Methods and apparatus for controlling water hardness

Abstract

The present invention is related to methods, apparatuses, and compositions for controlling water hardness. The methods, apparatuses and compositions also reduce scale formation. The present invention includes substantially water insoluble resin materials. The resin materials may be loaded with a plurality of cations.

1 . An apparatus for treating a water source comprising:
 (a) an inlet for providing the water to a first treatment reservoir;   (b) a water treatment composition comprising a substantially water insoluble resin material loaded with a plurality of one or more multivalent cations, wherein the composition is contained within the treatment reservoir;   (c) an outlet fluidly connected to the first treatment reservoir, wherein the outlet provides treated water from the treatment reservoir.   
     
     
         2 . The apparatus of  claim 1 , wherein the resin material comprises a weak acid cation resin. 
     
     
         3 . The apparatus of  claim 1 , wherein the resin material is selected from the group consisting of a gel type resin structure, a macroporous type resin structure, and combinations thereof. 
     
     
         4 . The apparatus of  claim 2 , wherein the weak acid cation resin is selected from the group consisting of a crosslinked acrylic acid polymer, a crosslinked methacrylic acid polymer, and mixtures thereof. 
     
     
         5 . The apparatus of  claim 1 , wherein the resin material has a surface comprising functional groups comprising carboxyl groups 
     
     
         6 . The apparatus of  claim 4 , wherein resin polymers have additional copolymers added selected from the group consisting of butadiene, ethylene, propylene, acrylonitrile, styrene, vinylidene chloride, vinyl chloride, and derivatives and mixtures thereof. 
     
     
         7 . The apparatus of  claim 4 , wherein the acrylic acid polymer is crosslinked with a polyvinyl aromatic. 
     
     
         8 . The apparatus of  claim 7 , wherein the polyvinyl aromatic is selected from the group consisting of polyvinyl aromatics such as divinyl benzene, trivinyl benzene, divinyl toluene, divinyl xylene, polyvinyl anthracene, and derivatives and mixtures thereof. 
     
     
         9 . The apparatus of  claim 4 , wherein the resin provides a polymer material having a molecular weight of about 150 to about 100,000 to the water source. 
     
     
         10 . The apparatus of  claim 4 , wherein the crosslinked acrylic acid polymer is about 0.5% to about 25% crosslinked. 
     
     
         11 . The apparatus of  claim 4 , wherein the crosslinked acrylic acid polymer is crosslinked at less than 8%. 
     
     
         12 . The apparatus of  claim 1 , wherein the multivalent cations comprise a mixture of calcium and magnesium ions. 
     
     
         13 . The apparatus of  claim 12 , wherein the mixture comprises a ratio of about 1:10 to about 10:1 of calcium ions to magnesium ions. 
     
     
         14 . The apparatus of  claim 12 , wherein the mixtures comprises a 2:1 ratio of calcium to magnesium ions. 
     
     
         15 . The apparatus of  claim 1 , wherein the resin comprises an exhausted ion exchange resin. 
     
     
         16 . The apparatus of  claim 1 , wherein the composition does not precipitate water hardness ions out of a source of water when contacted with the water. 
     
     
         17 . The apparatus of  claim 1 , wherein the composition is agitated in the treatment reservoir. 
     
     
         18 . The apparatus of  claim 17 , wherein the composition is agitated by a method selected from the group consisting of the flow of water through the column, by fluidization, mechanical agitation, air sparge, eductor flow, baffles, flow obstructers, static mixers, high flow backwash, recirculation, and combinations thereof. 
     
     
         19 . The apparatus of  claim 1 , wherein the inlet is located at the bottom of the reservoir, and the outlet is located at the top of the reservoir. 
     
     
         20 . The apparatus of  claim 1 , wherein the inlet further comprises a pressurized spray nozzle. 
     
     
         21 . The apparatus of  claim 20 , wherein the spray nozzle provides the water to the treatment reservoir at a rate of about 5 feet per minute to about 200 feet per min. 
     
     
         22 . The apparatus of  claim 1 , wherein the bed depth of the composition in the treatment reservoir is less than 1.5 feet. 
     
     
         23 . The apparatus of  claim 1 , wherein the treatment reservoir further comprises a head space above the composition. 
     
     
         24 . The apparatus of  claim 1 , wherein the treatment reservoir further comprises an oxidant. 
     
     
         25 . The apparatus of  claim 24 , wherein the oxidant is selected from the group consisting of chlorine, hydrogen peroxide, oxygen, and mixtures thereof. 
     
     
         26 . The apparatus of  claim 1 , further comprising at least one additional treatment reservoir, wherein said additional treatment reservoir comprises:
 (a) an inlet;   (b) a water treatment composition comprising a substantially water insoluble resin material loaded with a plurality of one or more multivalent cations; and   (c) an outlet.   
     
     
         27 . The apparatus of  claim 26 , wherein the at least one additional treatment reservoir is provided in series with the first reservoir. 
     
     
         28 . The apparatus of  claim 26 , wherein the at least one additional treatment reservoir is provided in parallel with the first reservoir. 
     
     
         29 . The apparatus of  claim 1 , wherein the first treatment reservoir comprises a portable, removable cartridge. 
     
     
         30 . The apparatus of  claim 26 , wherein the additional treatment reservoir comprises a portable, removable cartridge. 
     
     
         31 . The apparatus of  claim 1 , wherein there is not a filter connected to the outlet. 
     
     
         32 . The apparatus of  claim 1 , wherein the apparatus is located in an automatic washing system. 
     
     
         33 . The apparatus of  claim 32 , wherein the automatic washing machine is selected from the group consisting of an automatic ware washing machine, vehicle washing system, instrument washer, clean in place system, food processing cleaning system, bottle washer, and an automatic laundry washing machine. 
     
     
         34 . The apparatus of  claim 1 , wherein the apparatus is located upstream from an automatic washing machine. 
     
     
         35 . The apparatus of  claim 34 , wherein the automatic washing machine is selected from the group consisting of an automatic ware washing machine, vehicle washing system, instrument washer, clean in place system, food processing cleaning system, bottle washer, and an automatic laundry washing machine. 
     
     
         36 . The apparatus of  claim 1 , wherein the apparatus is located upstream from a water treatment device selected from the group consisting of a reverse osmosis water treatment device, a heat exchange water treatment device, a carbon filter, and mixtures thereof. 
     
     
         37 . The apparatus of  claim 1 , wherein the apparatus provides treated water to a device selected from the group consisting of a coffee machine, an espresso machine, an ice machine, a steam table, a booster heater, a grocery mister, a humidifier, and combinations thereof. 
     
     
         38 . A method for treating water comprising contacting a water source with a water treatment composition comprising a substantially water insoluble resin material loaded with a plurality of one or more multivalent cations, such that the water is treated. 
     
     
         39 . The method of  claim 38 , wherein the resin material comprises a weak acid cation resin. 
     
     
         40 . The method of  claim 38 , wherein the resin material is selected from the group consisting of a gel type resin structure, a macroporous type resin structure, and combinations thereof. 
     
     
         41 . The method of  claim 38 , wherein the weak acid cation resin is selected from the consisting of a crosslinked acrylic acid polymer, a crosslinked methacrylic acid polymer, and mixtures thereof. 
     
     
         42 . The method of  claim 39 , wherein the resin material has a surface comprising functional groups comprising carboxyl groups 
     
     
         43 . The method of  claim 41 , wherein resin polymers have additional copolymers added selected from the group consisting of butadiene, ethylene, propylene, acrylonitrile, styrene, vinylidene chloride, vinyl chloride, and derivatives and mixtures thereof. 
     
     
         44 . The method of  claim 41 , wherein the acrylic acid polymer is crosslinked with a polyvinyl aromatic composition. 
     
     
         45 . The method of  claim 44 , wherein the polyvinyl aromatic is selected from the group consisting of polyvinyl aromatics such as divinyl benzene, trivinyl benzene, divinyl toluene, divinyl xylene, polyvinyl anthracene, and derivatives and mixtures thereof. 
     
     
         46 . The method of  claim 41 , wherein the crosslinked acrylic acid polymer provides a polymer material having a molecular weight of about 150 to about 100,000 to a water source, when contacted with the water source. 
     
     
         47 . The method of  claim 41 , wherein the crosslinked acrylic acid polymer is about 0.5% to about 25% crosslinked. 
     
     
         48 . The method of  claim 38 , wherein the multivalent cations comprise a mixture of calcium and magnesium ions. 
     
     
         49 . The method of  claim 48 , wherein the mixture comprises a ratio of about 1:10 to about 10:1 of calcium ions to magnesium ions. 
     
     
         50 . The method of  claim 48 , wherein the mixtures comprises a 2:1 ratio of calcium to magnesium ions. 
     
     
         51 . The method of  claim 38 , wherein the resin comprises an exhausted ion exchange resin. 
     
     
         52 . The method of  claim 38 , wherein the composition does not precipitate water hardness ions out of the source of water when contacted with the water. 
     
     
         53 . The method of  claim 38 , wherein the step of contacting comprises passing the water through a treatment reservoir containing the composition. 
     
     
         54 . The method of  claim 38 , further comprising agitating the composition during the contacting step. 
     
     
         55 . The method of  claim 54 , wherein the composition is agitated by a method selected from the group consisting of the flow of water through the column, by fluidization, mechanical agitation, air sparge, eductor flow, baffles, flow obstructers, static mixers, high flow backwash, recirculation, and combinations thereof. 
     
     
         56 . The method of  claim 38 , further comprising heating the water source prior to the step of contacting the composition. 
     
     
         57 . The method of  claim 56 , wherein the water is heated to a temperature of about 30° C. to about 90° C. 
     
     
         58 . The method of  claim 38 , further comprising the step of increasing the pH of the water source prior to or during the step of contacting the composition. 
     
     
         59 . The method of  claim 58 , wherein the pH of the water source is increased to a pH of about 8 to about 10. 
     
     
         60 . The method of  claim 58 , wherein the step of increasing the pH of the water source comprises adding a source of calcite to the water or to the apparatus. 
     
     
         61 . The method of  claim 38 , wherein the composition provides about 10 to about 1000 parts per billion of a substantially water insoluble resin material to the water source during the step of contacting. 
     
     
         62 . The method of  claim 38 , wherein the composition provides about 10 to about 1000 parts per billion of a water soluble polymer material to the water source during the step of contacting. 
     
     
         63 . The method of  claim 62 , wherein the polymer material comprises a polyacrylate material. 
     
     
         64 . The method of  claim 63 , wherein the polyacrylate material comprises a low molecular weight polyacrylate material. 
     
     
         65 . The method of  claim 38 , wherein the treated water reduces scale formation on a surface contacted by the treated water. 
     
     
         66 . A method of using a treated water source to clean an article said method comprising:
 (a) treating a water source, wherein the step of treating the water source comprises contacting a water treatment composition comprising a substantially water insoluble resin material loaded with a plurality of one or more multivalent cations, with a water source to form a treated water source;   (b) forming a use solution with the treated water and a detergent; and   (c) contacting the article with the use solution such that the article is cleaned.   
     
     
         67 . A method for reducing scale formation in an aqueous system comprising contacting the aqueous system with a composition consisting essentially of a substantially water insoluble resin material loaded with a plurality of multivalent cations, such that scale formation in the aqueous system is reduced. 
     
     
         68 . A method for manufacturing a water treatment device comprising:
 (a) loading a composition comprising a substantially water insoluble resin material into a treatment reservoir, wherein said treatment reservoir comprises an inlet and an outlet; and   (b) exhausting the resin material, wherein said step of exhausting the resin material comprises loading a surface of the resin material with a plurality of multivalent cations.   
     
     
         69 . The method of  claim 68 , wherein the multivalent cations comprise a mixture of calcium and magnesium ions. 
     
     
         70 . The method of  claim 69 , wherein the mixture comprises a ratio of about 1:10 to about 10:1 of calcium ions to magnesium ions. 
     
     
         71 . The method of  claim 69 , wherein the mixture comprises a 1:1 ratio of calcium to magnesium ions. 
     
     
         72 . A method for reducing scale formation, comprising:
 (a) providing about 10 to about 1000 parts per billion of a substantially water insoluble resin material to a water source, such that scale formation is reduced.   
     
     
         73 . A method for reducing scale formation, comprising:
 (a) providing about 10 to about 1000 parts per billion of a water soluble polymer material obtained from a substantially water insoluble resin material.   
     
     
         74 . The method of  claim 73 , wherein the polymer material comprises a polyacrylate material. 
     
     
         75 . The method of  claim 74 , wherein the polyacrylate material comprises a low molecular weight polyacrylate material. 
     
     
         76 . A water treatment composition consisting essentially of a source of substantially water insoluble resin material, wherein said resin material is loaded with a plurality of cations selected from the group consisting of a source of column 1a, 2a or 3a elements from the Periodic Table, wherein said cations do not include calcium. 
     
     
         77 . The composition of  claim 76 , wherein said cations are selected from the group consisting of hydrogen, sodium, magnesium, aluminum, zinc, titanium ions, and mixtures thereof.