(39 OF 1970)

AND

THE PATENT RULES, 2003

COMPLETE SPECIFICATION

(See section 10 and rule 13)

"Electrochemical activation system"

M/s. Faith Innovations, E-107, Lajpat Nagar -I, New Delhi 110024 The following specification describes the invention: FIELD OF THE INVENTION

The invention relates to improved electrochemical activation systems, more particularly, to electrochemical activation systems comprising a flow-through electrochemical ceil (FEM), and electrolvsis of solutions therein.

BACKGROUND TO THE INVENTION

In the field of applied electrochemistry, chemical electrolysis generally occurs in an electrochemical cell, wherein an electric current is passed through either a solution of a solute, commonly aqueous, ionic substance or a molten ionic substance. Electrolysis processes produce new chemical species, which can subsequently take part in chemical reactions at the cell cathode and anode to form new compounds.

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-activated 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.

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 systems and associated systems suffer from various disadvantages and shortcomings.

In conventional electrochemical activation systems, electrolytic cells have a limited lifespan as 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.

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.

Another known metbodto de-scale the electrodes is the periodic reversal of polarity between an anode and a cathode. However, this method suffers from the disadvantages such as in many- cases polarity reversal is not possible or energy efficient. Further, it may have effect the dissolution of the cathode and it may deteriorate the quality of the cathode coating.

One of the biggest disadvantages associated with presently available electrochemical activation 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 systems require continuous adjustments to control mechanisms of the device in order to generate solutions of specific characteristics.

In the prior art, the devices usually have manually operated cleaning system. Through manual operation a user normally conducts a de-scaling operation on-site. The biggest disadvantage of the manually operated devices is quality of the product(s) is monitored manually and periodically and process variables are adjusted as needed to maintain quality and hence it requires continuous on-site presence of trained personnel.

Some people have tried to use automated cleaning devices and 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 descaling devices operate only on the measurement of time elapsed and the same is done by manually pressing a knob which requires user intervention. The other disadvantages of such devices are that the "time only" based flushing has inherent shortcomings as depending on quality of inputs (electrolyte, water and electricity) the deposition on cathode and membranes may change and predicting the time after which flushing would be needed is difficult.

OBJECT OF THE INVENTION

It is an object of the present invention to provide an electrochemical activation system ("ECA") that is adapted for production of stable electrochemically-activated solutions, on a continuous and industrial scale, and for a longer period than that by currently available electrochemical activation systems and devices and that will overcome or at least minimise some of the disadvantages associated with currently available electrochemical activation systems and devices.

Yet another object of the invention is to provide an electrolytic housing suitable for use within the electrochemical activation system.

Yet another object of the invention is to provide a method to ensure long life of electrolytic cells within an electrochemical activation system.

Yet another object of the invention is to provide a method for the management of an electrochemical activation system.

Yet another object of the invention is to provide a method that is adapted for the production of stable electrochemically-activated solutions, on a continuous and industrial scale, and for a longer period.

Yet another object of the invention is to provide a method of cleaning the membranes (electrolytic cells) for the production of quality disinfectant for a longer period of time.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated diagrammatic ally in the following drawings wherein:

FIG. 1 is a diagrammatic illustration of an electrochemical activation system of the type described, FIG. 2 is a diagrammatic illustration of a control system which controls operation of the system shown in FIG. 1

DESCRIPTION OF THE INVENTION

The invention relates to an electrochemical activation system comprises a cell which is adapted to produce the electrochemically activated solution, such as an anolyte or a catholyte solution, by means of an electrolysis process.

The invention further relates to a method for the management of an electrolytic cell exchange system that is adapted for the production of stable electrochemically-activated solutions, on a continuous and industrial scale, and for a longer period.

The electrolysis process used in the present invention is based on the known ECA technology (Electro - Chemical Activation). The ECA technology is based on an electrolysis process with water and possibly salt, for instance sodium chloride, as raw materials. Cell comprises of Cathode and anode segregated by a semi-permeable membrane. A suitable cell is a Flow Electrolyte Module (FEM) cell. Such a FEM-cell is known in the relevant field.

The operation of the system is described in the context of producing an anolyte solution and catholyte solution, for instance EOW, which can be used as disinfectant.lt is possible to envisage disinfection of food, medical instruments, spaces, surfaces and water sources. The EOW can be used in all phases (as ice, liquid or gas).

Figure 1 shows a diagram of a device for producing an electrochemically activated solution, such as an anolyte or a catholyte solution, such as Electrolyzed Oxidized Water (EOW). Device comprises a first control unit or processor such as CIC with display connected to main electrochemical unit housing cells, one or more salt reservoirs, one or more treated water reservoirs and a reservoir for the produced solution i.e. disinfectant according to the invention.

In a preferred embodiment, the electrochemical activation system has an array of Solenoid valves and pumps suitably located inside the system. This array is electrically connected to the Central Intelligence Controller. The system accommodates one or more electrolytic cells therein so as to produce anolyte and catholyte with particular physical and chemical characteristics, with specific conductivity and pH and quantity of oxidants as desired. The system further houses FEM cells which produce anolyte at pH level 7+1 and input water after conditioning is also at pH level 7+1.

The electrochemical activation system comprises of an inlet for water to water treatment unit with reservoir and an inlet for the electrolyte, which is preferably supplied in the form of a salt solution. Both the water treatment unit and inlet for electrolyte are connected to main electrochemical unit housing cells. The produced disinfectant, in this case Electrolyzed Oxidized Water (EOW), is delivered to disinfectant reservoir and the catholyte is discarded

The electrochemical activation system further has a mechanism to control the output dilution of the disinfectant. In an embodiment of the present invention, as shown in Figure 2, the pressing of button B l opens up Relays Rl, R2, R3 and the pressing of button B l close down Replay R4. The shutdown process of R4 opens up SVl (Solenoid valve 1) and the opening of SVl will start the working of Booster and pump. In this situation, SV3 always remains open and undiluted disinfectant from disinfectant reservoir passes through S V3 and the treated water from the reservoir comes through SVl. In an embodiment the reservoir may have the treated water. The reducer in line between Booster and SVl is set in such a manner that the quantity of water passing through reducer is 3 times the quantity of Disinfectant coming out of SV3. This is done manually after choosing the booster and pump of required flow rate. This ensures that 1:4 diluted disinfectant comes out of the outlet nozzle.

In another embodiment of the present inversion, as shown in Figure 2, the operator presses button B2 which open the Relays Rl, R2, and R4 are open and the pressing of button B2 close down Relay R3 which leads to opening up of SV2 and SV3. After SV2 and SV3 are opened up, the Booster and pump start working. Reducer in line of booster and SV2 is set in such a manner that same quantity of water and disinfectantis passed through to output. This ensures that 1:2 diluted disinfectant comes out of output nozzle.

In another embodiment of the present invention, as shown in Figure 2, the operator presses button B3 which opens up the Relays Rl and R2 open and it close down Relays R3 and R4. The closing of Relays R3 and R4 would start the operation of the pump only and it enables SV3 to open. This ensures that undiluted disinfectant comes out of the output nozzle. The electrochemical activation system further incorporates a Central Intelligent Controller ("CIC") to facilitate control and administration of the (electrochemical system) electrolytic cells.

In the known reverse osmosis systems, membranes are used for bringing down Tds of the raw water. These membranes basically absorb the scale forming elements in water and help bringing down the Tds of the water. During regular functioning of such systems it is observed that these systems work for a specific period of time after which they go to stand-by mode. In the prior art it was observed that during this stand-by mode the membranes are filled with high Tds water which causes accelerated choking of the membranes.

In an embodiment, the CIC further automatically cleans the membranes of the water treatment unit with clean water immediately before the end of the production cycle i.e. during the standby mode of the disinfectant. The water treatment unit has a system with flushing cycle of a predetermined time which can be varied according to the size of the water treatment unit. In one embodiment, the flushing cycle is of 35 minutes. In the present invention, for 30 minutes, hydroprep will function normally and the treated water will be pumped into reservoir. After the cycle of 30 minutes, the hydropep will stop and the treated water is pumped into membranes in reverse and drained out for the last 5 minutes. The system ensures the long life of membranes by cleaning the membranes with clean water after every cycle of production of the treated water.

By this system of autoflushing, only low Tds water remains in the membranes during the standby mode which increases the life of membranes. The invention further relates to a novel method of self cleaning wherein the method comprises the steps of automatically cleaning the membranes of the water treatment section with clean water immediately before the end of every production cycle.

The method of self-cleaning of the membranes comprises of flushing cycle of a predetermined time which can be varied according to the size of the water treatment unit. In one embodiment, the flushing cycle is of 35 minutes. In the method of the present invention, for 30 minutes, hydroprep will function normally and the treated water will be pumped into reservoir. After the cycle of 30 minutes, the hydropep will stop and the treated water is pumped into membranes in reverse and drained out for the last 5 minutes. The novel self-cleaning method ensures the long life of membranes by cleaning the membranes with clean water after every cycle of production of the treated water.

By this method of autoflushing, only low Tds water remains in the membranes during the standby mode which increases the life of membranes.

In an embodiment, the CIC of ECA system gets constant feedback of running time of the system and also feedback of current levels in the cells. The system goes into automated descaling of cells (using weak acid) upon predetermined elapse of time or when the current level goes below a predetermined limit.

The above two feedback mechanism through array of valves and pumps are used by CIC to start automoated flushing of cells and this ensures that the oxidant concentration in anolyte is always above the prescribed limit.

In an embodiment, it is found that in the conventional electrochemical activation systems during shutdown Catholyte and Anolyte remained inside the cells which lead to faster degradation of the cell coatings. The CIC of the present invention ensures automatic flushing out of catholyte and anolyte and filling of reactor with clean water during shutdown. This ensures that fresh water is remained inside the cells instead of Catholyte and Anolyte during shutdown which in turn ensures longer life of cells and is the reason of lesser breakdowns lesser scaling of FEM cells.

In another embodiment, the present invention incorporates a novel method of cleaning the membranes (cells) for the production of quality of disinfectant for a longer period of time. In the present method, the system ensures automatic flushing out of catholyte and anolyte and filling of reactor with clean water during shutdown. The novel method comprises the step of automatic flushing out of catholyte and anolyte during shutdown, cleaning the cells with the fresh water, removing said water from the cells and filling the cells with the fresh water. This novel method of cleaning the cells results in long life of cells and efficient working of the system.

In an embodiment of the present invention, the disinfectant reservoir and water treatment reservoir have sensors which would provide indications to the controller about level of water and the disinfectant. In case of water level being lower than the prescribed limit and /or disinfectant level being lower than the prescribed limit the sensors will provide the input to the controller which would enable the display unit to display the error to the user and in that case the functioning of the electrochemical activation system will stop.

The electrochemical activation system also may include a power supply unit ("PSU"), suitable for providing required levels of power to the system during operation of the same.

Thus, the invention enables the system to have efficient control over the quality of solutions produced oyer longer period of time.

Throughout the specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

The invention is of course not limited to the described and shown preferred embodiment and other embodiments are possible. The invention relates generally to any embodiment falling within the scope of protection as defined in the claims and it is to be understood that the claims will not necessarily limited to the features described herein and as seen in the light of the foregoing description and accompanying drawings.