ELECTRODE APPARATUS FOR REMOVING CONTAMINANTS FROM A FLUID
20210323848 · 2021-10-21
Assignee
Inventors
- Thomas Schuelke (Pinckney, MI, US)
- Mary K. ENSCH (Belleville, MI, US)
- Michael Becker (East Lansing, MI, US)
- Cory A. RUSINEK (Las Vegas, NV, US)
Cpc classification
C02F2209/006
CHEMISTRY; METALLURGY
International classification
Abstract
An electrode apparatus for removing contaminants from a fluid is provided. In another aspect, an electrochemical destruction apparatus for wastewater effluent using Boron-doped diamond electrodes is employed. A further aspect of the present apparatus includes a fluid-carrying conduit, electrodes located within the conduit, an electrical controller connected to the electrodes, a sensor connected to the controller being adapted to sense a chemical characteristic associated with contaminants in the fluid, and the controller automatically varying an electrical characteristic associated with at least one of the electrodes based, at least in part, on an input from the sensor. Yet another aspect includes a programmable controller and software which automatically employ a feedback control loop to increase or decrease electrical current density to contaminant-removing electrodes.
Claims
1. An apparatus comprising: a fluid-carrying conduit; electrodes located within the conduit being adapted to contact waste fluid flowing therethrough; an electrical controller connected to the electrodes; a sensor connected to the controller being adapted to sense a chemical characteristic associated with contaminants in the fluid; the controller being adapted to automatically vary an electrical characteristic of at least one of the electrodes based at least in part on an input from the sensor due to the chemical characteristic detected during the fluid flowing past the electrodes; and the electrical characteristic being adapted to cause the contaminants to be removed from the fluid.
2. The apparatus of claim 1, wherein: the contaminants include PFAS; at least two of the electrodes each comprise a middle section with holes spanning across a hollow fluid-flow path of the conduit; at least some of the holes of a first of the at least two of the electrodes are laterally offset from at least some of the holes of a second of the at least two of the electrodes, to create a turbulent flow of the fluid therebetween; at least one of the electrodes comprises a Boron-doped diamond layer; the electrical characteristic comprises an electrical current density increase or decrease after electricity is initially supplied to an anode of the electrodes; and the fluid is a waste liquid.
3. The apparatus of claim 1, wherein: at least two of the electrodes each comprise a middle section with holes spanning across a hollow fluid-flow path of the conduit; at least some of the holes of a first of the at least two of the electrodes are laterally offset from at least some of the holes of a second of the at least two of the electrodes, to create a turbulent flow of the fluid therebetween.
4. The apparatus of claim 1, wherein the electrical characteristic comprises an electrical current density increase or decrease after electricity is initially supplied to an anode of the electrode.
5. The apparatus of claim 1, wherein the electrical characteristic comprises periodically reversing polarity between the electrodes.
6. The apparatus of claim 1, wherein the sensor is a potentiometric measuring sensor.
7. The apparatus of claim 1, wherein the sensor is a fluoride ion selective electrode detector.
8. The apparatus of claim 1, wherein the sensor detects at least one of: pH, electrical conductivity, temperature or flow rate, of the fluid which includes water.
9. The apparatus of claim 1, wherein the electrodes destroy the contaminants.
10. The apparatus of claim 1, wherein the controller automatically varies at least one of: electrical conductivity, flow rate, temperature or pH, of the fluid to remove the contaminants depending on the input of the sensor.
11. The apparatus of claim 1, wherein the controller varies the characteristic, which is an amount of an electrical current density, depending on a concentration or species of the contaminants detected.
12. The apparatus of claim 1, wherein the electrodes include a stacked sandwich of alternating and spaced apart cathodes and anodes each with a fluid flow hole therein, the cathodes and anodes span transversely across a flow path of the fluid, and a central portion of the fluid flows in a substantially straight path from the conduit to an upstream one of the electrodes.
13. An apparatus comprising: a conduit carrying water therethrough; electrodes comprising a stacked sandwich of alternating and spaced apart cathodes and anodes each with a flow hole therein, the cathodes and anodes spanning transversely across a flow path of the conduit; at least one of the electrodes comprising a flat metallic substrate with a Boron-doped diamond layer thereon; an electrical controller connected to the electrodes, the electrical controller including non-transient memory within which is stored programmed software instructions, the instructions comprising an automated feedback control loop which changes electrical current density supplied to the electrodes; and the electrodes causing contaminants to be removed from the water.
14. The apparatus of claim 13, further comprising: a sensor connected to the controller and being adapted to sense a chemical characteristic associated with the contaminants in the water; and the software instructions varying an electrical characteristic of at least one of the electrodes based at least in part on an input from the sensor due to the chemical characteristic detected during the water flowing through the flow holes in the electrodes.
15. The apparatus of claim 13, wherein there are multiple of the flow holes in each of the electrodes, and at least some of the flow holes of the anodes are laterally offset from at least some of the holes of the cathodes, to create a turbulent flow of the water therebetween.
16. The apparatus of claim 13, wherein the software comprises instructions increasing or decreasing the electrical current density after electricity is initially supplied to the anodes, the contaminants include PFAS, and a central portion of the water flows in a substantially straight path from the conduit to an upstream one of the electrodes.
17. The apparatus of claim 13, wherein the software comprising instructions reversing polarity between the electrodes.
18. The apparatus of claim 13, wherein the controller automatically varies at least one of: electrical conductivity, flow rate, temperature or pH, of the water to remove the contaminants.
19. The apparatus of claim 13, further comprising: a holding tank; the contaminated water being fed into the holding tank; a pump pumping the water from the holding tank to the electrodes along the conduit; and the water flowing multiple cycles through the same conduit and the same electrodes before the water, in a cleaned state, exits an outlet.
20. A method of removing contaminants from a fluid, the method comprising: (a) flowing the fluid through an anode and a cathode which are spaced apart from each other; (b) sensing a chemical characteristic associated with the contaminants in the fluid; (c) varying an electrical characteristic of at least one of the anode and the cathode based at least in part on a sensed input; and (d) removing the contaminants from the fluid in response to energization of the anode and the cathode.
21. The method of claim 20, further comprising: automatically and in a closed-loop manner increasing or decreasing the electrical characteristic, which includes electrical current density, after electricity is initially supplied to the anode; and flowing a portion of the fluid, which includes water, to an upstream one of the anode and the cathode, without aeration, cavitation or bubbling of the water.
22. The method of claim 20, further comprising automatically reversing polarity between the anode and the cathode.
23. The method of claim 20, further comprising automatically varying at least one of: electrical conductivity, flow rate, temperature or pH, of the fluid to remove the contaminants.
24. The method of claim 20, further comprising: energizing multiples of the anode and multiples of the cathode; flowing the fluid through a conduit, the anodes and the cathodes being alternately stacked and spanning laterally across the conduit; and creating a turbulent flow of the fluid between the anodes and the cathodes as the fluid flows through holes which are offset from each other for at least one of the anodes and at least one of the cathodes.
Description
BRIEF DESCRIPTION OF DRAWINGS
[0008]
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DETAILED DESCRIPTION
[0017] An electrode apparatus 21 for removing contaminants from a fluid can be observed in
[0018] Pass-through reactor 25 includes a hollow central conduit 51 through which laterally extend and span anode and cathode electrodes 53 and 55, respectively. Conduit 51 can be a single pipe with lateral slots or multiple, coaxially arranged pipes segments. The electrodes are preferably arranged in a sandwich of alternating cathodes and anodes. This alternating cathode-anode-cathode-anode-cathode configuration advantageously provides assembly flexibility and simplicity. Electrically insulating and sealing gasket-like spacers 57 have an annular and hollow configuration, and are clamped between each adjacent pair of electrodes. The electrodes are clamped together by fasteners 59 such as threaded bolts and nuts on each lateral side of conduit 51, which extend through fastener holes in the electrodes. Moreover, stamped sheet metal electrical connectors are fastened to cathodes 55 on one lateral side of the conduit, while a similar electrical connector is fastened to each anode 53 on the opposite lateral side of the conduit. Threaded bolt and nut fasteners may be employed although it is also envisioned that solder or rivet fasteners may alternately be used to secure the connectors to projecting tails of the electrodes. To condense the packaging of the stacked sets of electrodes, alternating electrodes may be arranged laterally perpendicular to the adjacent ones such that their projecting tails are 90° offset between each adjacent electrode depending on the peripheral shapes of the electrodes.
[0019] This arrangement, after being electrically connected to an electrical circuit, is covered within an outer housing 77. Alternately, sets or groupings of three adjacent electrodes may be arranged in a sandwich of one upper cathode and one lower cathode with one anode therebetween, and gaskets are located between each set; this configuration advantageously provides added structural and mechanical stability when many electrodes are used.
[0020] As can be seen in
[0021] Each electrode 53 and 55 includes a Boron-doped diamond film or coating applied to a base substrate by microwave plasma-assisted chemical vapor deposition or hot filament chemical vapor deposition. The substrate is preferably a metal, such as molybdenum, niobium or tantalum. Alternately, free-standing Boron-doped diamond plates without substrate or electrically conductive silicon material, may be used. This BDD coating adds durability to the electrodes to avoid otherwise more frequent replacement during use and to also avoid the electrodes prematurely oxidizing themselves. The BDD material is ideally suited for a PFAS removing electrode since the diamond bond assists in breaking down the PFAS chemistry at least in part due to the diamond being a good hydroxyl radical promoter. It is also noteworthy that the relatively large surface area on both sides of the middle section of each electrode provides a desirable electrical potential drop between the adjacent spaced-apart electrodes in each set within reactor 25.
[0022] Thus, with this electrochemical oxidation technique in combination with the BDD electrodes and the automated control system to be discussed in greater detail hereinafter, mechanical filters are not needed for the PFAS removal. That said, additional chemicals, pH adjustments or filters may optionally be employed for other reasons within the plumbing circuit. It is expected with the present apparatus will significantly reduce energy consumption while effectively removing and even breaking down difficult to handle contaminants such as PFAS from a water supply. It is noteworthy that a central portion of the water flows in a substantially straight and direct path from the conduit (ignoring any incidental conduit surface-induced eddy currents) to an upstream one of the electrodes such that energy wasting aeration, cavitation and/or bubbling are not necessary to remove PFAS contaminants within the preferred example of the present apparatus.
[0023] An electrical circuit can be observed with reference to
[0024] Controller 93 includes a microprocessor, an output display screen 111, a keyboard 113, and an electrical circuit 115. It should be appreciated, however, that other input and output devices such as lights, switches and the like may be used. Controller 93 also includes memory upon which is stored programmable software instructions, in a non-transient form.
[0025] Sensor 95 may be a potentiometric measuring device such as a pH probe or electrode. For example, a fluoride ion selective electrode detector can be used. Furthermore, electrical conductivity, temperature and liquid flow rate may optionally be sensed, measured and automatically controlled in a closed loop feedback manner for the fluid passing through the present system.
[0026] The software instructions and control logic are illustrated in
[0027] The following nonlimiting examples set forth one possible automated real-time feedback loop methodology. The control variation for precursor molecules of contaminant A may initially apply a high current density (“CD”) and thereafter a low CD, either during a single cycle or providing the higher value in a first cycle and then the lower value in a reused second cycle of the same recycled fluid. The CD can subsequently be further reduced for any additional recycling of the fluid before it is finally discharged. These CD reductions for recycled configurations advantageously reduce the power consumption needs for the second and subsequent cycles. For the contaminant B example which contains long-chain molecules, an even greater CD can be employed at the anodes in a first cycle and then a lower CD may be used for subsequent cycles. And then with exemplary contaminant C which contains short-chain molecules, an even higher CD can be employed for both cycles of the same fluid if attraction of the contaminants to the electrodes and subsequent chemical breakdown of the contaminants by the electrodes requires this larger energy consumption in one or subsequent cycles of the fluid. Thus, the controller varies an electrical characteristic of at least one of the electrodes depending on a concentration and/or species of contamination detected. This multi-tiered automated feedback control is ideally suited where different contaminants may be present within the same wastewater treatment plumbing circuit such as a municipal or industrial wastewater treatment system which may contain PFAS, pharmaceutical chemicals, ammonia, uranine and the like, and the type of contaminant may or may not be present hour-to-hour or day-to-day.
[0028] In another example, the controller and software instructions may periodically reverse the polarity between the electrodes after a predetermined number of cycles or after real-time performance detection in the reactor, to flush the reactor and prevent or deter electrode fouling. Moreover, the present controller and software instructions may automatically vary an electrical characteristic, such as current density, to one set of electrodes different than another set of electrodes, within the same reactor based upon real-time sensed measurements of the fluid flowing therethrough.
[0029] The present apparatus can alternately be employed for remotely removing PFAS from a drinking water treatment unit when the unit is mostly saturated and then removed from the attached fresh water plumbing. One example of such a treatment unit is disclosed in International Patent Application Serial No. PCT/US20/18585 entitled “Electrode Apparatus for Creating a Non-Uniform Electric Field to Remove Polarized Molecules in a Fluid” which was invented by Fan et al. This PCT application is incorporated by reference herein.
[0030] Returning to the alternate construction shown in
[0031] An analytical characterization of BDD electrodes 53 and 55 is completed with an exposed surface area of 2.66×10.sup.−04 cm.sup.2. The polycrystalline BDD film preferably has uniform grain sizes of about 4-6 μm in diameter. A Boron concentration of −5×10.sup.20 cm.sup.−3 is employed. This allows the diamond film to exhibit semi-metallic conductivity.
[0032] Referring to
[0033] The starting concentration of each PFOA experiment is 6.5 parts per million (“ppm”). Cell voltages span +4 to +9 V. All test volumes start at room temperature and reach a maximum of 40° C. for the highest CD value. For the 1 mA/cm.sup.2 trials, the pH remains mostly constant at ˜5.0. At higher CDs, tests begin at a pH 5.0 and increase to ˜10.5.
[0034] BDD is an efficient producer of hydrogen gas and therefore, an abundance of hydroxyl ions are generated at the cathode surface. Moreover, electrolysis using BDD increases the pH to 11 with an applied current of −8 μA. At the highest applied current, it is possible to increase the local pH by 5 units. The present mechanism may be different for an experiment performed at 1 mA/cm.sup.2 that has a constant pH.
[0035] Each CD study is fit to 1st order kinetics. Every CD except 50 mA/cm.sup.2 has an average (n=3) linear coefficient of determination (R.sup.2) greater than 0.99. 50 mA/cm.sup.2 yielding an R.sup.2 of 0.96. The following Table 1 shows average 1st order rate constants (k.sub.o) expected for each CD study. The k.sub.o value increases as the CD increases. From
TABLE-US-00001 TABLE 1 Figures of merit for the standard CD studies, concentrations based on ISE. Current Average Average Average Density PFOA k.sub.0 linear PFOA (mA/cm.sup.2) (h.sup.−1) fit for k.sub.0 remaining (ppm) 1 0.44 ± 0.1 0.9981 4.3 ± 0.2 5 0.94 ± 0.1 0.9995 2.6 ± 0.2 10 1.24 ± 0.2 0.9979 2.0 ± 0.3 25 1.69 ± 0.3 0.9938 1.4 ± 0.5 50 2.25 ± 0.3 0.9669 0.9 ± 0.2
[0036] This is further supported by expected mixed CD studies of
[0037] The PFOA concentration values should begin to differ at each time point once the CD is lowered. The combination of 50 mA/cm.sup.2 and 1 mA/cm.sup.2 (50&1) provides the least degradation of PFOA. 50-5 and 50-10 should yield similar degradation rates and final PFOA concentrations. The 1st order rate constants for the whole hour will not have linear fits above 0.97.
[0038] The combined CD results should be fit to a sequential 1st order model. The 1st order rate constant for the first 0.25 hour, k.sub.1, and that for the remaining time of 0.25 to 1 h, k.sub.2, are determined. The average k.sub.1 for the first 0.25 hour of all mixed CD runs are expected to be around 2.4±0.3 hour.sup.−1. This should be a similar value as an obtained rate constant for the solo run of 50 mA/cm.sup.2, 2.3±0.3 hour.sup.−1. k.sub.2 is examined to determine if it changes when starting with a lower concentration (after 0.25 hour of degradation at 50 mA/cm.sup.2). These expected values are shown in Table 2 below. All these rate constants exhibit good linearity with R.sup.2 greater than 0.98. They are similar to k.sub.0 that should be obtained for the individual CD studies (Table 1).
TABLE-US-00002 TABLE 2 Figures of merit for the mixed CD studies, concentrations based on ISE. Current Average Average Average Density PFOA k.sub.1 PFOA k.sub.2 PFOA (mA/cm.sup.2) (h.sup.−1) (h.sup.−1) remaining (ppm) 50 & 1 2.51 ± 0.2 0.51 ± 0.1 2.39 ± 0.1 50 & 5 2.58 ± 0.4 1.15 ± 0.3 1.55 ± 0.4 50 & 10 2.08 ± 0.3 1.11 ± 0.1 1.71 ± 0.1
[0039] Overall, 50-5 is chosen over 50-10 to degrade PFOA if utilizing the present mixed CD apparatus. 50-5 has the highest k.sub.1 and k.sub.2 values. 50-5 has a larger standard deviation in its rate constants compared to 50-10 but obtains roughly 0.16 ppm lower remaining of PFOA after 1 hour. 50-5 should have slightly higher PFOA remaining compared to 25 mA/cm.sup.2 but 9 kW/m.sup.3 lower energy; suggesting that instead of running 25 mA/cm.sup.2, 50-5 could be more economical. Therefore, lowering the CD after the first 0.25 hour will obtain similar results as applying the higher CD for the whole test in this experimental setup.
[0040] To determine if shorter-chain PFAS are being formed, liquid chromatography-mass spectroscopy (“LC-MS”) measurements may be used. The ISE measures free F.sup.− as an indirect method of PFOA concentration while LC-MS directly measures the actual PFOA concentration. As such, utilizing the LC-MS analysis can provide insight into generation and presence of shorter-chain PFCAs in the wastewater, thereby causing the controller to automatically vary the CD electrical characteristics.
[0041]
[0042] An alternate configuration of the present sensor and feedback control loop can be used to vary a characteristic associated with temperature and/or pH, in addition to or instead of the electrical current density. If a temperature characteristic is changed, then a heating element is activated and energized to heat the fluid flowing thereby. If pH is changed, then the controller will activate a valve to add a buffer solution (using an environmentally-friendly chemical not including a chloride salt) from a reservoir coupled to the present plumbing system.
[0043] While various features of the present invention have been disclosed, it should be appreciated that other variations can be employed. For example, other or additional types of plumbing or electrical components may be used although certain benefits may not be achieved. Furthermore, while the fluid preferably includes water, other fluids may be employed, although some advantages may not be realized. It should be appreciated that features of one embodiment may be interchanged with features of another embodiment in any combination and order, and the claims may be multiply dependent upon each other and in any combination. Variations are not to be regarded as a departure from the present disclosure and all such modifications are intended to fall within the scope and spirit of the present invention.