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.

Description

TECHNICAL FIELD

This invention relates to an electrochemical activation system, adapted for production of electrically, electronically and/or electrochemically-activated solutions on a continuous and industrial scale. It also includes an electrolytic cell exchange module suitable for use within the system.

BACKGROUND ART

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 devices and associated systems suffer from various disadvantages and shortcomings.

In conventional electrochemical activation systems, electrolytic cells have a limited lifespan in that foreign matter deposits on electrodes and membranes, eventually coating the electrodes and blocking the membranes beyond operational limits. These deposits are dissolved and cleaned from the electrodes a number of times to extend the lifetime of the electrolytic cells until the electrolytic cells are no longer able to produce activated solutions with the required efficacy, at which time the electrolytic cells are discarded. These deposits also form in other parts of the system, such as connecting tubing and valves.

Electrode Cleaning: Acid Washing

Depending on the quality and chemical composition of a feed stock, which is usually water or an aqueous solution of a salt, an electrochemical activation operation is periodically interrupted at relatively frequent intervals to clean the electrodes, particularly the cathode, of scale and precipitates that accumulate and form a deposit on it. This deposited scale or precipitate, which has entirely different conductivity and dielectric and surface characteristics to the clean, usually coated surface of the electrode, behaves very differently to what was intended to be achieved and prevents continued successful operation of the electrolytic cell.

In an attempt to de-scale the electrodes, membrane and other parts of the hydraulic system and to restore its original surfaces and regain optimal operational efficiency, one practice at present involves washing an affected surface with an appropriate solvent, such as a dilute solution of an inorganic acid, e.g. 1% to 5% hydrochloric acid. However, besides problems such as chemical and biocompatibility, especially in sensitive applications such as in food processing, or medical and dental applications, such solvents often pose environmental pollution and disposal problems. The use of acid is regarded as a risk in many markets and as such creates problems in commercial exploitation of the technology. In addition, the use of acid increases the general risks of operation, which iIn turn causes increased difficulties in obtaining FDA and other regulatory approvals.

Electrode Cleaning: Polarity Reversal

An alternative practice to de-scale the electrodes involves periodic reversal of polarity between an anode and a cathode. This is intended to help dissolve precipitated scale and remove it particularly from the cathode surface, where it is mostly formed. However, this practice suffers from the following disadvantages.

• • Most salts that form scale crystals have a relatively low solubility constant and, once precipitated from a solution, often require more energy to re-dissolve than to precipitate in the first place. Accordingly, in many cases polarity reversal is not possible or energy efficient.
  • Many systems use a semi-permeable and/or ion exchange membrane on and in which the scale forms and which is prone to being severely affected by precipitated scale. However, not being as electrically active as the electrodes during a forward or reverse current, it is even more difficult to clean than the electrodes.
  • In electrochemical and electrolytic processes, the anode is prone to dissolution, while the cathode is not. Accordingly, in order to prolong electrode life and avoid premature failure, the anodes are often coated with platinum group metal oxides.

However, due to the high costs of such coatings, the cathodes are generally not coated or if so, then normally with a lighter or sub-standard grade coating compared to that of the anode. For this reason many electrode manufacturers do not recommend polarity reversal, as it could cause dissolution of the cathode or deterioration in the quality of the cathode coating.

Operational Control

Another disadvantage associated with presently available electrochemical activation devices and systems is a lack of efficient control over the quality of solutions produced over time. Deterioration of the membrane, electrodes and coatings can result therein that sub-standard activated solutions are produced. Current electrochemical activation devices require continuous adjustments to control mechanisms of the device in order to generate solutions of specific characteristics. The normal manner of using such technology is to operate the device either manually or to use automated devices.

• • Manual operation: Through manual operation a user normally conducts a de-scaling operation on-site. Acid of various dilutions (e.g. 3%) is run manually through the device and cells for de-scaling purposes. Quality of the product(s) is monitored manually and periodically and process variables are adjusted as needed to maintain quality. The obvious disadvantage associated with manual operation, other than the non-desirable use of acid, is that it requires continuous on-site presence of trained personnel.
  • Automated devices: Through automated devices de-scaling of the cells and device is automated. Albeit that such automation solves the problem of having to de-scale manually, such automated devices are often too expensive for many markets. In addition, automated de-scaling does not solve the problem of using acid in the device. Another disadvantage of known automated devices is the need to incorporate expensive in-line sensor technologies, such as ORP and pH meters, for real time monitoring and control of the quality of solutions and for ensuring that the solutions have been adequately activated.
    Feed Preparation

Saline intake is another area of potential problems associated with currently available electrochemical activation devices and systems. Two of these problems relate to control of flow rate through the cells, and stabilisation of conductivity levels of a saline feed solution. Electrochemical activation devices are dependent on water supply and are normally connected to a municipal supply or tap. Variations in hydraulic pressures, as often occur in municipal and other water systems, cause variations in flow rate of water through the cell(s), resulting in variations in the quality and quantity of activated solutions generated. Also, a saline solution is normally fed into incoming water by means of a venturi. However, variations in water pressure also result in variations in the performance of the venturi, the level of conductivity and again in quality and quantity variations in the activated solutions.

Power Supply Unit

A further disadvantage of known electrochemical activation devices is that power supply units utilised in the same often experience inefficiencies in power conversion and rectification; which are generally manifested as heat. This inefficiency not only wastes electricity, but also creates a further problem in that the heat must be channelled away. Also, where two or more units are used together, they have to be “balanced” against one another, often due to slight variations in output voltage and current. This is not always easy to achieve and differences between these units often arise, which causes further heat generation and an associated reduction in efficiency and reliability of the system as a whole.

Complex Design and Cost Considerations

Many of the present electrochemical activation devices are complex, suffering from having many components that are not built for easy maintenance or replacement. This adds to increased complexity and reduced reliability of these devices. In addition, there is a real demand to reduce costs of these devices to within affordable levels, particularly for industries such as water treatment, food processing, and the medical and dental fraternity. More particularly, there is a need to simplify the device, while at the same time improving its reliability and without any deterioration in the quality of activated solutions generated.

OBJECT OF THE INVENTION

It is an object of the present invention to provide an electrochemical activation system that is adapted for on- or off-site production of electrically, electronically and/or electrochemically-activated solutions, particularly on a continuous and industrial scale, that will overcome or at least minimise some of the disadvantages associated with currently available electrochemical activation systems and devices.

It is a further object of the invention to provide an electrolytic cell exchange module suitable for use within the electrochemical activation system.

It is a further object of the invention to provide a method for the management of an electrolytic cell exchange system.

DISCLOSURE OF THE INVENTION

For ease of reading, the following terminology is used within this specification:

• • “Anion-containing solution” is also referred to as the “anolyte solution” or “anolyte”;
  • “Cation-containing solution” is also referred to as the “catholyte solution” or “catholyte;
  • “ECA”=ElectroChemical Activation;
  • “ECAM”=ElectroChemical Activation Management;
  • “PSU”=Power Supply Unit;
  • “MCU”=Monitoring and Control unit;
  • “ORP”=Oxidation-Reduction Potential;
  • “PLC”=Programmable Logic Controller;
  • “CPU”=Central Processing Unit;
  • “ITM”=electronic Identification and Tracking Means; and
  • “RMS”=Root Mean Square

According to the invention there is provided an electrochemical activation (“ECA”) system adapted for production, and particularly on-site production, of separable and both of an aqueous, mixed oxidant, predominantly anion-containing solution and an aqueous, mixed reductant, predominantly cation-containing solution, the ECA system being characterised therein that it includes at least one electrolytic cell exchange module designed for accommodating one or more electrolytic cells therein, the electrolytic cell exchange module being removably arranged within the ECA system and characterised in either being disposable or reusable within the ECA system.

The ECA system also may include a power supply unit (“PSU”), suitable for providing required levels of power to the system during operation of the same. The PSU may include an intelligent controller and may either be integrally located within the electrolytic cell exchange module or may be a removable PSU.

The PSU may be adapted for the ECA system such that a power circuit does not supply a steady DC signal to the system, but rather converts a negative half of an AC cycle into a positive signal for providing a sinoidal envelope with, for example, a 12V RMS voltage with a frequency of approximately 110 to 120 Htz, depending on the frequency of the mains electricity supply. In addition, the PSU may be adapted to generate a high switching frequency wave with a frequency of more than 1 kHtz, and preferably between 45 and 95 kHtz, and most preferably at 70 kHtz, which is superimposed on the sinoidal envelope, resulting in a signal that may vary, for the above example, between 0 and nearly 18 volts at different points in the cycle.

The PSU of the ECA system may further be characterised therein that all major heat generating components in the electronics circuitry are positioned and assembled in such a way that the heat is safely conducted away to a liquid medium being electrolysed for always maintaining the circuits at an optimum temperature during operation.

The ECA system further may Include an integral monitoring and control unit (“MCU”) that is operatively associated with the PSU and suitable for monitoring power supply status throughout an activation cycle, the MCU being characterised therein that upon occurrence of a fault condition, it automatically switches off certain circuits within the ECA system depending on the error condition. Under these conditions a minimum number of circuits may remain active so as to enable the ECA system to indicate the presence of an error condition to an operator.

The MCU may be adapted particularly to monitor and control one or more of the following variables, namely anolyte output flow rate; catholyte output flow rate; total system flow rate; pump motor current; PSU output; level of anolyte in an anolyte holding tank and level of catholyte in a catholyte holding tank. In addition, the MCU provides user control means for switching on and switching off of the ECA system, as well as automatic shutdown capacity after completion of a production cycle.

The ECA system also may include other disposable or exchangeable components such as pump(s), valve(s), gas separation unit(s), flow meter(s), and condition and quality monitoring devices, including pH, ORP and conductivity meters.

The ECA system may be characterised therein that it is not directly connected to a tap and as such operational efficiency is not affected by pressure variations in external water supply systems. More particularly, the ECA system of the invention may incorporate a feed preparation system arranged in fluid communication with the electrolytic cell exchange module for premixing a saline solution of fixed concentration so as to ensure that a consistent feed solution is presented to the electrolytic cells. The feed preparation system may include at least one saline storage container for storing the premixed saline solution and from where the saline solution is fed directly into the electrolytic cells of the electrolytic cell exchange module under a controlled flow rate by means of pumping, gravity feeding, pressurised feeding or the like.

With this invention, only one premixed feed solution is used. Variations in the activated solutions produced may be achieved, inter alia, by varying the nature and concentration of the saline content of the feed solution, or by varying voltage applied to the electrolytic cells. This arrangement improves stability (in terms of pH, ORP, etc.) in the activated solutions generated and eliminates the need for sophisticated electronic and hydraulic controls, thereby reducing system costs and making it more affordable to a larger section of the market, particularly where small volumes of activated solutions are required, such as in dental surgery.

Depending on the scale of operation and some site-dependant logistics, the electrolytic cell exchange module, PSU, MCU and the feed preparation system may all removably be arranged within a single ECA device.

The electrolytic cell exchange module may be dimensioned for accommodating a series of electrolytic cells therein and, more particularly, may be modularised to incorporate different numbers of electrolytic cells for different production volumes. The electrolytic cells may be interconnected electrically and/or hydraulically either in series or in parallel.

The electrolytic cell exchange module may be characterised therein that it includes pH control means incorporated within the same. The ECA system also may include water softeners, which may be located in the electrolytic cell exchange module, for reducing the need for de-scaling of electrodes.

The electrolytic cell exchange module also may include a housing for protecting the enclosed electrolytic cells from impact and mishandling.

The electrolytic cell exchange module also may include at least one gas separation device adapted for trapping gasses that may be produced during the electrolytic activation reaction.

The electrolytic cell exchange module may removably be arranged within the ECA system such that it can be taken off-site for de-scaling, servicing and maintenance of the electrolytic cells and subsequent reinstallation in the ECA system after reconditioning.

The electrolytic cell exchange module incorporates a programmable logic controller (“PLC”) or a central processing unit (“CPU”) to facilitate control and administration of the electrolytic cells. In particular, the PLC or CPU may be adapted to control fluid flow through the electrolytic cells, automatically switching off after a predetermined volume of product has been generated and as such obliging a user to dispose of or exchange the electrolytic cell exchange module in order to maintain production efficiency and product quality.

The electrolytic cell exchange module also may incorporate electronic identification and tracking means (“ITM”) for uniquely identifying and tracking various component parts within the module, facilitating the use only of approved and authorised component parts and for indicating unauthorised tampering with the electrolytic cell exchange module. This would improve safety and prevent the use of sub-standard, pirated or non-serviced component parts or unauthorised components produced by an unlicensed manufacturer.

The ITM may be operatively associated with the MCU and may include a unique alphanumerical serial number; a secure communications interface; and a non-volatile memory containing the status and history log of each component part within the electrolytic cell exchange module. The ITM also may include a micro-controller. In one form of the invention the ITM is integrated with each component part, e.g. in the form of an electronic micro-chip, so as to render the component part tamperproof, the arrangement being such that any attempt to divorce the ITM from the component part renders the latter inoperable. The ITM may be adapted to capture status information during normal operation of the electrolytic cell exchange module and to keep track of the remaining operational period, the arrangement being such that when a pre-determined operating milestone is reached, the ITM sends a signal to the MCU to shut down the system so as to prevent further use of the electrolytic cell exchange module.

The unique alphanumerical serial number may be verifiable by the CPU, and may be correlated to one or more predetermined criteria such as operational parameters. One or more of these pre-determined criteria or parameters, (e.g. operating hours, allocation to a specific system at a particular site, operating in conjunction with another component equipped with a similar ITM), may be used to isolate specific identifying numbers to be allocated for use by the ECA system at the time of manufacturing and decoded with an identical set of rules by the device performing the validation during normal operation. In this way, at the time of manufacturing, or if required, subsequent servicing, specific components, such as the electrolytic cells, or the PSU, may be coded to operate only under certain desired and defined conditions.

The secure communications interface may be wired or wireless and data may be communicated by means of a secure communications protocol. A physical interface may include one or more data lines that may be driven serially or in parallel.

The non-volatile memory may contain current and/or history status information pertaining to each component part, to the system and/or the environment within which the component part is used. Thus, measurements or observations may be made internally or externally to the component part and saved to the ITM memory. Specific conditions may apply with regard to the data written to or changed on the non-volatile memory, such as the type of host device interfacing to the component part and the type of status change occurring.

The history status information stored in the non-volatile ITM memory may be used to provide information to a service centre when performing repairs. Without limiting the scope thereof, the history status information may include details regarding identity of a manufacturer; date of manufacture and production date stamp; identity of respective users; identity and access history of individual service technicians, number of de-scale cycles or operation cycles of the electrolytic exchange module; the number of conditionings and hours in service; number of service hours remaining before a reconditioning cycle (default start value is programmable); and the date of the last/previous conditioning.

Other interface lines to the ITM may include electrical power supply as well as additional control lines to control either the ITM as a whole or one or more of its component parts or both. “Intelligent ITM's” (i.e. an ITM including an on-board micro-controller) may generate some or all of these control lines internally, whereas “dumb ITM's” (i.e. an ITM excluding an on-board micro-controller) may utilise such control lines to manage, read and write access to the non-volatile memory.

Each electrolytic cell arranged within the electrolytic cell exchange module may include two co-axial cylindrical electrodes and a cylindrical diaphragm located co-axially between the two electrodes so as to separate an annular inter-electrode space into a co-axial, annular catholytic and an annular anolytic chamber arrangement. The electrolytic cell may have predetermined design and geometrical relationships for ensuring optimum fluid flow and re-circulation patterns. More particularly, the electrolytic cell may have a relatively small, annular, cross-sectional total open area for fluid flow for allowing turbulent fluid flow there through so as to ensure maximum exposure of the solutions to the electric field.

The electrolytic cell may be adapted to produce an electrolytically, electrically or electrochemically activated, aqueous solution by means of electrolysis of a relatively low concentration aqueous salt solution. Hydraulic flow through the electrolytic cell may be such that the electrolytically activated, aqueous solution may be prepared from any one of the following solutions, namely an anion-containing solution; a cation-containing solution; a mixture of an anion-containing solution and a cation-containing solution; an anion-containing solution having been prepared from an anion-containing solution, a cation-containing solution or a mixture of an anion-containing solution and a cation-containing solution; and a cation-containing solution having been prepared from an anion-containing solution, a cation-containing solution or a mixture of an anion-containing solution and a cation-containing solution.

The electrolytic cell may be operated under a relatively low current, preferably of about 5 to 15 A, and a relatively high voltage, preferably of about 6 to 48 V, and more preferably between 12V and 36 V, for providing a relatively high voltage gradient or electric field intensity at the interface between the electrode surface and electrolyte, estimated to be about 10⁶ V/cm.

Levels of saline concentration and mineral content of the feed solution, as well as operational variables of the electrolytic cell, such as flow rates, flow regimes, -paths, and -rates of recycle, currents and potential differences, may all be adjustable so as to produce anolyte and catholyte with particular physical and chemical characteristics, with specific conductivity, redox potential and pH, concentration of “activated species” and other characteristics, for different specific applications.

According to another aspect of the invention there is provided an electrochemical activation system adapted for producing separable and both of an aqueous, mixed oxidant, predominantly anion-containing solution and an aqueous, mixed reductant, predominantly cation-containing solution, the ECA system being characterised therein that it includes at least one through-flow electrolytic cell; feed preparation means arranged in fluid communication with the electrolytic cell for introducing into the same a premixed saline solution of fixed concentration; distribution means, such as a hydraulic manifold, for distributing feed solution in a parallel, serial or hybrid manner, through the electrolytic cell; and collection means for continuously collecting the predominantly anion-containing and predominantly cation-containing solutions.

The hydraulic manifold may also incorporate an integral, alternatively separate, means of gas/liquid separation, for separating any gases that may be produced as a result of electrolysis and for preventing formation of a gas or air lock in the hydraulic system.

The invention also provides for an electrochemical activation management (“ECAM”) system which is adapted to cooperate with the ECA system for managing removal, reconditioning and installation of the electrolytic exchange modules and electrolytic cells of the ECA system, and which keeps track of movement and history of individual electrolytic exchange modules. The tracking is effected by cooperation with the ITM of the electrolytic exchange modules.

The ECAM system may be arranged in communication with one or more components of the ECA system, by means of a direct or remote network or modem connection, the arrangement being such that data is collected from these components at a remote database and communicated through to a centralised master ECAM database for consolidation and correlation. A secondary function of the ECAM system is to correlate specific electrolytic cell exchange modules with customer and service centre information. Information on the history of each of these is recorded in the centralised master ECAM database, which enables a manufacturer to manage and plan the manufacturing process better, schedule maintenance and be prepared for receiving electrolytic cell exchange modules that have reached the end of their life cycle.

The ECAM system includes a cleaning unit adapted for remote cleaning and conditioning of the electrolytic cell exchange modules, the cleaning unit comprising its own power supply means, monitoring and control unit, a cleaning solution dispenser, pump and an electrolytic cell exchange module holder. The cleaning solution dispenser is similar in function to that of the saline storage container in the ECA system, but is able to dispense larger volumes of different fluids through to the electrolytic cell exchange module. The configuration of the cleaning unit is such that it circulates cleaning solution through the electrolytic cell exchange module a number of times before disposing of the waste fluids. The final cycle of the cleaning process is a rinse cycle, which is used to wash out the electrolytic cell exchange module with clean water to remove final traces of deposits, as well as traces of the cleaning solution.

The cleaning process may be performed without the need for manual intervention. Also, the cleaning unit may be adapted to save specific parameters onto the ITM of the electrolytic cell exchange module, for example a unique identification and access code for the service technician, the date of last conditioning, identification of the cleaning unit used, and the number of conditionings and service hours remaining. The cleaning unit has its own ITM and also saves operational information in its own status and history log.

SPECIFIC EMBODIMENT OF THE INVENTION

Without limiting the scope thereof, the invention will now be illustrated by means of a non-limiting example only and with reference to the accompanying figures wherein—

FIG. 1 shows ECAM and ECA system overview;

FIG. 2 is a schematic flow sheet of the ECA system according to the invention;

FIG. 3 shows the basic components of the feed preparation system;

FIG. 4 is the electrolytic cell with the power supply unit (PSU), with an illustration of the ITM of FIG. 8 integrated with the electrolytic cell exchange module;

FIG. 5 shows one example of the hydraulic flow sheet of the activation unit;

FIG. 6 is the wiring circuit of one example of the lay out of indicators/alarms;

FIG. 7 shows a level sensor circuit;

FIG. 8 shows some of the basic wiring of the control circuit incorporating an ITM included in the ECA system of the invention, depicting its external interfaces;

FIG. 9 is the control panel of a typical ECA device; and

FIG. 10 is a diagrammatical illustration of a typical lifecycle of an electrolytic cell exchange module according to the invention.

The lifecycle of an electrolytic cell exchange module begins with the manufacturing of an electrolytic cell exchange module, which includes allocation of a unique ITM and programming of manufacturing information into its non-volatile memory. A copy of this information is loaded into the ECAM database. As the electrolytic cell exchange module is distributed to a remote service centre, information about the destination is also captured into the ECAM database. Each service centre may update its local database with the information contained in its electrolytic cell exchange modules so as to keep track of stock. When an electrolytic cell exchange module is shipped to a customer, the service centre may capture the customer details and send this information to the ECAM database on a regular basis.

When the electrolytic cell exchange module requires maintenance, status information is drawn from the ITM and maintenance information loaded onto the same. This information is also copied to the ECAM database. In the event of total failure of an electrolytic cell exchange module, as well as in those cases where an electrolytic cell exchange module has completed its life cycle, the electrolytic cell exchange module is returned to the manufacturing plant for refurbishment. This information is also captured in the ECAM database.

The ECA system, which is located on-site with a user, will only be able to update specific status information, but not maintenance information. Service centres for electrolytic cell exchange modules will have the ability to update maintenance information, but not customer status information other than exchange information pertaining to the electrolytic cell exchange module. The manufacturer of the ECA system will have the ability to change or erase all information stored within the electrolytic cell exchange module.

Data objects incorporated in the ECAM database include electrolytic cell exchange modules, ECA devices, and customers and service centres details. The following information would typically be stored with respect to the electrolytic cell exchange modules, namely ITM status, including manufacturing date, deployment date and refurbishment date; ITM history; service details, including service type and date stamp; conditioning history; ECA device type and status, including manufacturing, deployment and refurbishment dates. Information that would typically be stored with respect to the customers and service centres include contact details; e.g. commencement and termination dates of the contract, and premiums payable; payment details; ITM details; and exchange history of the particular electrolytic cell exchange module. In addition, the ECAM system has the ability to generate various reports on demand, including customer history, service centre history, electrolytic cell exchange module history and various statistical reports such as the number of customers per region, failures per region, and current and projected number of exchanges and refurbishments of electrolytic cell exchange module per month.

A programming unit is used in a manufacturing plant to initialise the electrolytic cell exchange modules and other component parts within the ECA system. This unit interfaces to the electrolytic cell exchange module and is able to program specific parameters into the ITM of new electrolytic cell exchange modules, such as the serial number, manufacturing date, number of conditionings and service hours left. It can also clear the history log.

Referring to FIG. 8, the basic wiring of the control circuit, power is supplied to the ITM through the two lines identified by tag 2. Control lines 3 consist of zero, one, or more lines through which control information is sent to the ITM. Communication line 4 is referenced to the ground power line and is used to send software control information to and receive status information back from the ITM. Control output 5 has one or more lines, each being an enabler to activate specific parts of the component being identified and managed.

Conventional component identification means rely on database management systems to keep track of information pertaining to various component parts. Statuses are maintained and updated in the database only and a particular component part can only be identified if matched against this database. Even if distributed databases are used for tracking components over vast areas, the databases nevertheless has to be in constant inter-communication to ensure that the component part is effectively tracked, data discrepancies avoided and that the data remains current. The ITM according to the invention eliminates the need for constant communication between databases to ensure that statuses of component parts remain up to date and it provides means to validate a component part's ITM without having to verify this online against a database.

The applicant believes that the ECA system and electrolytic cell exchange module according to the invention will obviate the need to use acid on-site for de-scaling the electrodes and accordingly improve safety levels associated with this technology. Fluid feed is effectively separated from the electrical system, further reducing the risk level of the ECA system. The need for expensive electronic and other automated de-scaling features within the ECA system is obviated, lowering the cost of the technology. Furthermore, the risk of piracy and copies electrolytic cells being used in the ECA system can be reduced through more effective control. Another long-term benefit envisaged by the applicant is that increasing levels of intelligence can be built into the electrolytic cell exchange modules for monitoring, management and administrative purposes.

Also, reusable electrolytic cell exchange modules can be de-scaled, serviced and maintained at a central depot where quality of the electrode coatings, membrane and the like can be checked regularly, thereby increasing quality assurance on the technology and improving the chances of regulatory approvals. Alternatively, mobile hand held de-scaling units could be used to de-scale the electrolytic cell exchange modules. These hand-held mobile de-scale units could be supplied to a user or be used by a technician who could visit the user regularly to effect the service of the ECA system. These de-scale units may include sealed acid canisters or another means to reduce the risk of acid spills. By attaching the de-scale unit to a Steds device or alternatively, detaching the electrolytic cell exchange module from the Steds device and attaching it to the de-scale unit, one could apply the acid through the electrolytic cell exchange module under controlled conditions, in an out-room for example.

It will be appreciated that many variations in detail are possible without departing from the scope or spirit of the invention as defined in the consistory statements hereinbefore.

Claims

1. An electrochemical activation (“ECA”) system adapted for production, and particularly on-site production, of separable and both of an aqueous, mixed oxidant, predominantly anion-containing solution and an aqueous, mixed reductant, predominantly cation-containing solution, the ECA system being characterised therein that it includes at least one electrolytic cell exchange module designed for accommodating one or more electrolytic cells therein, the electrolytic cell exchange module being removably arranged within the ECA system and characterised in either being disposable or reusable within the ECA system.

2. The ECA system as claimed in claim 1 characterised therein that it also includes a power supply unit (“PSU”) suitable for providing required levels of power to the system during operation of the same, the PSU including an intelligent controller and either being integrally located within the electrolytic cell exchange module or being a removable PSU.

3. The ECA system as claimed in claim 2 characterised therein that the PSU is adapted for the ECA system such that a power circuit does not supply a steady DC signal to the system, but rather converts a negative half of an AC cycle into a positive signal for providing A sinoidal envelope with, for example, a 12V RMS voltage with a frequency of approximately 110 to 120 Htz, depending on the frequency of the mains electricity supply.

4. The ECA system as claimed in claim 2 characterised further therein that the PSU is adapted to generate a high switching frequency wave with a frequency of more than 1 kHtz, and preferably between 45 and 95 kHtz, and most preferably at 70 kHtz, which is superimposed on the sinoidal envelope, resulting in a signal that vary, for the example in claim 3, between 0 and nearly 18 volts at different points in the cycle.

5. The ECA system as claimed in claim 2 characterised therein that all major heat generating components in the electronics circuitry are positioned and assembled in such a way that the heat is safely conducted away to a liquid medium being electrolysed for maintaining the circuits at an optimum temperature during operation.

6. The ECA system as claimed in claim 1 characterised therein that the system includes an integral monitoring and control unit (“MCU”) that is operatively associated with the PSU and that is suitable for monitoring power supply status throughout an activation cycle, the MCU being characterised therein that upon occurrence of a fault condition, it automatically switches off certain circuits within the ECA system depending on the error condition.

7. The ECA system as claimed in claim 6 characterised therein that the MCU is adapted particularly to monitor and control one or more of the following variables, namely anolyte output flow rate; catholyte output flow rate; total system flow rate; pump motor current; PSU output; current drawn by each electrolytic cell; level of anolyte in an anolyte holding tank and level of catholyte in a catholyte holding tank; and wherein the MCU also provides user control means for switching on and switching off of the ECA system, as well as automatic shutdown capacity after completion of a production cycle.

8. The ECA system as claimed in claim 1 characterised therein that the system incorporates a feed preparation system arranged in fluid communication with the electrolytic cell exchange module for premixing a saline solution of fixed concentration so as to ensure that a consistent feed solution is presented to the electrolytic cells, the feed preparation system including at least one saline storage container for storing the premixed saline solution and from where the saline solution is fed directly into the electrolytic cells of the electrolytic cell exchange module under a controlled flow rate by means of pumping, gravity feeding, pressurised feeding or the like.

9. The ECA system as claimed in claim 8 characterised therein that only one premixed feed solution is used in the system and wherein variations in the activated solutions are achieved, inter alia, by varying the nature and concentration of the saline content of the feed solution, flow rate or hydraulic scheme, or by varying voltage applied to the electrolytic cells.

10. The ECA system as claimed in claim 1 characterised therein that the electrolytic cell exchange module is dimensioned for accommodating a series of electrolytic cells therein and, more particularly, is modularised to incorporate different numbers of electrolytic cells for different production volumes, and wherein the electrolytic cells is interconnected in the electrolytic cell exchange module electrically and/or hydraulically either in series or in parallel.

11. The ECA system as claimed in claim 1 characterised therein that the electrolytic cell exchange module includes pH control means, ORP and conductivity sensors incorporated within the same.

12. The ECA system as claimed in claim 1 characterised therein that the system also includes water softeners, which may be located in the electrolytic cell exchange module, for reducing the need for de-scaling of electrodes.

13. The ECA system as claimed in claim 1 characterised therein that the electrolytic cell exchange module includes a housing for protecting the enclosed electrolytic cells from impact and mishandling.

14. The ECA system as claimed in claim 1 characterised therein that the electrolytic cell exchange module includes at least one gas separation device adapted for trapping gasses produced during an electrolytic activation reaction.

15. The ECA system as claimed in claim 1 characterised therein that the electrolytic cell exchange module is removably arranged within the ECA system such that it can be taken off-site for de-scaling, servicing and maintenance of the electrolytic cells and subsequent reinstallation in the ECA system after reconditioning.

16. The ECA system as claimed in claim 1 characterised therein that the electrolytic cell exchange module incorporates a programmable logic controller (“PLC”) or a central processing unit (“CPU”) to facilitate control and administration of the electrolytic cells, wherein the PLC or CPU is adapted to control fluid flow through the electrolytic cells, automatically switching off after a predetermined volume of product has been generated and as such obliging a user to dispose of or exchange the electrolytic cell exchange module in order to maintain production efficiency and product quality.

17. The ECA system as claimed in claim 1 characterised therein that the electrolytic cell exchange module also incorporates electronic identification and tracking means (“ITM”) for uniquely identifying and tracking various component parts within the module, facilitating the use only of approved and authorised component parts and for indicating unauthorised tampering with the electrolytic cell exchange module.

18. The ECA system as claimed in claim 17 characterised therein that the ITM is operatively associated with the MCU and includes a micro-controller; a unique alphanumerical serial number; a secure communications interface; and a non-volatile memory containing the status and history log of each component part within the electrolytic cell exchange module.

19. The ECA system as claimed in claim 17 characterised therein that the ITM is integrated with each component part, e.g. in the form of an electronic micro-chip, so as to render the component part tamperproof, the arrangement being such that any attempt to divorce the ITM from the component part renders the latter inoperable.

20. The ECA system as claimed in claim 17 characterised therein that the ITM is adapted to capture status information during normal operation of the electrolytic cell exchange module and to keep track of the remaining operational period, the arrangement being such that when a pre-determined operating milestone is reached, the ITM sends a signal to the MCU to shut down the system so as to prevent further use of the electrolytic cell exchange module.

21. The ECA system as claimed in claim 18 characterised therein that the unique alphanumerical serial number is verifiable by the CPU and is correlated to one or more predetermined operational parameters, such as operating hours, allocation to a specific system at a particular site, or operating in conjunction with another component equipped with a similar ITM, which operational parameters is used to isolate specific identifying numbers to be allocated for use by the ECA system at a time of manufacturing and is decoded with an identical set of rules by the device performing the validation during normal operation.

22. The ECA system as claimed in claim 18 characterised therein that the secure communications interface is wired or wireless and data is communicated by means of a secure communications protocol.

23. The ECA system as claimed in claim 18 characterised therein that the non-volatile memory contains current and/or history status information pertaining to each component part, to the system AND/OR the environment within which the component part is used, the arrangement being such that measurements or observations are made internally or externally to the component part and saved to the non-volatile ITM memory.

24. The ECA system as claimed in claim 23 characterised therein that the history status information includes details regarding identity of a manufacturer; date of manufacture and production date stamp; identity of respective users; identity and access history of individual service technicians, number of de-scale cycles or operation cycles of the electrolytic exchange module; the number of conditionings and hours in service; number of service hours remaining before a reconditioning cycle (default start value is programmable); and the date of the last/previous conditioning.

25. The ECA system as claimed in claim 1 characterised therein that each electrolytic cell arranged within the electrolytic cell exchange module includes two c-axial cylindrical electrodes and a cylindrical diaphragm located co-axially between the two electrodes so as to separate an annular inter-electrode space into a co-axial, annular catholytic and an annular anolytic chamber arrangement, wherein the electrolytic cell has a relatively small, annular, cross-sectional total open area for fluid flow for allowing turbulent fluid flow there through so as to ensure maximum exposure of the solutions to the electric field, and wherein the electrolytic cell is adapted to produce an electrolytically, electrically or electrochemically activated, aqueous solution by means of electrolysis of a relatively low concentration aqueous salt solution.

26. The ECA system as claimed in claim 25 characterised therein that the electrolytically, electrically or electrochemically activated, aqueous solution is prepared from any one of the following solutions, namely an anion-containing solution; a cation-containing solution; a mixture of an anion-containing solution and a cation-containing solution; an anion-containing solution having been prepared from an anion-containing solution, a cation-containing solution or a mixture of an anion-containing solution and a cation-containing solution; and a cation-containing solution having been prepared from an anion-containing solution, a cation-containing solution or a mixture of an anion-containing solution and a cation-containing solution.

27. The ECA system as claimed in claim 25 characterised therein that the electrolytic cell is operated under a relatively low current, preferably of about 5 to 15 A, and a relatively high voltage, preferably of about 6 to 48 V, and more preferably between 12V and 36 V, for providing a relatively high voltage gradient or electric field intensity at the interface between the electrode surface and electrolyte, estimated to be about 106 V/CM.

28. The ECA system as claimed in claim 25 characterised therein that levels of saline concentration and mineral content of the feed solution, as well as operational variables of the electrolytic cell, such as flow rates, flow regimes, -paths, and-rates of recycle, currents and potential differences, are all adjustable so as to produce anolyte and catholyte with particular physical and chemical characteristics, with specific conductivity, redox potential and pH, concentration of “activated species” and other characteristics, for different specific applications.

29. An ECA system adapted for producing separable and both of an aqueous, mixed oxidant, predominantly anion-containing solution and an aqueous, mixed reductant, predominantly cation-containing solution, the ECA system being characterised therein that it includes at least one through-flow electrolytic cell; feed preparation means arranged in fluid communication with the electrolytic cell for introducing into the same a premixed saline solution of fixed concentration; distribution means, such as a hydraulic manifold, for distributing feed solution in a parallel, serial or hybrid manner, through the electrolytic cell; and collection means for continuously collecting the predominantly anion-containing and predominantly cation-containing solutions.

30. The ECA system as claimed in claim 29 characterised therein that the hydraulic manifold incorporates an integral, alternatively separate, means of gas/liquid separation for separating any gases produced as a result of electrolysis and for preventing formation of a gas or air lock in the hydraulic system.

31. An electrolytic cell exchange module characterised therein that it is designed for accommodating a series of electrolytic cells therein and, more particularly, is modularised to incorporate different numbers of electrolytic cells for different production volumes, and wherein the electrolytic cells is interconnected in the electrolytic cell exchange module electrically and/or hydraulically either in series or in parallel, and arranged in fluid communication with a feed preparation system.

32. The electrolytic cell exchange module as claimed in claim 31 characterised therein that it is removably arranged within an ECA system such that it can be taken off-site for de-scaling, servicing and maintenance of the electrolytic cells and subsequent reinstallation in the ECA system after reconditioning.

33. The electrolytic cell exchange module as claimed in claim 31 characterised therein that it incorporates a programmable logic controller (“PLC”) or a central processing unit (“CPU”) to facilitate control and administration of the electrolytic cells, wherein the PLC or CPU is adapted to control fluid flow through the electrolytic cells, automatically switching off after a predetermined volume of product has been generated and as such obliging a user to dispose of or exchange the electrolytic cell exchange module in order to maintain production efficiency and product quality.

34. The electrolytic cell exchange module as claimed in claim 31 characterised therein that it incorporates electronic identification and tracking means (“ITM”) for uniquely identifying and tracking various component parts within the module, facilitating the use only of approved and authorised component parts and for indicating unauthorised tampering with the electrolytic cell exchange module.

35. The electrolytic cell exchange module as claimed in claim 31 characterised therein that it includes pH control means, water softeners, and at least one gas separation device adapted for trapping gasses produced during an electrolytic activation reaction.

36. An electrochemical activation management (“ECAM”) system characterised therein that it is adapted to cooperate with an ECA system for managing removal, reconditioning and installation of electrolytic cell exchange modules and electrolytic cells of the ECA system, and which keeps track of movement and history of individual electrolytic exchange modules.

37. The ECAM system as claimed in claim 36 characterised therein that it is arranged in communication with one or more components of the ECA system by means of a direct or remote network or modem connection, the arrangement being such that data is collected from these components at a remote database and communicated through to a centralised master ECAM database for consolidation and correlation.

38. The ECAM system as claimed in claim 36 characterised therein that it correlates specific electrolytic cell exchange modules with customer and service centre information, the arrangement being such that information on the history of each of these is recorded in a centralised master ECAM database, which enables a manufacturer to manage and plan a manufacturing process better, schedule maintenance and be prepared for receiving electrolytic cell exchange modules that have reached the end of their life cycle.

39. The ECAM system as claimed in claim 36 characterised therein that it includes a cleaning unit adapted for remote cleaning and conditioning of the electrolytic cell exchange module, the cleaning unit comprising its own power supply means, monitoring and control unit, a cleaning solution dispenser, pump and an electrolytic cell exchange module holder, the configuration of the cleaning unit being such that it circulates cleaning solution through the electrolytic cell exchange module a number of times before disposing of the waste fluids, and wherein the final cycle of the cleaning process is a rinse cycle, which is used to wash out the electrolytic cell exchange module with clean water to remove final traces of deposits, as well as traces of the cleaning solution.

40. The ECAM system as claimed in claim 39 characterised therein that the cleaning process is performed without the need for manual intervention and further characterised therein that the cleaning unit includes its own ITM for saving operational information in its own status and history log, and is also adapted to save specific parameters onto the ITM of the electrolytic cell exchange module, for example a unique identification and access code for the service technician, the date of last conditioning, identification of the cleaning unit used, and the number of conditionings and service hours remaining.

41. The ECA system as claimed in claim 2 characterised therein that each electrolytic cell is associated with at least one dedicated in-line miniature field-effect transistor-based pH, ORP and conductivity sensor, which is located in either the PSU of MCU, the arrangement being such that each electrolytic cell constitutes a modular and independent unit.

42-44. (canceled)