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.

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)