SYSTEM AND METHOD FOR PRODUCING TEMPERATURE STABLE CHEMICAL SOLUTIONS

Abstract

A system for automatically producing a brine solution having a concentration of a primary solute that is stable at a defined temperature comprises a controller, a mixing reservoir, a primary solute concentration sensor, and a storage tank. Methods for automatically producing solutions are described.

Claims

1. A method for automatically producing a brine solution having a concentration of a primary solute that is stable at a defined temperature, the method comprising the steps of: inputting into a controller a storage temperature of a primary solute in the brine solution; inputting into the controller an identity of at least one additive and a concentration of the additive in the brine solution; initiating the controller to generate a chemical brine solution composition with the primary solute and the at least one additive, the solution composition having concentrations of each of the primary solute and the at least one additive corresponding with the storage temperature; mixing the primary solute with a solvent to form a chemical solution and measuring the chemical solution with a primary solute concentration sensor to verify that the concentration of the primary solute is within a target concentration, the concentration sensor communicating a concentration of the primary solute in the chemical solution to the controller; comparing the primary solute concentration of the brine solution to a target concentration of the primary solute, diluting the brine solution with the solvent if the primary solute in the brine solution is over-concentrated, increasing the concentration of the primary solute in the brine solution if the primary solute in the brine solution is under-concentrated; automatically diverting the brine solution to a storage tank if the primary solute concentration in the brine solution is within tolerance of the target concentration for the primary solute; and mixing the at least one additive into the brine solution at a quantity and at a rate determined by the controller for the chemical brine solution composition.

2. The method of claim 1, further comprising inputting into the controller the identity of a plurality of additives and the concentration of each of the additives.

3. The method of claim 1, wherein automatically diluting the solution comprises adding solvent to the chemical solution and wherein automatically increasing the concentration of the chemical slurry comprises adding primary solute to the chemical solution.

4. The method of claim 1, further comprising data logging quantity of brine solution produced.

5. The method of claim 1 further comprising in-line mixing the at least one additive into the brine solution at a quantity and at a rate determined by the controller for the chemical brine solution composition and then diverting a final brine solution to another container.

6. The method of claim 1 further comprising diverting a final brine solution to another container and then adding the at least one additive into the brine solution at a quantity and at a rate determined by the controller for the chemical brine solution composition.

7. A system for automatically producing a brine solution having a concentration of a primary solute that is stable at a defined temperature, the system comprising: a controller configured to receive a storage temperature of a primary solute in the brine solution as a first input, the controller configured to receive a second input comprised of an identity of at least one additive and a concentration of the additive to be blended with the primary solute solution, the controller further configured to generate a chemical brine solution composition comprised of the primary solute and in-line mixing of the at least one additive, the solution composition having concentrations of each of the primary solute and the at least one additive configured by the controller to correspond with the storage temperature and prevent primary solute precipitation; a mixing reservoir configured to receive the primary solute and a solvent to form therein a chemical solution; a primary solute concentration sensor disposed within the mixing reservoir and configured to measure the concentration of the primary solute in the chemical solution, the concentration sensor communicating a concentration of the primary solute in the chemical slurry to the controller, wherein the controller is configured to verify that the concentration of the primary solute is within a target concentration; and a storage tank for receiving the brine solution after being diverted by the controller from the mixing reservoir, the storage tank further configured to receive the at least one additive at a quantity and a rate determined by the controller for the chemical brine solution.

8. The system of claim 7, further comprising a human machine interface operatively coupled to the controller for receiving the first and second inputs from a user.

9. The system of claim 7, wherein the controller is further configured to receive a plurality of inputs comprised of additive identities and associated additive concentrations.

10. The system of claim 9, wherein the controller is further comprises a memory portion for receiving data associated with the amount of brine solution produced for each primary solute and additive combination.

11. A method for automatically producing a final chemical solution having a concentration of a primary solute that is stable at a defined temperature, the method comprising the steps of: inputting into a controller a storage temperature of a primary solute in the solution; inputting into the controller an identity of at least one additive and a concentration of the additive to be blended with the primary solute solution; initiating the controller to generate an initial chemical solution composition with the primary solute and the at least one additive, the solution composition having concentrations of each of the primary solute and the at least one additive configured to correspond with the storage temperature; mixing the primary solute with a diluting agent to form an initial chemical solution or slurry and measuring the initial chemical solution or slurry with a primary solute concentration sensor to verify that the concentration of the primary solute is within a target concentration, the concentration sensor communicating a concentration of the primary solute in the initial chemical slurry to the controller; comparing the primary solute concentration of the initial chemical solution to a target concentration of the primary solute; diluting the initial chemical solution with the diluting agent if the primary solute in the solution is over-concentrated; increasing the concentration of the primary solute in the initial chemical solution if the primary solute in the solution is under-concentrated; diverting the solution to a storage tank if the primary solute concentration in the initial chemical solution is within tolerance of the target concentration for the primary solute; and mixing the at least one additive into the initial chemical solution at a quantity and at a rate determined by the controller for the final chemical solution composition.

12. The method of claim 11 further comprising in-line mixing the at least one additive into the initial chemical solution at a quantity and at a rate determined by the controller for the chemical solution composition before diverting e final chemical solution to another container.

13. A method for automatically producing a brine solution containing sodium chloride as a primary solute and secondary solutes at a concentration to achieve a desired ice melting capacity or ice melting rate at a defined temperature, the method comprising the steps of: inputting into a controller a desired brine use temperature and a desired performance value consisting of one of an ice melting capacity or an ice melting rate; inputting into the controller an identity of at least one additive as the secondary solute; initiating the controller to generate a chemical brine solution composed of sodium chloride solute and the at least one additive, the chemical brine solution having concentrations of each of the at least one additive and sodium chloride to achieve e selected performance value at the selected brine use temperature; mixing the sodium chloride with water to form a chemical solution and measuring the chemical solution with a concentration sensor to verify that the concentration of the sodium chloride is within a target concentration, the concentration sensor communicating a concentration of the sodium chloride solute in the chemical solution to the controller; comparing a sodium chloride concentration of the brine solution to a target concentration of the sodium chloride solute, diluting the brine solution with the water if the sodium chloride in the brine solution is over-concentrated and increasing the concentration of the sodium chloride in the brine solution if brine solution is under-concentrated; automatically diverting the brine solution to a storage tank if the sodium chloride concentration in the brine solution is within tolerance of the target concentration; and mixing the at least one additive into the brine solution at a quantity and at a rate determined by the controller for the chemical brine solution composition.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] FIG. 1 illustrates a system having a controller for making a solution containing one or more solutes at an optimized concentration for a user's application in accordance with certain aspects of the invention; and

[0011] FIG. 2 is a flow chart that illustrates a process of making a solution using the system of FIG. 1 utilizing a controller programmed to make the solution containing one or more solutes at an optimized concentration for maximum ice melting effectiveness while being stable to precipitation at a selected temperature in accordance with aspects of the invention.

DETAILED DESCRIPTION

[0012] Following are more detailed descriptions of various related concepts related to, and embodiments of, methods and apparatus according to the present disclosure. It should be appreciated that various aspects of the subject matter introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the subject matter is not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

[0013] The application relates to an apparatus and method and control system for automatically making aqueous solutions of one or more solutes with an optimum concentration to maximize performance while avoiding precipitation at a given temperature. More particularly, it relates to a brine making system for use in making aqueous deicing liquids containing sodium chloride optionally with other performance enhancing chemicals such as magnesium chloride, calcium chloride, or organic based performance enhancers and corrosion inhibitors, which will have the maximum concentration of sodium chloride possible while avoiding precipitation of any solids at a selected temperature. The system includes a human machine interface (HMI) in which the user inputs a desired composition of deicer liquid components and a desired storage temperature for the liquid. The system includes a Programmable Logic Controller (PLC) which identifies the maximum sodium chloride concentration that will be stable to precipitation at a selected temperature and concentration of other performance enhancing additives from an internal database. The system includes an area where sodium chloride and water are mixed and a concentration sensor used to determine if the solution needs to be made more concentrated or dilute. When the sodium chloride concentration is within a given tolerance of the calculated optimum, the solution is diverted to an exit port. The system also includes a controlled pumping system to deliver quantities of other optional liquid additives (such as solutions of calcium chloride or magnesium chloride) to the exit port to achieve the selected ratio of additives to sodium chloride brine in the final mixture.

[0014] Referring now to FIG. 1, there is illustrated a chemical solution blending system 100 that includes a controller 110 having a human machine interface 112 (a work station; wireless smart device; input panel, etc.) operatively coupled to the controller for receiving inputs from a user and a memory portion 114 configured to receive data associated with the amount of chemical solution produced for each primary solute and additive combination. System 100 also includes a mixing reservoir 120, a plurality of blending solutes 130, at least one conduit system 140 for the solutes to be directed to reservoir 120; a concentration sensor 150 disposed within reservoir 120 that is communicatively coupled to controller 110 and at least one storage tank 160 operatively coupled to reservoir 120 that receives the brine solution at rate of about 80 gallons per minute in this example. The various additives A, B and C are added into tank 160 at a rate of about 20 gallons per minute in this example.

[0015] In one example embodiment of system 100 for use in connection with generating a brine solution for de-icing applications, system 100 is configured to automatically produce a brine solution having a concentration of a primary solute, in this case salt or sodium chloride, which is stable at a defined temperature. In this example embodiment, system 100 includes controller 110 configured to receive a storage temperature of a primary solute (from primary solute holder 134) in the brine solution as a first input from a user at human interface 112 and to receive a second input from interface 112 of an identity of at least one additive (from an additive holder 136) and a concentration of the additive to be blended with the primary solute solution. Controller 110 is programmed to generate a chemical brine solution composition in reservoir 120 comprised of the primary solute and in-line mixing of the one additive so that the solution composition has concentrations of each of the primary solute and the selected additive to correspond with the storage temperature that was input by the user and to prevent the primary solute from precipitating or crystallizing. In this example embodiment, mixing reservoir 120 receives the primary solute and a solvent from solvent holder 132 (via a command from controller 110) to form therein a chemical solution. Primary solute concentration sensor 150 located or disposed within mixing reservoir 120 measures the concentration of the primary salute in the chemical solution and then sensor 150 communicates (either hardwire or wirelessly) a concentration of the primary solute in the chemical slurry to controller 110. Controller 110 then verifies that the concentration of the primary solute is within a target concentration determined by a blending program in the controller. Storage tank 160 receives the brine solution (at a flow rate of about 80 gallons per minute, in this example) after being diverted by controller 110 from mixing reservoir 120 and receives one or more additive(s) A, B and C 136 at a quantity and a rate determined by the controller 110 program for the chemical brine solution.

[0016] In another embodiment, a sensor is included in storage tank 160 so as to measure a discharge temperature as the brine solution is coming out of tank 160. This feature can serve as additional feedback as to how the programmed temperature for the initial brine solution has changed when compared to the actual discharge temperature as the brine solution is being used. In a related embodiment, controller 110 is configured to receive a plurality of inputs from the user via interface 112 of additive identities and associated additive concentrations. In this example embodiment, memory portion 114 receives data associated with the amount of brine solution produced for each primary solute and additive A, B or C combination.

[0017] Referring now to FIG. 2, there is illustrated a flowchart of a method 200 for automatically producing a brine solution having a concentration of a primary solute that is stable at a defined temperature. In this example embodiment, the blending process utilizes a controller programmed to make the solution containing one or more solutes at an optimized concentration for maximum ice melting effectiveness while being stable to precipitation at a selected temperature. Method or blending process 200 implements a brine solution process using a system as in FIG. 100, which includes a controller 210 with a brine blending program, a user input interface 212 for inputting at least the brine storage temperature (and optionally the discharge temperature in other applications). A separate user interface 213 (or the same interface 212 can be used) is used to input the additive(s) identity liquid deicer additive and concentration of liquid deicer additive. In this example embodiment, controller 210 (or PLC or other controller device) is programmed to calculate required initial chemical solution and required additive additions.

[0018] In this example embodiment, solvent A and solid chemical (primary solute, such as sodium chloride) are held in tanks or bins 232 and 234, respectively. At the start of the blending process, the user inputs at step 212 into controller 210 a storage temperature of a primary solute in the brine solution and then at step 213 inputs into controller 210 an identity of at least one additive and a concentration of the additive in the brine solution. Then at step 240, controller 210 is initiated to generate a chemical brine solution composition with the primary solute and solvent A (or at least one additive) with the solution composition having concentrations of each of the primary solute and solvent A corresponding with the user selected storage temperature. After mixing the primary solute with solvent A to form a chemical solution, at step 244 the concentration of the solid chemical in the chemical solution is tested by measuring the chemical solution with a primary solute concentration sensor (such as sensor 150 of system 100) to verify that the concentration of the primary solute is within a target concentration.

[0019] In flowchart 200, a dashed line 220 illustrates the concentration sensor communicating a concentration of the primary solute in the chemical solution to controller 210 and controller 210 compares the primary solute concentration of the brine solution to a target concentration of the primary solute. At step 246, controller 210 determines that the concentration is high hence a diluting of the brine solution with the solvent (move to step 242) if the primary solute in the brine solution is over-concentrated. Controller 210 drives the process to step 248 where the concentration is low and there is a need to increase the concentration of the primary solute in the brine or chemical solution if the primary solute in the brine solution is under-concentrated. At step 250, if the primary solute concentration in the brine solution is within tolerance of the target concentration for the primary solute, process 200 automatically diverts the brine solution to a storage tank at step 252. At step 256 the liquid deicer additive (step 236) is mixed into the brine solution of the storage tank at a quantity and at a rate (steps 256) determined by controller 210 for the chemical brine solution composition. At step 264 the brine solution is optionally measured another time and checked with controller 210 and adjusted if need be. Finally, at step 260 the brine solution from the storage tank has its data logged in to controller 210 (quantity of blended liquid deicer solution produced).

[0020] In a related embodiment, the blending method is modified to input into the controller the identity of a plurality of additives and the concentration of each of the additives. In yet another related embodiment, the step of automatically diluting the solution also includes adding solvent to the chemical solution and wherein automatically increasing the concentration of the chemical slurry includes adding primary solute to the chemical solution. In yet another related embodiment, in-line mixing occurs of the at least one additive into the brine solution at a quantity and at a rate determined by the controller for the chemical brine solution composition and then diverting a final brine solution to another container.

[0021] In yet another related embodiment, a method is provided for automatically producing a final chemical solution having a concentration of a primary solute that is stable at a defined temperature, the method including the steps of inputting into a controller a storage temperature of a primary solute in the solution and an identity of at least one additive and a concentration of the additive to be blended with the primary solute solution. The controller is initiated to generate the chemical solution composition with the primary solute and the at least one additive, the solution composition having concentrations of each of the primary solute and the at least one additive configured to correspond with the storage temperature. Next step in process is mixing the primary solute with a diluting agent to form an initial chemical solution or slurry and measuring the initial chemical slurry with a primary solute concentration sensor to verify that the concentration of the primary solute is within a target concentration, the concentration sensor communicating a concentration of the primary solute in the initial chemical solution to the controller. Further in the blending process, the primary solute concentration of the chemical solution is compared to a target concentration of the primary solute. The initial chemical solution is then diluted with the diluting agent if the primary solute in the solution is over-concentrated and the concentration of the primary solute in the chemical solution is increased if the primary solute in the solution is under-concentrated. The initial chemical solution is then diverted to a storage tank if the primary solute concentration in the chemical solution is within tolerance of the target concentration for the primary solute. The at least one additive is then mixed into the initial chemical solution at a quantity and at a rate determined by the controller for the final chemical solution composition. In a related embodiment, in-line mixing of the at least one additive into the initial chemical solution at a quantity and at a rate determined by the controller for the final chemical solution composition occurs before diverting the final chemical solution to another container. This method is useful for generating chemical solutions such as, but not limited to, gasoline mixtures having different additives to boost octane or handle extra cold or hot weather; or coolant mixtures to prevent freezing lines at different or lower temperatures and uses.

[0022] The following patents and publications are incorporated by reference in their entireties: U.S. Pat. Nos. 7,810,987; and 8,251,569.

[0023] While the invention has been described above in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. Upon reading the teachings of this disclosure many modifications and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure and the appended claims. It is indeed intended that the scope of the invention should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.