines to manage, read
and write access to the non-volatile memory.
[0062] Each electrolytic cell arranged within the electrolytic cell
exchange module may include two co-axial cylindrical electrodes and
a cylindrical diaphragm located co-axially between the two
electrodes so as to separate an annular inter-electrode space into
a co-axial, annular catholytic and an annular anolytic chamber
arrangement. The electrolytic cell may have predetermined design
and geometrical relationships for ensuring optimum fluid flow and
re-circulation patterns. More particularly, the electrolytic cell
may have a relatively small, annular, cross-sectional total open
area for fluid flow for allowing turbulent fluid flow there through
so as to ensure maximum exposure of the solutions to the electric
field.
[0063] The electrolytic cell may be adapted to produce an
electrolytically, electrically or electrochemically activated,
aqueous solution by means of electrolysis of a relatively low
concentration aqueous salt solution. Hydraulic flow through the
electrolytic cell may be such that the electrolytically activated,
aqueous solution may be prepared from any one of the following
solutions, namely an anion-containing solution; a cation-containing
solution; a mixture of an anion-containing solution and a
cation-containing solution; an anion-containing solution having
been prepared from an anion-containing solution, a
cation-containing solution or a mixture of an anion-containing
solution and a cation-containing solution; and a cation-containing
solution having been prepared from an anion-containing solution, a
cation-containing solution or a mixture of an anion-containing
solution and a cation-containing solution.
[0064] The electrolytic cell may be operated under a relatively low
current, preferably of about 5 to 15 A, and a relatively high
voltage, preferably of about 6 to 48 V, and more preferably between
12V and 36 V, for providing a relatively high voltage gradient or
electric field intensity at the interface between the electrode
surface and electrolyte, estimated to be about 10.sup.6 V/cm.
[0065] Levels of saline concentration and mineral content of the
feed solution, as well as operational variables of the electrolytic
cell, such as flow rates, flow regimes, -paths, and -rates of
recycle, currents and potential differences, may all be adjustable
so as to produce anolyte and catholyte with particular physical and
chemical characteristics, with specific conductivity, redox
potential and pH, concentration of "activated species" and other
characteristics, for different specific applications.
[0066] According to another aspect of the invention there is
provided an electrochemical activation system adapted for producing
separable and both of an aqueous, mixed oxidant, predominantly
anion-containing solution and an aqueous, mixed reductant,
predominantly cation-containing solution, the ECA system being
characterised therein that it includes at least one through-flow
electrolytic cell; feed preparation means arranged in fluid
communication with the electrolytic cell for introducing into the
same a premixed saline solution of fixed concentration;
distribution means, such as a hydraulic manifold, for distributing
feed solution in a parallel, serial or hybrid manner, through the
electrolytic cell; and collection means for continuously collecting
the predominantly anion-containing and predominantly
cation-containing solutions.
[0067] The hydraulic manifold may also incorporate an integral,
alternatively separate, means of gas/liquid separation, for
separating any gases that may be produced as a result of
electrolysis and for preventing formation of a gas or air lock in
the hydraulic system.
[0068] The invention also provides for an electrochemical
activation management ("ECAM") system which is adapted to cooperate
with the ECA system for managing removal, reconditioning and
installation of the electrolytic exchange modules and electrolytic
cells of the ECA system, and which keeps track of movement and
history of individual electrolytic exchange modules. The tracking
is effected by cooperation with the ITM of the electrolytic
exchange modules.
[0069] The ECAM system may be arranged in communication with one or
more components of the ECA system, by means of a direct or remote
network or modem connection, the arrangement being such that data
is collected from these components at a remote database and
communicated through to a centralised master ECAM database for
consolidation and correlation. A secondary function of the ECAM
system is to correlate specific electrolytic cell exchange modules
with customer and service centre information. Information on the
history of each of these is recorded in the centralised master ECAM
database, which enables a manufacturer to manage and plan the
manufacturing process better, schedule maintenance and be prepared
for receiving electrolytic cell exchange modules that have reached
the end of their life cycle.
[0070] The ECAM system includes a cleaning unit adapted for remote
cleaning and conditioning of the electrolytic cell exchange
modules, the cleaning unit comprising its own power supply means,
monitoring and control unit, a cleaning solution dispenser, pump
and an electrolytic cell exchange module holder. The cleaning
solution dispenser is similar in function to that of the saline
storage container in the ECA system, but is able to dispense larger
volumes of different fluids through to the electrolytic cell
exchange module. The configuration of the cleaning unit is such
that it circulates cleaning solution through the electrolytic cell
exchange module a number of times before disposing of the waste
fluids. The final cycle of the cleaning process is a rinse cycle,
which is used to wash out the electrolytic cell exchange module
with clean water to remove final traces of deposits, as well as
traces of the cleaning solution.
[0071] The cleaning process may be performed without the need for
manual intervention. Also, the cleaning unit may be adapted to save
specific parameters onto the ITM of the electrolytic cell exchange
module, for example a unique identification and access code for the
service technician, the date of last conditioning, identification
of the cleaning unit used, and the number of conditionings and
service hours remaining. The cleaning unit has its own ITM and also
saves operational information in its own status and history
log.
SPECIFIC EMBODIMENT OF THE INVENTION
[0072] Without limiting the scope thereof, the invention will now
be illustrated by means of a non-limiting example only and with
reference to the accompanying figures wherein--
[0073] FIG. 1 shows ECAM and ECA system overview;
[0074] FIG. 2 is a schematic flow sheet of the ECA system according
to the invention;
[0075] FIG. 3 shows the basic components of the feed preparation
system;
[0076] FIG. 4 is the electrolytic cell with the power supply unit
(PSU), with an illustration of the ITM of FIG. 8 integrated with
the electrolytic cell exchange module;
[0077] FIG. 5 shows one example of the hydraulic flow sheet of the
activation unit;
[0078] FIG. 6 is the wiring circuit of one example of the lay out
of indicators/alarms;
[0079] FIG. 7 shows a level sensor circuit;
[0080] FIG. 8 shows some of the basic wiring of the control circuit
incorporating an ITM included in the ECA system of the invention,
depicting its external interfaces;
[0081] FIG. 9 is the control panel of a typical ECA device; and
[0082] FIG. 10 is a diagrammatical illustration of a typical
lifecycle of an electrolytic cell exchange module according to the
invention.
[0083] The lifecycle of an electrolytic cell exchange module begins
with the manufacturing of an electrolytic cell exchange module,
which includes allocation of a unique ITM and programming of
manufacturing information into its non-volatile memory. A copy of
this information is loaded into the ECAM database. As the
electrolytic cell exchange module is distributed to a remote
service centre, information about the destination is also captured
into the ECAM database. Each service centre may update its local
database with the information contained in its electrolytic cell
exchange modules so as to keep track of stock. When an electrolytic
cell exchange module is shipped to a customer, the service centre
may capture the customer details and send this information to the
ECAM database on a regular basis.
[0084] When the electrolytic cell exchange module requires
maintenance, status information is drawn from the ITM and
maintenance information loaded onto the same. This information is
also copied to the ECAM database. In the event of total failure of
an electrolytic cell exchange module, as well as in those cases
where an electrolytic cell exchange module has completed its life
cycle, the electrolytic cell exchange module is returned to the
manufacturing plant for refurbishment. This information is also
captured in the ECAM database.
[0085] The ECA system, which is located on-site with a user, will
only be able to update specific status information, but not
maintenance information. Service centres for electrolytic cell
exchange modules will have the ability to update maintenance
information, but not customer status information other than
exchange information pertaining to the electrolytic cell exchange
module. The manufacturer of the ECA system will have the ability to
change or erase all information stored within the electrolytic cell
exchange module.
[0086] Data objects incorporated in the ECAM database include
electrolytic cell exchange modules, ECA devices, and customers and
service centres details. The following information would typically
be stored with respect to the electrolytic cell exchange modules,
namely ITM status, including manufacturing date, deployment date
and refurbishment date; ITM history; service details, including
service type and date stamp; conditioning history; ECA device type
and status, including manufacturing, deployment and refurbishment
dates. Information that would typically be stored with respect to
the customers and service centres include contact details; e.g.
commencement and termination dates of the contract, and premiums
payable; payment details; ITM details; and exchange history of the
particular electrolytic cell exchange module. In addition, the ECAM
system has the ability to generate various reports on demand,
including customer history, service centre history, electrolytic
cell exchange module history and various statistical reports such
as the number of customers per region, failures per region, and
current and projected number of exchanges and refurbishments of
electrolytic cell exchange module per month.
[0087] A programming unit is used in a manufacturing plant to
initialise the electrolytic cell exchange modules and other
component parts within the ECA system. This unit interfaces to the
electrolytic cell exchange module and is able to program specific
parameters into the ITM of new electrolytic cell exchange modules,
such as the serial number, manufacturing date, number of
conditionings and service hours left. It can also clear the history
log.
[0088] Referring to FIG. 8, the basic wiring of the control
circuit, power is supplied to the ITM through the two lines
identified by tag 2. Control lines 3 consist of zero, one, or more
lines through which control information is sent to the ITM.
Communication line 4 is referenced to the ground power line and is
used to send software control information to and receive status
information back from the ITM. Control output 5 has one or more
lines, each being an enabler to activate specific parts of the
component being identified and managed.
[0089] Conventional component identification means rely on database
management systems to keep track of information pertaining to
various component parts. Statuses are maintained and updated in the
database only and a particular component part can only be
identified if matched against this database. Even if distributed
databases are used for tracking components over vast areas, the
databases nevertheless has to be in constant inter-communication to
ensure that the component part is effectively tracked, data
discrepancies avoided and that the data remains current. The ITM
according to the invention eliminates the need for constant
communication between databases to ensure that statuses of
component parts remain up to date and it provides means to validate
a component part's ITM without having to verify this online against
a database.
[0090] The applicant believes that the ECA system and electrolytic
cell exchange module according to the invention will obviate the
need to use acid on-site for de-scaling the electrodes and
accordingly improve safety levels associated with this technology.
Fluid feed is effectively separated from the electrical system,
further reducing the risk level of the ECA system. The need for
expensive electronic and other automated de-scaling features within
the ECA system is obviated, lowering the cost of the technology.
Furthermore, the risk of piracy and copies electrolytic cells being
used in the ECA system can be reduced through more effective
control. Another long-term benefit envisaged by the applicant is
that increasing levels of intelligence can be built into the
electrolytic cell exchange modules for monitoring, management and
administrative purposes.
[0091] Also, reusable electrolytic cell exchange modules can be
de-scaled, serviced and maintained at a central depot where quality
of the electrode coatings, membrane and the like can be checked
regularly, thereby increasing quality assurance on the technology
and improving the chances of regulatory approvals. Alternatively,
mobile hand held de-scaling units could be used to de-scale the
electrolytic cell exchange modules. These hand-held mobile de-scale
units could be supplied to a user or be used by a technician who
could visit the user regularly to effect the service of the ECA
system. These de-scale units may include sealed acid canisters or
another means to reduce the risk of acid spills. By attaching the
de-scale unit to a Steds device or alternatively, detaching the
electrolytic cell exchange module from the Steds device and
attaching it to the de-scale unit, one could apply the acid through
the electrolytic cell exchange module under controlled conditions,
in an out-room for example.
[0092] It will be appreciated that many variations in detail are
possible without departing from the scope or spirit of the
invention as defined in the consistory statements hereinbefore.
* * * * *