Abstract:
An apparatus for producing electrolyzed water includes an electrochemical cell and a solution reservoir containing a solution and having an outlet. An injection pump has an input end in fluid communication with the outlet of the solution reservoir and an output end in fluid communication with the electrochemical cell, wherein the injection pumps an amount of the solution from the solution reservoir to mix with a water solution and enter the electrochemical cell. A current feedback sensor senses a cell current in the electrochemical cell. A current control unit in data communication with the current feedback sensor and the injection pump wherein the current control unit compares the cell current with a preselected current and adjusts the amount of solution pumped from the injection pump responsive to the comparison. The apparatus may also include an automatic control feedback system to monitor and adjust pH.

Description:
RELATED APPLICATIONS 
     This application claims the benefit under §119(e) of U.S. Provisional Application Ser. No. 60/617,159, filed on Oct. 8, 2004, which is hereby incorporated by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to an apparatus and method for producing stabilized electrolyzed water, and more particularly to a system that includes a control feedback loop responsive to a predetermined optimum current to control cell water quality output. 
     BACKGROUND OF THE INVENTION 
     Electrolyzed oxidizing (EO) water has been conventionally produced. Electrolyzed water is classified into three types: acidic electrolyzed water (germicidal, used for hygienic purposes), alkaline ionized water (having medical effects; drinking water), and alkaline electrolyzed water (lipid-detergent). Acidic electrolyzed water is used to sanitize food-processing equipment and fresh-cut vegetables in food industries, because of its great potential for food-related and other disinfecting processes due to its high bacterial activity. 
     Acidic EO water is normally generated from the anode electrode through electrolysis of a dilute aqueous NaCl solution. The Cl −1  ions are electrochemically oxidized to Cl 2  gas on the anode surface, which gas is partially hydrolyzed to hypochlorous acid (HOCl) in solution phase and to other ions. The relatively high batericidal activity of the acidic EO water is attributed to so-called active chlorine which comprises dissolved Cl 2 , OCl − , and HOCl, and is also attributed to the high oxidation-reduction potential (ORP) of the acidic EO water. However, the dissolved Cl 2  is readily evaporated or otherwise lost from the acidic EO water during storage or a treatment period, resulting in a loss of batericidal activity over time. This loss may also affect other important properties of EO water, such as its pH, ORP, and HOCl concentration, which should be known for proper use of the acidic EO water in a given service application. 
     Prior versions of electrolyzing devices include a system for producing electrolyzed oxidizing (EO) water wherein feed water solution including a saline solution component is supplied to an electrolytic cell comprising both an anode chamber and a cathode chamber. The feed water solution is cathodically electrolyzed in the cathode chamber to produce EO water as an antioxidant solution called alkaline catholyte. Catholyte is a mild alkaline solution with a pH range of 10.5 to 12.0 and ORP of −600 to −900 mV. The feed water solution is anodically electrolyzed in the anode chamber to produce EO water as an oxidant solution called anolyte, whose pH is modified in the process. Anolyte is a strong oxidizing solution with a pH range of 0.0-8.5 and an Oxidation-Reduction Potential (ORP) of +600 to +1200 mV. 
     It is desirable to have a preselected current maintained consistently in the electrochemical cell. Prior versions, however, had difficulties maintaining the current of the electrochemical cell at a current relatively close to the preselected current. 
     SUMMARY OF THE INVENTION 
     The invention includes an apparatus for producing electrolyzed water. The apparatus includes an electrochemical cell and a solution reservoir containing a solution and having an outlet. The invention also includes an injection pump having an input end in fluid communication with the outlet of the solution reservoir and an output end in fluid communication with the electrochemical cell, wherein the injection pumps an amount of the solution from the solution reservoir to mix with a water solution and enter the electrochemical cell. The apparatus also includes a current feedback sensor to sense a cell current in the electrochemical cell and a current control unit in data communication with the current feedback sensor and the injection pump wherein the current control unit compares the cell current with a preselected current and adjusts the amount of solution pumped from the injection pump responsive to the comparison. 
     Another embodiment of the apparatus includes an electrochemical cell having an input portion and an output portion and a solution reservoir containing a solution and having an outlet in fluid communication with an electrochemical call. The apparatus further includes a blend pump having an input end in fluid communication with a catholyte solution exiting the output portion of the electrochemical cell and an output end in fluid communication with the solution from the solution reservoir entering the electrochemical cell wherein the blend pump pumps an amount of the catholyte solution from the output portion of the electrochemical cell to mix with the solution entering the electrochemical cell. The apparatus further includes a pH feedback sensor to sense an output pH of an amount of solution exiting the electrochemical cell and a pH control unit in data communication with the pH feedback sensor and the blend pump, wherein the pH control unit compares the output pH with a preselected pH and adjusts the amount of catholyte solution pumped from the blend pump responsive to the comparison. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a schematic diagram of the system in accordance with the present invention. 
         FIG. 2  shows a sectional view of the electrochemical cell of  FIG. 1 . 
         FIG. 3  shows a diagram of the steps included in the method in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Although the following detailed description contains many specific details for purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the exemplary embodiment of the invention described below is set forth without any loss of generality to, and without imposing limitations thereon, the claimed invention. 
     Referring to  FIG. 1 , water is provided from a water source  10  into a flow line  15  that supplies the water to a conventional EO water electrochemical cell  20 . A variable speed injection pump  25  receives an aqueous solution from a solution reservoir  30  comprising, for example, a dilute sodium chloride (NaCl) solution. Alternatively, for example, hydrochloric acid, potassium chloride, magnesium chloride, and other salt compounds may be utilized in the solution reservoir  30 . 
     The injection pump  25  pumps an amount of saline into the flow line  15  to mix with the water before entering the electrochemical cell  20 , thus forming a feed water solution mixture to be electrolyzed. The feed water solution to be electrolyzed typically comprises a dilute aqueous NaCl solution, such as 0.01% to 25% by weight NaCl solution, although the invention can alternatively be practiced to electrolyze other aqueous solutions of KCl, MgCl 2  and other salts. 
     Referring to  FIG. 2 , an electrochemical cell  20  is formed by placing metallic electrodes  45 ,  47  into an electrolyte where a chemical reaction either uses or generates an electric current. The form of electrochemical cell  20  utilized in the invention is one in which an externally supplied electric current is used to drive a chemical reaction that would not occur spontaneously. 
     Electrochemical cell  20  includes a plurality of anode chambers  35  and cathode chambers  37  (only one shown) separated by a membrane  40 . One or more flat plate-like anode electrodes  45  and cathode electrodes  47  (one of each electrode shown) are disposed in the anode chambers  35  and cathode chambers  37 , respectively. The anode and cathode electrodes  45 ,  47  can comprise titanium or titanium coated with a precious metal, such as platinum, or alternatively any other suitable electrode material. The cell electrodes  45 ,  47  preferably have a fixed surface area. The membrane  40  can comprise either a non-ion selective separator membrane comprising, for example, non-woven polyester fabric, or an ion selective permeable membrane comprising, for example, a perfluorosulfonate ionomer. When the feed water solution to be electrolyzed comprises a dilute aqueous NaCl saline solution, the membrane  40  allows Na +  ions to move toward the cathode electrode  47  from the anode chamber  35  and Cl −  ions to move toward the anode electrode  45  from the cathode chamber  37 . The membrane  40  is spaced between the electrodes by electrically insulating plastic spacers. The electrodes  45 ,  47  are connected to a conventional electrical power supply  50 . 
     The feed water solution is supplied to both the anode chambers  35  and cathode chambers  37  via a feed water solution supply conduit  54  that is branched to have an anode supply conduit section  56  and cathode supply conduit section  58  from the common conduit  54 . The anode supply conduit section  56  supplies the feed water solution only to anode chambers  35  via a manifold (not shown) that communicates with each of the plurality of anode chambers  35 . The cathode supply conduit section  58  supplies the feed water solution only to cathode chamber  37  via a manifold (not shown) that communicates with each of the plurality of cathode chambers  37 . 
     The feed water solution is cathodically electrolyzed in the cathode chambers  37  to produce EO water as alkaline catholyte. The feed water solution is anodically electrolyzed in the anode chambers  35  to produce EO water as anolyte whose pH may be modified or adjusted. The pH-modified anolyte is discharged from the anode chambers  35  by way of an anolyte discharge conduit  60  for collection and use. The catholyte is discharged from the cathode chambers  37  by way of a catholyte discharge conduit  62  for collection, and in some embodiments may be recycled back to the anode chambers  35 . 
     The pH of the anolyte discharged by way of conduit  60  from anode chambers  35  is controlled to be above approximately 5, and preferably between about 5 to 6, in order to provide more stable bactericidal activity over time where the active chlorine concentration of the anolyte is generally constant at all pH values in that range. Some applications benefit from producing an EO acidic output water at a higher pH to reduce potential corrosion of some surfaces that will be cleaned and to provide a more stable solution to preserve its bactericidal activity over longer periods of time. The invention is capable of generating EO acidic water over a wide range of outlet pH through the use of an automated pH control loop which controls the amount of catholyte recirculated to the inlet of the cell. This automated pH control loop and the separate cell current control loop provide the ability to independently adjust the chlorine concentration and the pH. This allows the user to select a pH setpoint of between 5 and 6 where nearly 100% of the chlorine generated in the more stable form of HOCl, hypochlorous acid. 
     Referring to  FIG. 1 , the pH of the acidic EO output water is measured by a pH sensor  80  located in the anolyte discharge conduit  60 , which provides feedback of actual pH to a pH controller  85 . The controller  85  automatically adjusts the speed of a blend pump  90  to control the actual pH to the pH setpoint of the controller  85 . The blend pump  90  is connected to output line  62  and discharges to a mixing chamber  95  wherein the recirculated catholyte is thoroughly mixed with the water from the water source  10  and the solution from reservoir  30 . Sensor  80 , pump  90 , and mixing chamber  95  comprise the automated pH control loop. 
     The power consumed in the electrolytic cell  20  affects the properties of the EO water leaving the cell  20 . The electrolytic cell  20  preferably operates in a flooded condition, which causes the cell  20  to act as a variable resistor. Thus, varying the conductivity of the water in turn varies the cell  20  resistance. If voltage from the power supply  50  is held constant, as it is in some embodiments, then varying the conductivity of the water in the cell  20  may control the power to the electrolytic cell  20 . 
     Referring to  FIG. 1 , a control unit  70  controls the pump speed of the saline injection pump  25 , and thus controls the relative amount of saline injected into the electrochemical cell  20 . An automatic feedback control loop is included in the system, enabling the control unit  70  to adjust and optimize the amount of saline injected into the cell  20 . The control unit  70  operates responsive to feedback information from a current sensor  75  located between the power supply  50  and the electrochemical cell  20 . Current sensor  75  senses the current supplied by the power supply  50 . 
     The control unit  70  is provided with a value for the optimum current setpoint, which is predetermined and independently established. The automatic feedback loop comprising current sensor  75 , control unit  70 , and pump  75  provides feedback data of the actual cell current detected by the current sensor  75  to the control unit  70 , and the control unit  70  responds by comparing the actual cell current with the setpoint current to determine the proper adjustment to the speed of the injection pump  25 . 
     In operation, power is supplied to the electrochemical cell  20  from the power supply  50 . The pump  25  delivers the solution from the solution reservoir  30  to mix with the water and any fluid pumped from the blend pump  90  to mix therewith. The current sensor  75  provides a feedback signal of the actual cell current consumed by the electrochemical cell  20 , and communicates the actual cell current information back to the control unit  70  through an automatic control feedback loop. The control unit  70  receives the feedback signal from the current sensor  75 , and responds by comparing the amps of the actual cell current with the amps of the predetermined optimum setpoint current. If the actual cell current does not equal the setpoint current, the control unit  70  changes or adjusts the output signal to the saline injection pump  25  to vary the pump speed. If the actual cell current is greater than the setpoint current, the pump speed is decreased. If the actual cell current is less than the setpoint current, the pump speed is increased. 
     Varying the pump speed of the injection pump  25  accordingly varies the amount of saline injected into the electrochemical cell  20 , and as a result changes the conductivity of the feed water solution that enters the cell  20 . The corresponding change or adjustment in conductivity will result in an adjustment of the resistance in the electrochemical cell  20 , and thus will result in an adjustment of the actual cell current toward the setpoint current. Such a feedback control system continues indefinitely until the actual cell current adjusts to become substantially equal to the predetermined optimum setpoint current, in order to ultimately optimize water quality output from the electrochemical cell  20 . 
     The invention has several important advantages. The automatic current control feedback loop controls the electrochemical cell by automatically adjusting the conductivity of the water fed to the cell. Further, the system automatically adjusts the amount of chlorine generated to achieve the desired chlorine level. Further, the pH of the EO acidic output water may be automatically controlled by the pH feedback loop responsive to comparisons between the actual pH of the cell current and a predetermined optimum setpoint pH. The combination of these two automated control loops allows independent adjustment of HOCl and pH to allow the output water to be optimized to suit the specific application. 
     The invention can be practiced to produce anodically electrolyzed water for use in many hygiene-sensitive service applications for on-site generation of stable and strong disinfecting solution. Such applications include washing food surfaces, such as poultry products and fresh produce, as well as cleaning food contact surfaces such as food processing equipment, food handling facilities, utensils, and also washing hands in food industries, restaurants, service centers, and homes. The anolyte produced pursuant to the invention also is useful for cleaning other surfaces such as floors, carpets, and shower curtains to reduce cross-contamination in medical/dental services, homes, and nursing care facilities. The invention is also suited for agricultural applications to replace other chemical pesticides and fungicides. 
     Although some embodiments of the present invention have been described in detail, it should be understood that various changes, substitutions, and alterations can be made hereupon without departing from the principle and scope of the invention. Accordingly, the scope of the present invention should be determined by the following claims and their appropriate legal equivalents.