U.S. patent application number 12/015417 was filed with the patent office on 2008-10-09 for methods and apparatus for decontaminating enclosed spaces.
This patent application is currently assigned to Bioquell UK Limited. Invention is credited to Nicholas Mark Turner Adams, David Watling.
Application Number | 20080247922 12/015417 |
Document ID | / |
Family ID | 28676495 |
Filed Date | 2008-10-09 |
United States Patent
Application |
20080247922 |
Kind Code |
A1 |
Adams; Nicholas Mark Turner ;
et al. |
October 9, 2008 |
METHODS AND APPARATUS FOR DECONTAMINATING ENCLOSED SPACES
Abstract
A portable apparatus for decontaminating an enclosed room or
other space includes a passageway having an air inlet at one end
and an outlet at the other end. A pump causes a flow of air through
the passageway from the inlet to the outlet. A heater heats the air
flowing through the passageway to a predetermined temperature, a
evaporator being in communication with the passageway. Liquid
decontaminant is pumped from a supply of decontaminant to the
evaporator to be evaporated and for the evaporant to be delivered
to the air flow in the passage to flow in the air flow from the
outlet to the rooms to be decontaminated. A universally rotating
nozzle is provided at the outlet to distribute the decontaminant
containing air throughout the enclosure.
Inventors: |
Adams; Nicholas Mark Turner;
(Hampshire, GB) ; Watling; David; (Dorking,
GB) |
Correspondence
Address: |
WORKMAN NYDEGGER
60 EAST SOUTH TEMPLE, 1000 EAGLE GATE TOWER
SALT LAKE CITY
UT
84111
US
|
Assignee: |
Bioquell UK Limited
Andover
GB
|
Family ID: |
28676495 |
Appl. No.: |
12/015417 |
Filed: |
January 16, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10509192 |
Sep 24, 2004 |
|
|
|
PCT/GB03/01386 |
Mar 28, 2003 |
|
|
|
12015417 |
|
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Current U.S.
Class: |
422/292 |
Current CPC
Class: |
A61L 2/186 20130101;
A61L 2202/25 20130101; A61L 9/015 20130101; A61L 2/208 20130101;
A61L 2/24 20130101 |
Class at
Publication: |
422/292 |
International
Class: |
A61L 2/20 20060101
A61L002/20 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 28, 2002 |
GB |
0207452.4 |
May 22, 2002 |
GB |
0211851.1 |
Claims
1. An apparatus for decontaminating an enclosed space comprising:
means for providing a flow of heated air; means for delivering a
liquid decontaminant to the heated air to be evaporated into the
heated air to produce an air stream containing a vapor of the
decontaminant for delivery to a space to be decontaminated; and a
self contained unit comprising a duct to be positioned within the
enclosed space having an inlet end and an outlet end, a fan for
causing air to flow from the enclosed space through the duct, a
filter for filtering air at the inlet end of the duct, means for
holding a supply of aqueous hydrogen peroxide solution, means for
delivering aqueous hydrogen peroxide solution from the means for
holding to a heater to evaporate the aqueous hydrogen peroxide to
produce hydrogen peroxide/water vapor which is entrained in the air
flow passing through the duct, and a nozzle at the outlet end of
the duct, all internal and external surfaces of the apparatus open
to the enclosure being exposed to the hydrogen peroxide/water vapor
carrying air in the enclosure to decontaminate the surfaces.
2. The apparatus as claimed in claim 1, wherein the components of
the apparatus are mounted to a support for transport of the
apparatus.
3. The apparatus as claimed in claim 2, wherein the self-contained
unit is a mobile or portable unit for movement from location to
location where it is to be used.
4. The apparatus as claimed in claim 3, wherein the supply of
hydrogen peroxide/water vapor and/or the nozzle are readily
removable for transport of the apparatus.
5. The apparatus as claimed in claim 1 further comprising a control
box for controlling operation of the apparatus, wherein means are
provided for delivering air causing hydrogen peroxide/water vapor
from the atmosphere in the enclosure through the control box to
decontaminate inner surfaces of the control box.
6. The apparatus as claimed in claim 1 further comprising a
separate monitoring unit for monitoring the temperature of the
atmosphere in the enclosure and the concentration of hydrogen
peroxide/water vapor in the atmosphere, wherein means are provided
for delivering a flow of air carrying hydrogen peroxide/water vapor
through the enclosure of the monitoring unit to decontaminate
interior surfaces of the monitoring unit.
7. The apparatus as claimed in claim 1 further comprising means for
rotating the nozzle universally to deliver hydrogen peroxide/water
vapor throughout the enclosure.
8. The apparatus as claimed in claim 1 further comprising means for
continuously rotating the nozzle while the hydrogen peroxide/water
vapor is dispersed therethrough.
9. An apparatus for decontaminating a space comprising: an
elongated duct having a first end with an inlet opening formed
thereat for receiving air from the environment surrounding the duct
and having an opposing second end with a nozzle formed thereat for
dispensing the air within the duct into the environment surrounding
the duct; a fan coupled with the duct, the fan being configured to
draw air from the environment into the duct through the inlet
opening and to blow the air out of the duct through the nozzle into
the environment; a heater coupled with the duct, the heater being
configured to heat the air traveling through the duct; a container
housing a supply of an aqueous hydrogen peroxide solution; an
evaporator coupled with the duct downstream of the heater so that
the heated air passes through the evaporator, the evaporator also
being in fluid communication with the container so that when the
aqueous hydrogen peroxide solution is delivered from the container
to the evaporator, the aqueous hydrogen peroxide solution is
evaporated by the evaporator to produce a hydrogen peroxide/water
vapor that is entrained into the heated air flowing through the
duct; and a pump configured to deliver the aqueous hydrogen
peroxide solution from the container to the evaporator.
10. The apparatus for decontaminating a space as recited in claim
9, further comprising a support frame that supports the duct.
11. The apparatus for decontaminating a space as recited in claim
9, wherein the nozzle is freely exposed at the second end of the
duct so that the air having the hydrogen peroxide/water vapor
entrained therein can be dispensed therefrom into the environment
surrounding the duct.
12. The apparatus for decontaminating a space as recited in claim
9, further comprising means for continuously rotating the nozzle
while the air having the hydrogen peroxide/water vapor entrained
therein is dispensed therefrom.
13. The apparatus for decontaminating a space as recited in claim
9, wherein the duct, fan, heater, container, evaporator and pump
from a manually transportable unit.
14. The apparatus for decontaminating a space as recited in claim
9, wherein the evaporator is configured to perform flash
evaporation of the aqueous hydrogen peroxide solution.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 10/509,192 filed Sep. 24, 2004, which is a U.S.
nationalization of PCT Application No. PCT/GB03/01386, filed Mar.
28, 2003, which claims priority to United Kingdom Application Nos.
0207452.4, filed Mar. 28, 2002 and 0211851.1, filed May 22, 2002,
the disclosure of which are incorporated herein by specific
reference.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] This invention relates to methods and apparatus for
decontaminating enclosed spaces such as hospital wards and clean
rooms in which a manufacturing or other processes take place in
sterile conditions.
[0004] 2. The Relevant Technology
[0005] Vaporized aqueous solution of hydrogen peroxide has been
used to decontaminate the internal surfaces of enclosures used for
aseptic processing in the pharmaceutical industry since about 1990,
but it has always been difficult to use the same technology to
decontaminate larger enclosed volumes such as rooms.
[0006] The conventional apparatus for decontaminating enclosures
comprises a gas generator in a closed circuit including the
enclosure such as described in U.S. Pat. No. 5,173,258. In this
design the hydrogen peroxide and water vapors are produced by flash
evaporation of an aqueous solution into a heated air stream, which
then carried the gas to the space to be decontaminated. The air and
mixture of gases then mixes with the air inside the chamber before
being returned to the gas generator, where the gas is decomposed,
dried, heated and more liquid is flash evaporated and the air
mixture is returned to the chamber.
[0007] The processes performed on the returned gas are complex, and
include the steps of decomposing the gas, drying and re-heating.
This complete process was considered necessary because it was
understood that the hydrogen peroxide gas decomposed according to a
half-life rule and hence to maintain an adequate concentration
inside the chamber a circulating system that decomposed the gas was
thought to be necessary.
[0008] Recent work by Watling, ISPE Conference Zurich, September
1999 has shown that the gas does not decompose but is stable. It is
therefore not necessary to remove the returning gas from the
chamber.
[0009] S. S. Block reports in the 5th Edition of Disinfection,
Sterilization and Preservation page 189 that a 3% hydrogen peroxide
aqueous solution gives a log 8 reduction of Staphylococcus aureus
in under 20 minutes. A slower rate of deactivation has been found
in experimental work when exposing Staphylococcus aureus to gas
generated from 35% solution, when the process was operated at a
temperature below the dew point thus causing condensation. Under
these gassing conditions the first droplets of dew form on the
organism at a much higher concentration than that of the original
liquid, typically about 65% w/w, the exact value depending on the
moisture content of the carrier gas.
[0010] As stated above, in the conventional system the air in the
chamber to be decontaminated is dried prior to injecting the
decontaminating gas. This is done either to allow a high level of
gas concentration to be achieved before the onset of condensation,
or to operate the process avoiding condensation maintaining the gas
in a dry state. The vapor pressure equations for hydrogen peroxide
and water may be used to calculate the concentration of the
hydrogen peroxide and water vapor that will cause condensation and
hence may be used either to avoid the conditions that will cause
the onset of condensation or to calculate the concentration of any
condensate that may be formed as a result of passing the flash
evaporated vapors into the sealed enclosure. If the RH in the
chamber is high the condensation will form quickly but as a
relatively weak solution. Evaporating 35% w/w hydrogen peroxide
into a chamber at 20.degree. C. and 85% RH will cause the
condensate to form at in excess of 6% w/w, although the
concentration of the vapor will be about 120 ppm. It is well known
that 6% hydrogen peroxide is active against microorganisms and will
cause bio-deactivation of surfaces. If it is intended to operate a
process where condensation is formed it is therefore not necessary
to reduce the humidity in the chamber under normal operating
conditions as the RH will be less than 85% and hence the
condensation will form at a concentration greater than 6%. The same
is not true when operating a process that is intended to avoid
condensation, in such a process it is essential to ensure that the
moisture content of the air inside the enclosed space at the start
of the process is low.
[0011] It is believed that the difference between the liquid
process as reported by Block and a gaseous dew process is the rate
of delivery of the hydrogen peroxide condensation. It follows that
using a standard recirculating gas generator placed outside the
space to be bio-decontaminated; there may not be an adequate
evaporation capacity to achieve a sufficiently high condensation
rate to deactivate the organism inside the chamber. The
deactivation process may be enhanced by the use of mixtures of
chemicals but the principal of the rate of delivery still remains.
Whilst for a dry gas process the rate of delivery of hydrogen
peroxide and water vapor are not so critical it is still important
to evaporate the liquid as fast as is practical as this will
shorten the time required to raise the gas concentration and
achieve a satisfactory bio-decontamination.
[0012] An analysis of the equations governing the vapor pressure of
water and hydrogen peroxide by Watling et al and published in the
PDA Journal of Science and Technology November/December 2002 vol
56, No 6 291-299, shows that the gas concentration inside a chamber
may be raised to the dew point by passing flash evaporated vapor
into the sealed enclosure, but as soon as the dew point is reached
condensation will form at a higher concentration than the
evaporated liquid thus reducing the gas concentration. The gas
concentration will continue to fall as more liquid is evaporated
until the equilibrium vapor pressure for the evaporated liquid is
reached at the temperature of the chamber.
[0013] There are two views about the mechanisms involved in the
bio-decontamination using hydrogen peroxide and water vapor. The
first is that it is important to ensure that the gas remains in the
dry state and the second that condensation is essential. It has
been well established that dry hydrogen peroxide gas at elevated
temperatures will bio-deactivate micro-organisms, and the same dry
process has been shown to work at room temperatures. The
condensation process in which the gas concentration is raised to
the dew point and condensation is allowed to form appears to be
faster at room temperatures.
SUMMARY OF THE INVENTION
[0014] The apparatus and method described in the present invention
will work equally well with both the dry and condensation
processes. When operating a dry process it is essential to monitor
the water and hydrogen peroxide concentration in the gaseous phase
to ensure that they remain below the saturated vapor
concentrations. When operating a condensation process it is helpful
to have an indication of the point during the cycle when
condensation starts to form and the subsequent rate of formation. A
technique and apparatus to make such a measurement of condensation
is described patent application UK 0291983.1
[0015] An ideal bio-decontamination cycle is in three phases. The
first phase is to bring all of the equipment to thermal stability
but may also be used to adjust the relative humidity in the chamber
to a pre-set level, the second is used to raise the gas
concentration to the required level and maintain that concentration
for a sufficient length of time to achieve the required level of
bio-decontamination, and the third and last phase to reduce the
concentration of the sterilant in the enclosed space to a
predetermined value.
[0016] U.S. Pat. No. 4,863,688 discloses a method of selectively
destroying organisms within a chamber such as an incubator
comprising the steps of introducing vapor phase hydrogen peroxide
into the chamber at a rate sufficient to cause a predetermined
concentration of hydrogen peroxide to be reached while preventing a
substantial change in pressure or condensation of the hydrogen
peroxide in the chamber. When the predetermined period of time has
elapsed, the vapor phase hydrogen peroxide is removed from the
chamber. In a preferred embodiment disclosed an incubator is
provided with a separate apparatus for producing a flow or air
containing hydrogen peroxide vapor which is delivered to the
incubator. Alternatively the apparatus for producing the air flow
containing hydrogen peroxide vapor may be built into the
incubator.
[0017] RU-C-2054295 discloses a device for sanitary treatment of
air for use in livestock and poultry facilities and in various
branches of industry including biological, food, light industry,
chemical, coal, construction and other applications. The device
includes a housing with an inlet and an outlet, a heating element,
disinfected evaporator in the form of a perforated header closed at
one end and enclosed in a porous sheath, the header is installed
along the housing axis. The device has a reservoir containing
disinfectant solution secured to the housing and connected to the
open end of the evaporator. The tubular evaporator is arranged in
the porous sheath along a spiral line and the heating element is
mounted within the centre of the spiral.
[0018] This invention provides a method of decontaminating an
enclosed space comprising the steps of providing an aqueous
solution of hydrogen peroxide in the enclosed space, producing
hydrogen peroxide/water vapor from said aqueous solution, creating
an air stream in the enclosed space, introducing hydrogen
peroxide/water vapor into the air stream, distributing the hydrogen
peroxide/water vapor containing air stream throughout the space to
be decontaminated and then removing the hydrogen peroxide/water
vapor from the space; characterized in that the air stream is
heated before hydrogen peroxide/water vapor is introduced to it,
the hydrogen peroxide/water vapor is flash evaporated from an
aqueous solution of hydrogen peroxide/water vapor from said supply
into the air stream, and the air stream carrying the flash
evaporated hydrogen peroxide/water vapor is distributed throughout
the enclosed space to achieve bio-decontamination of the enclosed
space.
[0019] By placing the gas generator inside the room and simply
heating the carrier gas and then evaporating this sterilant into
the air stream it is possible to use the available energy much more
efficiently. The increase in efficiency is derived from the removal
of the system for decomposing and drying the carrier gas, and also
because there is no need for any pipe work to transport the carrier
gas and decontaminant from an external generator.
[0020] This increased efficiency provides more energy for the
primary function of heating the carrier gas and flash evaporating
the liquid. The efficiency increase is so great as it allows a
trebling of the rate of flash evaporation from the same energy
source and hence the rate of increase in the gas concentration or
the achievable rate of formation of condensation once the dew point
has been reached is also trebled.
[0021] The simplified design is also much smaller and lighter than
a conventional gas generator and hence considerably less expensive
to manufacture. It is therefore realistic to place a number of such
devices inside a sealed enclosure to be decontaminated. This
reduction in size and weight makes the apparatus portable and hence
makes it practical to use the same apparatus to bio-decontaminate a
number of facilities either on the one site or at different
locations. As stated above it is important to make measurements of
the hydrogen peroxide and water vapor concentrations.
[0022] To satisfy this requirement an instrument module that is
placed inside the enclosed space has been devised that will also
link back to the control system that is external to the enclosed
space. Provision has been made within the control systems both at
the gas generator (s) and the instrument module to connect a number
of condensation sensors so that the process may be operated either
as a dry gas or as a saturated vapor process Each simplified
generator will have its own control system, which is linked to a
control box external to the room and connected by a single control
cable. By using a central control system, such as a laptop
computer, it is possible to control a number of generators that are
linked together from outside the enclosed space. With the present
arrangement it is possible to control eight generators from a
single laptop, should a larger number be required a second computer
would be needed. It is also possible to control multiple aeration
units and dehumidifiers from the same laptop computer.
[0023] Because the apparatus is portable and may therefore be used
at different sites in order to ensure that the apparatus does not
carry contamination from one location to another it is essential
that all of the external and internal surfaces are
bio-decontaminated during the gassing cycle. To achieve this
objective components have been mounted in such a way to ensure that
they are exposed to the sterilizing gas. The tubular steel frame
has been sealed and the control box is purged with the sterilizing
gas drawn from the room. Tests have been performed to check that
following a bio-decontamination cycle all of the surfaces of the
apparatus have been rendered safe.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Various embodiments of the present invention will now be
discussed with reference to the appended drawings. It is
appreciated that these drawings depict only typical embodiments of
the invention and are therefore not to be considered limiting of
its scope.
[0025] FIG. 1 is a wholly diagrammatic view of an apparatus for
generating and delivering an air flow containing an evaporated
decontaminant to an enclosed space;
[0026] FIG. 2 is a similar view to FIG. 1 showing the components of
the apparatus including the evaporator, liquid sterilant supply and
outlet nozzle in greater detail;
[0027] FIG. 3 is a perspective view of a portable unit embodying
the apparatus of FIGS. 1 and 2;
[0028] FIG. 4 in an exploded view of the unit of FIG. 3;
[0029] FIG. 5 is a plan view of the evaporator;
[0030] FIG. 6 is a cross-sectional view on the line 6-6 of FIG.
5;
[0031] FIG. 7 is a cross-sectional view of an alternative form of
evaporator;
[0032] FIG. 8 is a perspective view of a control box for the
apparatus of FIGS. 3 and 4 with a lid of the box shown open;
[0033] FIG. 9 is an exploded view of a monitoring unit for use in
conjunction with the apparatus of FIGS. 3 and 4; and
[0034] FIGS. 10 and 11 show further embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The gas generator apparatus will be described firstly with
reference to FIGS. 1 and 2. Room air, which may or may not already
contain previously supplied hydrogen peroxide and water vapor, is
drawn into an inlet conduit 10 through a HEPA filter 11 by a
variable speed motor driven fan 12. The HEPA filter 11 removes any
particles from the air stream to ensure that the delivered air is
of the correct quality when the generator is used in a clean room.
The conduit delivers the air to a heater 13 where the temperature
is raised to a predetermined level as described below.
[0036] The heated air then passes into an evaporator 14 where a
liquid sterilant comprising aqueous hydrogen peroxide is flash
evaporated. By way of example, the sterilant may comprise an
aqueous solution containing 30 to 35% hydrogen peroxide. If the
sterilent includes peracetic acid, the proportion of hydrogen
peroxide can be reduced to 15% with 0.5% peracetic acid and a
balance of water. In practice the heater 13 and the evaporator 14
are combined in a single unit as shown in FIGS. 2 to 7 to which
reference will be made later. The physical shape and dimensions of
the combined heater/evaporator are designed to control the energy
balance between that used to heat the carrier gas and that used for
flash evaporation.
[0037] A supply of aqueous hydrogen peroxide liquid is stored in a
container 15 and is pumped to the evaporator 14 by a liquid pump
16. The carrier gas and vapors are delivered from the evaporator
through a conduit 17 to a distribution nozzle 18 for delivery of
the sterilant vapor to the space to be decontaminated. The liquid
container is demountable from the frame 19 to reduce the weight of
the unit and make it more easily hand carried.
[0038] FIGS. 3 and 4 show a practical embodiment in which the gas
generator apparatus is supported in an tubular steel framework 19
for ease of movement. The apparatus is light enough to be carried
by the user and as can be seen in FIG. 4 can have caster wheels 20
to enable it to be easily maneuvered into position.
[0039] The tubular framework is sealed to prevent any contamination
being introduced to the enclosure by the frame. Ideally, the
apparatus should not be placed inside a housing unit. Any covering
of the apparatus would restrict the sterilant gas movements around
and through the apparatus, which is essential to ensure that the
apparatus itself is also surface decontaminated because otherwise
it may contaminate the area in which it is placed. FIGS. 3 and 4
also show the enclosed control box 70 for the apparatus which will
be described in greater detail below.
[0040] FIG. 3 shows the outlet nozzle in greater detail. The nozzle
has a motorized power unit 18a which rotates the nozzle assembly
about a vertical axis. The nozzle assembly includes a laterally
extending arm 18b having an enclosed drive for rotating the nozzle
tip 18c about a horizontal axis to provide a universal discharge of
heated air/hydrogen peroxide sterilant vapor around the room or
other enclosure. The motor and nozzle assembly are formed as a unit
and may be detached at the coupling 18d shown in FIG. 4 from the
outlet of the evaporator and dismounted from the frame to be
transported independently of the gas generator unit.
[0041] Multiple units may be provided as necessary and separate fan
units may also be provided to circulate the sterilant atmosphere
throughout the room or enclosure.
[0042] An ideal decontamination cycle may have three distinct
phases. In the first optional phase, the relative humidity in the
room or other enclosure is adjusted to a pre-set level. In the
second phase the gas concentration of sterilant gas is raised to
form a required layer of condensation over all surfaces in the
enclosure for a sufficient length of time to achieve the required
level of decontamination. In the third and last phase the sterilant
is removed from the enclosure. This is achieved using the room
aerator system described and illustrated in International Patent
Publication No. WO 02/11864.
[0043] If a HVAC system is available for the room or enclosure then
this may be used to achieve the required level of relative humidity
at the start of the process, and if the HVAC exhausts to a safe
area to remove the sterilant at the end. Alternatively a portable
dehumidifier may be used to adjust the initial relative humidity
and a catalytic scrubber used to circulate the gas to remove the
sterilant.
[0044] In the decontamination cycle referred to above the initial
phase of treatment in the adjustment of the relative humidity in
the room or chamber may be omitted and the process commenced at the
current prevailing conditions in the enclosure since the relative
humidity in the enclosure would normally be well below dew point
and so a considerable amount of sterilant/water vapor would need to
be generated in the enclosure before condensation would occur.
[0045] Reference is now made to FIGS. 5 and 6 which illustrate the
combined heater/evaporator 14/15 in greater detail. The
heater/evaporator comprises a cast cylindrical aluminum block 30
which is mounted framework 19 with the axis of the block extending
vertically. The lower end of the block has a shallow cylindrical
recess 31 and a circular base plate 32 is attached to the periphery
of the block extending across the recess by screws (not shown) the
base plate 32 has a central aperture 33 in which the end of the
inlet conduit 10 is mounted to deliver a supply of air to the
recess in the block.
[0046] The upper end of the block also has a cylindrical recess 34
and a central top plate 35 is mounted on the periphery of the block
over the recess by set screws 36. The top plate 35 has a central
aperture 39 in which an outlet conduit 40 from the block is
mounted.
[0047] The block is formed with a central cylindrical cavity 37
extending into the block from the upper end thereof in which the
outlet conduit 40 extends stopping short of the bottom of the
cavity. The block 30 has a multiplicity of axially extending
passageways 38 adjacent the outer surface of the block and spaced
around the block leading from the lower recess 31 and the block
upper recess 34 for flow of air from the bottom recess to the top
recess from where the air can flow into the cavity 37 and thence
into the outlet conduit 40. The liquid sterilant from the storage
container 15 is delivered via one or more inlet conduits 41
providing injection points which extend through the top plate 35
adjacent to the outlet conduit 40. The conduits 41 lead into the
cavity 37 in the block but stop short of the bottom of the cavity.
A second inlet conduit 41 is shown and preferably three such
conduits are provided at spaced locations around the outlet
conduit.
[0048] The body 30 is encircled by a cylindrical jacket in which an
electrical resistance heater 42 is mounted for heating the body 30
to a requisite temperature to pre-heat the airflow through the
block and also to ensure that sterilant delivered by the conduit 41
to the bottom of the cavity 37 of the block is flash evaporated
from the bottom of the cavity to produce a vapor which is entrained
in the flow of air through the flow of heated air through the
outlet conduit 40 for delivery into the room to be sterilized.
[0049] The heating unit of the heater-evaporator is coupled to the
control unit to the apparatus and a temperature probe 44 is mounted
in a radial drilling 45 in the body 30 below the cavity 37 to
measure the temperature of the body for adjusting, through the
control unit, the power supply to the resistance heating element to
enable the body to be maintained at a requisite temperature for
pre-heating the air flowing through the body and flash evaporating
the sterilant delivered to the body.
[0050] FIG. 7 of the drawings shows an alternative form of heater
13 in which the outlet from the fan 12 is coupled to an inlet 50 to
a lower chamber 51 containing an electrically powered air heater
52. At the upper end of the chamber 51 there is an annular
evaporator block 53 having a central port 54 for gas flow and an
evaporator plate 55 is located on top of the block. The block has a
spirally wound heating element 56 embedded adjacent the surface of
the block. Thus the heater 52 can be used to raise the temperature
of the air flowing through the device to one level and the second
heater 56 can be used to maintain the surface of the evaporator
plate at the requisite temperature for flash evaporation of an
aqueous solution of hydrogen peroxide.
[0051] The heater has an upper chamber 57 in which an outlet
conduit 58 is mounted having ports 59 spaced around the conduit
through which air can enter the conduit from the upper chamber as
indicated by the arrows. The lower end of the conduit is closed by
an air deflector 61 which partially overlies the evaporation plate
and causes the air flow emerging from the port 54 in the evaporator
heater to disperse outwardly over the evaporator plate before
flowing upwardly and hence through the port 59 into the inlet
conduit. Delivery tubes for aqueous hydrogen peroxide extend
downwardly through the upper chamber 57 to stop just short of the
surface of the evaporation plate to drip aqueous hydrogen peroxide
onto the plate which flash evaporates and is entrained in the air
flow over the plate which passes upwardly into the outlet conduit
58. The arrangement is otherwise similar to that of FIGS. 3 and
4.
[0052] Reference is now made to FIG. 8 of the drawings which shows
the control box of the gas generator of FIGS. 3 and 4 in greater
detail. The control box comprises a casing 70 having a lid 71 shown
in the open position in FIG. 8. The fan 11 which is of the
centrifugal type is mounted in the upper end of the box and has an
upwardly facing mounting plate 72 formed with an outlet port 73 to
receive the evaporator 13,14 with the inlet to the evaporator in
communication with the port 73.
[0053] A liquid pump 74 is mounted on one side of the box powered
by an electric motor for delivering aqueous hydrogen peroxide to
the evaporator. A mains cable connection for the unit for the
various motors and other devices requiring power supply is
indicated at 75. The cable also provides couplings to the
controllers 76 for the unit which are mounted on the inside of the
lid 71.
[0054] To ensure that contamination does not reach the enclosure
from the interior of the control box for the gas generator, a fan
77 is mounted on one side of the control box to deliver air
carrying sterilant from the surrounding atmosphere in the enclosure
through the control box to sterilize the interior surfaces of the
control box.
[0055] Reference is now made to FIG. 9 of the drawings which shows
in exploded form a monitoring unit for monitoring air temperature,
gas concentration and humidity in the enclosure. The monitoring
unit comprises a box 80 to receive the monitoring equipment and
mounted on wheels 81 to enable the box to be readily maneuvered
around the enclosure and also moved from side to side where it is
to be used. The box has a lid 82 formed with inlet and outlet ports
83,84 respectively. The inlet port has a motor driven fan 85
disposed below the port to draw in air from the enclosure
containing the dispersed sterilant to cause an air flow through the
elements in the box to sterilize the interior surfaces of the box
and thereby to ensure that the room or other enclosure is not
contaminated by anything within the interior of the box.
[0056] The apparatus described particularly with reference to FIGS.
3 to 9 is intended to be readily portable or transportable from
room to room where it is to be used. It provides a source of heated
air carrying hydrogen peroxide vapor sterilant directly into the
room and distributes the air flow throughout the room until
condensation occurs on all surfaces within the room. No external
pipework connections are required to pass through walls of the room
just power supply and control cables for the apparatus. No special
installation requirements arise as in conventional gas generator
circuit systems as referred to earlier.
[0057] Thus each of the components of the equipment required to
sterilize a room, that is the gas generating apparatus, the gas
distribution system, the instrument-module, the dehumidifier and
the aeration unit are all manufactured such that they can readily
be carried by a single person.
[0058] Reference is now made to a further form of apparatus in
accordance with the invention shown in FIG. 10. The apparatus is
mounted on a mobile trolley and comprises a gas generator 100. Air
is drawn in through a HEPA filter 101 by a fan 102 and passed into
a vaporizer 103. Inside the vaporizer the air is first heated by a
heater (not shown) and then passes over an evaporation plate (also
not shown) A pump 105 delivers liquid sanitant from a sanitant
bottle 106 in the form of droplets onto the evaporation plate from
which it is flash evaporated.
[0059] The heated air carrying the sanitant vapor is passed to a
distribution plenum 108 and exits to the room at high velocity
through one or more nozzles 109.
[0060] Provision is made either to connect a number of optical type
condensation monitors 120 directly to the gas generator and hence
to a control module 121 (see FIG. 11), or the monitors may be
connected directly to the control module. The optical condensation
monitors measure the layer of condensation as it builds up on a
surface or surfaces of the monitor.
[0061] Connecting condensation monitors to the gas generator has
the advantage of reducing the number of connections to the control
module, especially when a number of gas generators are used.
[0062] The condensation monitors are placed around the room at the
locations where the rate of condensation is the lowest.
[0063] A complete multiple installation is shown in FIG. 11, with
three gas generators 100 each with eight condensation monitors 120.
Also connected to the control system is an aeration unit 122 used
to remove the gas at the end of the cycle and the dehumidifier 123.
A separate instrument module 124 is also shown which has additional
instrumentation to measure the gas concentration and the RH within
the room. A single communications cable connects 24 all of the
components to the control module.
[0064] The normal technique to establish if a decontamination
process has been successful is to place Biological Indicators
(BIs), in those parts of the chamber where it is the most difficult
to achieve a kill. It is often undesirable or not permitted to
place BIs in a room, but it is necessary to know that deactivation
to the required level has been achieved.
[0065] To overcome this difficulty condensation monitors may be
used to establish that the mass and the rate of formation of
condensate are sufficient to achieve deactivation of the
microorganisms on the surfaces. It has been well established that
once the required conditions have been achieved that the "D" value
for the most resistant organisms is about two minutes.
[0066] Therefore an exposure of the organisms under the correct
conditions for twelve minutes will achieve a log 6 reduction in the
count of viable organisms.
[0067] Satisfactory decontamination will only be achieved in a room
if a sufficiently high rate of liquid sanitant vapor is delivered
into the room to provide an adequate rate of formation of
condensation.
[0068] But to be assured that decontamination has been achieved it
is necessary to measure the condensation levels with time in
multiple locations in the room.
[0069] The data from the condensation monitors together with the
information from the other instruments in the room may then be used
to establish that a satisfactory deactivation cycle has been
completed.
[0070] The condensation sensors may be used in one of two ways. The
first is to measure and then control the level of condensation by
adjusting the liquid evaporation rate and the second is simply to
use the monitor as a switch. When used as a switch it simply gives
a signal when an adequate amount of condensation has formed and the
process is then considered to be complete or allowed to dwell in
that state giving a sufficient period during which the organisms
are killed. There is a further variation to the "switch" method in
which two sensors are used at each location set at different levels
of condensation. The first indicates when condensation has started
and the second when the level of condensation is sufficient to have
caused a satisfactory level. It may then be necessary to have a
"dwell" period during which the kill occurs.
[0071] The condensation monitors of the above apparatus are optical
devices which measure the layer of condensation. An electronic
device may be used instead that gives a switch signal when a known
level of condensation has arrived. The switch level depends on the
construction of the sensor plate. Sensor plates are single use
disposable items and hence are inexpensive. The plates plug into a
box which may be placed at a remote location within the room.
[0072] The present invention may be embodied in other specific
forms without departing from its spirit or essential
characteristics. The described embodiments are to be considered in
all respects only as illustrative and not restrictive. The scope of
the invention is, therefore, indicated by the appended claims
rather than by the foregoing description. All changes which come
within the meaning and range of equivalency of the claims are to be
embraced within their scope.
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