HK1123007B - Solution making system and method - Google Patents

Description

System and method for producing solution

Information of related applications

This application is a continuation-in-part application of U.S. patent application No. 11/190,395 filed on 27.7.2005, the contents of which are expressly incorporated herein by reference.

Technical Field

Aspects of the present invention relate to an apparatus and method for producing a chemical solution (e.g., a saline solution) and a control system. More particularly, aspects of the present invention relate to an apparatus for dissolving a chemical in a solvent to produce a solution of a specific concentration.

Background

Chemicals dissolved in solvents at specific concentrations are used in various industries. For example, the use of saline solutions to reduce the amount of snow and ice on roads, sidewalks, driveways and other surfaces is a common industry practice. The salt solution is generally formed by mixing rock salt and water to make a solution. The concentration of the solution can then be adjusted by adding fresh water to dilute the mixture or adding salt to concentrate the mixture. About 23-27 weight percent of the solution is effective for removing ice and snow (where sodium chloride is at least one of the salts). With this concentration range, the solution can melt ice and snow at ambient temperatures of about-10 degrees Fahrenheit. An accident may occur if the required concentration cannot be maintained in the solution and the correct amount cannot be applied on the road. For example, too little salt in the mixture cannot lower the freezing point of water below ambient conditions, resulting in a mixture that can promote road icing as opposed to previously melting accumulated ice.

One method of monitoring and adjusting the concentration of a solution is to measure the specific gravity of the solution and add a solvent (fresh water in the case of certain salts) to the solution until the desired specific gravity is reached. The method then correlates the specific gravity of the solution with the concentration of the solution. At least one conventional system provides for the production of large quantities of water-soluble rock salt and Calcium Magnesium Acetate (CMA) particles for the production of salt solutions to be used as liquid de-icers, which will be used to spray roads, sidewalks, driveways, and runways to melt snow and ice. An electronic densitometer (specific gravity measuring device) measures the specific gravity of a brine/water solution. If the specific gravity is too high or too low, a valve is opened or closed to regulate the amount of fresh water in the mixture. In this way, the mixture is adjusted to the required salinity.

As described above, the method of producing a salt solution using specific gravity as an indication of concentration correlates specific gravity with concentration. This association may be erroneous in some situations. For example, solids such as silica, dirt, and other foreign matter in the solution may affect the specific gravity of the solution and/or the reading of the measurement device. This in turn leads to undesirable salt concentration levels of the solution based on fluctuations in the mixed solution. Furthermore, specific gravity-based measurements are typically a series of individual measurements spaced apart in time and course, rather than continuous measurements during one or more mixing operations.

Also, other mixing systems are unidirectional and cannot account for fluctuations that occur in the mixing operation, providing mixtures with too high or too low a concentration.

Accordingly, there is a need in the art for an apparatus and method for producing mixtures at precise concentration levels.

Disclosure of Invention

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter.

The present application discloses an improved system and method for mixing compounds and/or additives. The system and method described are capable of producing a solution having a desired concentration of chemical species. Alternatively, it may produce a solution with a minimum certain chemical concentration or a maximum certain chemical concentration. The system includes an area for mixing chemicals and a concentration sensor for determining whether the solution needs to be concentrated or diluted. If the concentration is within the tolerance of the target concentration, the solution may be transferred to a reservoir or other container.

Although multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive.

Brief Description of Drawings

A more complete understanding of the present invention and potential advantages thereof may be acquired by referring to the following description of illustrative embodiments thereof in consideration of the accompanying drawings.

Fig. 1 shows a perspective view of a solution maker according to an embodiment of the present invention.

Fig. 2 shows a front view of a storage hopper of a solution maker according to one embodiment of the invention.

FIG. 3 illustrates a cross-sectional elevation view of a storage hopper of a solution maker according to one embodiment of the invention.

FIG. 4 illustrates a cut-away perspective view of a storage hopper of a solution maker according to one embodiment of the invention.

FIG. 5 illustrates an internal cross-sectional view of a storage hopper of a solution maker according to one embodiment of the invention.

FIG. 6 illustrates an interior view of a storage hopper of a solution maker according to one embodiment of the invention.

FIG. 7 illustrates a rear view of a storage hopper of a solution maker according to one embodiment of the invention.

FIG. 8 shows an end view of a storage hopper of a solution maker according to one embodiment of the invention.

FIG. 9 shows a cross-sectional end view of a storage hopper of a solution maker according to one embodiment of the invention.

Fig. 10 shows a grid of a solution maker according to an embodiment of the invention.

Fig. 11 shows a control panel of a solution maker according to an embodiment of the present invention.

Fig. 12 shows a control panel and mechanical components of a solution maker according to one embodiment of the invention.

Fig. 13 illustrates a control manifold with a programmable logic controller and a human-machine interface for a solution maker according to one embodiment of the invention.

Fig. 14 shows a flow of a solution maker according to an embodiment of the invention.

FIG. 15 shows a perspective view of a solution maker and control panel according to one embodiment of the invention.

Figure 16 illustrates a perspective view of a floatation assembly according to one embodiment of the present invention.

Fig. 17 illustrates the addition of solvent to a first portion of a solution maker according to one embodiment of the invention.

Fig. 18 illustrates mixing of solvent and chemicals in a first portion of a solution maker according to an embodiment of the invention.

Fig. 19 shows an interior view of a first portion of a solution maker according to one embodiment of the invention.

Fig. 20 shows an interior view of a first portion of a solution maker according to one embodiment of the invention.

Fig. 21 shows an interior view of a second portion of a solution maker according to an embodiment of the invention.

Fig. 22 is a flow diagram illustrating a process of manufacturing a mixture of chemicals, slurries and/or solvents according to aspects of the invention.

Fig. 23A-23C show flow diagrams illustrating methods of mixing additives into a slurry in accordance with aspects of the present invention.

Fig. 24 is a flow chart illustrating a process of releasing slurry into another vessel in accordance with aspects of the present invention.

Fig. 25A-25B illustrate various processes for dispensing at least one of a solution and/or a mixture according to aspects of the present invention.

Fig. 26 shows an alternative solution maker according to aspects of the invention.

Fig. 27 shows another alternative solution maker according to aspects of the invention.

Detailed Description

The aspects outlined previously may be embodied in various forms. The following description illustratively shows various combinations and configurations in which the aspects may be practiced. It is to be understood that the described aspects and/or embodiments are merely examples and that other aspects and/or embodiments may be utilized and structural and functional modifications may be made without departing from the scope of the present disclosure.

Note that various connections between elements are set forth in the following description. Note that these connections are typically direct and or indirect unless otherwise noted, and this description is not intended to be limiting in this respect.

This description is divided into six sections to assist the user in understanding the various aspects of the invention. These parts include:

a. solution making machine

b. Additive agent

c. Dispensing

d. Chemicals, solutions and solvents

e. Modifying

f. Examples and applications

Solution making machine

A solution maker is provided. More specifically, aspects of the present invention provide an apparatus and method for producing a solution having a desired concentration, such as a salt solution, by measuring the concentration of the solution, determining the amount of solvent added to the solution, and adding the amount of solvent to the solution. Throughout this application, a solution that is any combination of a solvent and a partially or fully dissolved chemical may also be referred to as a slurry. For example, for the purposes of this application, a highly concentrated mixture of salt and solvent in which the salt is not fully dissolved in the solvent may be referred to as a slurry. The apparatus may also be configured to separate the precipitate from the chemical and solvent and rinse out the deposited precipitate. Thus, the device may be configured to separate foreign matter such as insoluble silica, dirt, and gravel from the solution.

The solution maker may operate in a manual mode in which a user monitors a control panel to determine when the solution concentration is the desired concentration. Alternatively, the solution maker may be operated automatically and independently adjust the concentration level. In addition, solution makers may operate in a range of operations, with some aspects being automatically processed, while others are processed based on operator instructions.

In one embodiment, the solution maker may be configured to produce a clean brine solution by dissolving one or more salts (e.g., sodium chloride) in water or other solvent. In other embodiments, the solution maker may be used to dissolve other chemicals. Examples include calcium magnesium acetate, calcium chloride, magnesium chloride, potassium acetate, potassium formate, sodium formate, magnesium acetate, diammonium phosphate, urea, ethyl glycol, propylene glycol, and others. The solution maker may produce a solution having a desired target concentration, a desired target concentration range, or a concentration equal to or greater than the target concentration. The solution maker may also dilute the solution or slurry that has been produced.

As shown in fig. 1-3, one aspect of the solution maker 100 may include a mixer 102 having a first container 104 and a second container 106. An exemplary suitable capacity for the mixer 102 is 5 cubic yards. The first container 104 and the second container 106 are separated by a filter grid 142. The first container 104 is adapted to receive a chemical for dissolution in a solvent to produce a solution. For the production of the brine solution, the component may be, for example, sodium chloride (NaCl or salt) or calcium magnesium sulfate. The chemical substance may have any suitable form. For example, if the chemical is a salt, it may be in the form of pellets or rocks. Other components may be used to produce other solutions. As will be described in more detail below, the solution maker may be calibrated to produce different solutions using different chemicals or solvents. In one embodiment, the solution maker mixes sodium chloride and fresh water to produce a brine solution. The chemical in the first portion may provide a layer of the chemical. For example, in producing a brine solution, a salt layer may form in the first container 104.

The first container 104 is also adapted to receive a solvent for mixing with the chemical to produce the desired solution. The components of the brine maker can flow downward and the solvent passes through the layer of chemicals in the first container 104 due to the force of gravity. The solvent may be delivered to the first vessel 104 in any suitable manner. A solvent line to the mixer 102 may be provided. An optional, self-regulating heating element may be coupled to the solvent line to prevent freezing of the solvent. In the embodiment of fig. 1, the solvent is delivered via a solvent valve 136 that actuates flow from a solvent inlet 138. The solvent valve 136 may be provided as an electrically actuated valve and may be actuated by a controller controlled valve, such as a Programmable Logic Controller (PLC)216 (see fig. 12). Although many types of controllers may be used, the term PLC is used in describing the controllers of aspects of the present invention for simplicity. The valve may be actuated based on one or more level sensors and/or may be operator controlled or some combination of automatic and operator controlled. As described more fully below and shown in fig. 3, a first level sensor 118, a second level sensor 120, and a third level sensor 122 may be provided. As shown in fig. 8, 12, and 19, in certain embodiments, the solvent inlet 138 may be pressurized and may provide solvent to the solution maker 100 via the solvent valve 136, the conduit 200, the manual valve 186, the manual valve 158, the conduit 176, and the spray head 178 to the dilution valve 134. The new solvent valve 136 may also include a manual override (override). Of course, although particular configurations are described herein, solution makers within the scope of the present invention may include more or fewer component parts, as will be appreciated by those skilled in the art.

The filter grate 142 substantially prevents the chemical from passing through the first container 104 of the mixer 102 into the second container 106 of the mixer 102 before the chemical dissolves in the solvent. Perforations may be provided in the filter grid 142. When a solution including a solvent and dissolved chemicals is formed in the first container 104, perforations in the strainer 142 allow the solution to pass through the strainer 142 and into the second container 106 of the mixer 102. Fig. 5 shows one embodiment of a grid 142 suitable for use with a solution maker. As shown, the filter grid 142 may include a plurality of annular perforations 143. The diameter of the perforations 143 is approximately 3/16 inches. Ideally, perforations 143 are large enough to allow solution to flow through strainer 142, but small enough to prevent chemicals from passing through strainer 142. Thus, the strainer 142 serves to support the chemicals, collect debris, and allow the passage of solutions. In one aspect, the grids 142 are non-metallic and include cross-members of 1-1/2 inch fiberglass construction.

Fig. 19 and 20 show the interior of the first container 104 of the solution maker. In FIG. 19, the spray head 178 and the filter grid 142 for emitting desolventizing agent can be seen. Fig. 20 shows fluid flow through the spray head 178.

As mentioned above, one or more level sensors may be provided. The level sensor is a level sensing device. They may be provided with a switch that sends a signal to PLC 216. In this way, a level sensor may be operatively connected to an input of PLC 216. The level sensor may be provided as any suitable device. In one embodiment, a suitable level sensor is a mechanical switch with a float device that activates a microswitch. In another embodiment, inductive-capacitive approximation switches may be employed. The level sensor maintains the level of the liquid in the mixer 102 (and more particularly the first portion of the mixer 102) at a desired level. Generally, a high water level may overflow the mixer 102 and create an overflow while a low water level may cause the transfer pump 124 to spin dry thus damaging the pump seals.

As shown in fig. 3, first, second, and third level sensors 118, 120, and 122 are provided, respectively. Reference is made to fig. 7 and 9 to further illustrate the level sensor. In some embodiments, more than three level sensors may be provided. Alternatively, no level sensor may be provided. The first level sensor 118 is adjacent the mixer 102 and substantially adjacent the second level sensor 120 and is connectable to an input of the PLC 216. The first level sensor 118 detects whether the water level in the mixer 102 is low. If the liquid level is low and the solution maker 100 is in the run mode, the pump 124 is transitioned to the "off" state if the solution maker 100 is in the run mode. This protects the pump 124 from damage caused by dry fibers.

The second level sensor 120 is generally adjacent to the first level sensor 118 and the third level sensor 122 and is connectable to an input of the PLC 126. The second level sensor 120 detects whether there is a sufficient amount of water or other solvent in the mixer 102. Upon detection of a sufficient amount of solvent, the pump 124 is activated and switched to a "run" state. The pump 124 is locked into the "run" state until the batch is complete or the first level sensor 118 detects a low level.

A third level sensor 122 is adjacent the mixer 102 and generally adjacent the second level sensor 120 and is connectable to an input of the PLC 216. The third liquid level sensor 122 detects whether the mixer 102 maintains a predetermined liquid level. If this level is sensed, the solvent valve 136 is switched to a "closed" position, thereby preventing the mixer 102 from overflowing.

The second container 106 of the mixer 102 includes a saline solution suction line 164 and a saline outlet valve 154 connected to the conduit 148. The brine outlet valve 154 is connected to the transfer pump 124 via the outlet conduit 148. The solvent dilution inlet 146 and the pump suction may be connected to a conduit 148. As shown, the pump 124 may be placed in communication with the solution sensor 132.

In one example, the solution sensor 132 measures the concentration of a chemical in a solution. In one aspect, the sensor is a conductivity sensor. For example, it may be a conductivity sensor of the loop (terodial) type, which is solid without contact points and measures the induction field of the solution. However, many conductivity sensors are known in the art. In another aspect, the solution sensor 132 may be a refractometer. The refractive properties of the solution vary according to concentration. The refractometer measures the refractive index of the solution and PLC 216 can then properly calculate and adjust the concentration reading. In other aspects, a gravimeter or other device for detecting the specific gravity of the solution may be used as the solution sensor 132.

Solution sensor 132 can be configured to measure continuously, thus providing a continuous input to PLC 216 rather than periodic snapshots, thereby increasing the efficiency of the machine.

Alternatively, a refractometer may be used instead of the solution sensor 132. The refractive properties of the solution vary according to concentration. The refractometer measures the refractive index of the solution and the PLC 216 can then properly calculate and adjust the concentration.

In another aspect, the solution sensor 132 may be combined with a temperature sensor. This is desirable because, in the case where the solution sensor is a conductivity sensor, the resistance of the solution varies with temperature as well as with concentration. The readings from the solution sensor and the temperature sensor may be used to form a temperature compensated conductivity reading. This reading can be converted to a concentration curve, which in turn expresses the reading of the solution as a temperature-compensated concentration by weight. A concentration curve relating temperature compensated conductivity to concentration may be developed for any chemical species in the solution. Thus, for example, in a brine maker, a sodium chloride concentration profile is utilized. As described above, in one aspect, the solution sensor measures the temperature and conductivity of the solution. The properties of brine change with temperature, so it is desirable to measure temperature to determine the actual concentration.

Alternatively, the solution sensor 132 may operate without the assistance of a temperature sensor. This is desirable because the solution sensor directly measures a property that does not change with temperature. It is also desirable because it is less costly and less complex to operate without sensing temperature.

As described more fully below, solutions outside the tolerance of the target concentration will be conditioned, while solutions within the target tolerance may be processed to a reservoir. By measuring and adjusting the concentration halfway, the solution maker continuously produces a solution of a target concentration without intervention of an operator.

Referring to fig. 1, 12 and 13, solution sensor 132 is in operable communication with PLC 216. In response to the determined concentration, PLC 216 may activate dilution valve 134 or diverter valve 130 to ensure that only the solution of the desired concentration is diverted to the tank. The target concentration of the solution may be any desired concentration. For saline solutions, suitable target concentrations may be in the range of 19.6 to 27 weight percent. For example, the target concentration is 23.3 wt%. In addition to establishing the desired solution concentration, a desired solution concentration tolerance may be established, wherein certain deviations from the desired solution concentration are deemed acceptable. An acceptable deviation may be +/-0.3% of the target concentration.

Diverter valve 130 diverts flow from pump 124 through return line 126 if the solution concentration is above or below the target concentration and through product line 128 if the solution concentration is within approximately the desired concentration. Diverter valve 130 may be controlled by PLC 216 (and/or by an operator or a combination thereof) and depends on the relationship between the target concentration and the actual concentration. The out-of-tolerance solution of the target concentration may be diverted to conduit 126, valve 156, conduit 180, and stir nozzle 166 for re-passing through mixer 102. Further, while particular embodiments of a diversion mechanism are provided, alternative mechanisms known to those skilled in the art may be used to divert solutions outside of a target concentration tolerance or target concentration range to the mixer 102.

The return line 126 passes the flow of liquid through the valve 156, the conduit 180, and the agitation nozzle 166 in the first vessel 104 of the mixer 102. The solution passes through a return pipe 126 and returns to the mixer 102. The production tubing 128 leads to a storage tank 410 (see fig. 14). The diverter valve 136 may also include a manual override.

Dilution valve 134 is controlled by PLC 216. The dilution valve 134 may be in communication with the solution pump 124. While pump 124 is delivering a flow of solution and while solution sensor 132 senses that the actual concentration of the solution is above the target concentration, then dilution valve 134 is actuated open to deliver enough solvent to dilute the solution. The dilution valve 134 is in communication with a solvent inlet 138. Dilution valve 134 actuates open while pump 124 is delivering flow and while solution sensor 132 senses that the actual concentration of the solution is above the target concentration. When dilution valve 134 is open, solvent passes from solvent inlet 138 through dilution valve 134 into conduit 212 and into dilution inlet 146. The solvent is mixed with the solution from the second container 106 of the mixer 102 into the pump 124. The dilution valve 134 allows enough solution to dilute the over-concentrated solution to the target concentration so that the solution is not over-diluted. The dilution valve 134 may also include a manual override.

The sensed solution may be diluted in any suitable manner at any suitable point. For example, the sensed solution may be diluted by adding solvent to the outlet tube. Alternatively, the sensed solution may be diluted by returning to the mixer 102 and further mixing with the solvent in the mixer 102.

The flow measurement device 204 shown in fig. 12 may be provided for measuring the volume of finished solution transferred to the reservoir. Flow measurement device 204 can be placed in communication with PLC 216. In addition, an additional pump 210, flow measurement device 206, and actuation valve 208 may be provided to allow flow into conduit 128. Additive pump 210, flow measurement device 206, and actuated valve 208 may communicate with PLC 216 to effect mixing with the solution as the additive is transferred to the reservoir, as described more fully below.

In use, solids such as mud and silica may be mixed into the solution maker. These solids typically cause the formation of a precipitate in the solution maker. In general, it is desirable that the solution be as clean as possible. The foreign matter in the solution is abrasive. This abrasiveness can cause excessive wear on pumps, flow meters, and valves associated with the production and use of saline solutions. The sediment deposition caused by foreign matter suspended in the solution sinks with time and forms a layer of sediment in the reservoir. Cleaning deposits is time consuming and requires the machine to be taken offline.

In one embodiment, the second vessel 106 of the mixer 102 is configured to be easily cleaned. The second container 106 (see, e.g., fig. 3 and 21) thus includes at least one ramp along which sediment slides into a mud tank at the bottom of the ramp. A suitable slope for at least one of the ramps is about 15 degrees. In the illustrated embodiment, the second container 106 includes a first ramp 150, a second ramp 152, and a third ramp 202. The sediment passing through the grate 142 collects in the sump area formed by the first, second and third inclined surfaces 150, 152 and 202 at the bottom of the second vessel 106 of the mixer 102. The mud bin area is, for example, approximately 12 inches by 12 inches. Other coatings that facilitate cleaning are known to those skilled in the art.

A mud tank outlet 108 may be provided to enable sediment to be flushed out of the mixer 102. Such flushing may be accomplished via spray bar 402 (e.g., shown in fig. 2 and 9) and nozzle 162 (e.g., shown in fig. 3). A plurality of nozzles, for example, a nozzle disposed on each of the left, right, and rear walls of the mud tank, can be used to force the sediment through the mud tank and out of the solution maker. The solution maker may be configured for rinsing of the sediment or for manual rinsing of the sediment. Further, the precipitate may be flushed from the mixer 102 while the chemical is in the first container 104 of the mixer 102, or the precipitate may be flushed from the mixer 102 when the chemical is substantially absent from the first container 104 of the mixer 102. The grate 142 in the mixer 102 supports the weight of the chemicals, thus allowing the chemicals to flush the sediment while in the mixer 102.

Thus, the solution maker also provides a means for separating foreign matter, such as undissolved silica, dirt, and grit, from the mixer 102. Foreign matter may accumulate in the mud box area from which sediment may be later washed away. In addition, the solution maker can achieve the deposition of foreign matter that is washed out of the mixer 102 while the chemical substance remains in the first portion of the mixer 102.

In another embodiment, the solution maker may be devoid of a purging system as described above. In this alternative embodiment, a mixer 102 that is less expensive to manufacture may be employed, thereby saving costs in an environment where the mixer 102 does not need to be cleaned or where the mixer 102 does not need to be cleaned regularly. Here, a system that does not accumulate debris or is relatively clean may employ a mixer 102 without a purge.

In some embodiments, the solution maker may contain 1000-. Thus, the mixer 102 is made strong enough to support the load. The mixer 102 may be made of any suitable material. In one embodiment, a suitable material from which the mixer 102 may be constructed is fiberglass. The glass fibers are very strong and impervious to the salt solution. More specifically, the mixer 102 may be composed of glass fibers having a tensile strength of 16000Ib and a phloroglucinol resin. Other suitable materials for the mixer 102 include, but are not limited to, stainless steel and polypropylene. The inner surface of the mixer 102 may be coated with a ceramic resin. Such a coating may have a thickness of about 0.050 inches, for example. Integral structural ribs may be provided in the mixer 102 to limit the bend from full to empty to within one inch. In one embodiment, the combined thickness of the glass fibers and resin in the mixer 102 is about 0.35 inches. Structural regions such as ribs, corners and structural faces may be provided as additional layers of woven fiberglass mats having a total thickness of about 0.50 inches.

In use, the solution maker may be used by the highway sector to produce a brine solution to remove ice from a roadway. The solution maker can be used outdoors in cold climates. Thus, the solution maker may have one or more components that are heated. A heating element 168 (see, e.g., fig. 3) may be disposed in the mixer 102. A temperature sensing device in communication with PLC 216 may be disposed in mixer 102. The temperature sensing device indicates whether the heating element 168 needs to be activated to raise the temperature of the mixer 102. These elements may be thermostatically activated to be active or inactive and capable of maintaining a temperature of 32 degrees fahrenheit or greater to prevent freezing of the container.

Thus, the mixer 102 may be heated to minimize the likelihood of the mixer freezing in cold climates. In one embodiment, a silicone mat heater may be configured in the mixer 102. For example, two 9 square feet silicone pads may be configured in the mixer 102. A roll tarp such as a fixedly mounted roll tarp may be used in combination with a heater for heating the mixer 102. Such roll tarpaulins may have an arch structure and a roll mechanism and are used to retain heat and remove debris. If provided, the roll tarpaulin may be installed on the open top of the mixer 102. Other heating methods are known to those of ordinary skill in the art.

Fig. 11-13 illustrate an embodiment of a control panel for a solution maker. Control panel 50 may include a mechanical fluid flow control device, conductivity sensor 132, PLC 216, and Human Machine Interface (HMI) 214. In another embodiment, PLC 216 communicates with HMI 214 to create a data log. The solution produced and transferred to the tank is measured via flow measurement device 204 (see, e.g., fig. 12) and recorded in PLC program 216. The measurement may be made by a flow meter of a flow switch. Calculations are introduced in the PLC program 216 to determine the amount of solution, chemicals and solvents produced during the production process. The data log thus creates a report that can be viewed on the HMI 214 or printed on a printer. These reports may be created daily and may show the total amount of solution produced during the operating season as well as the amount of chemicals and solvents (and additives when they are introduced into the solvent). A multi-user report may be generated. For example, daily or seasonal totals may be created that are suitable for different individuals for accounting and billing purposes.

The control panel 500 may include one or more processors that control the operation of the control panel. The control panel 500 may also include memory including at least one of solid state (RAM, ROM, flash memory, magnetic storage, etc.) and dynamic memory (CD, DVD, hard drive, etc.). The control panel may have no or various input/output pathways, including but not limited to wired (e.g., USB, firewire, and other wired pathways), wireless (e.g., IEEE 802.11)^*Wi-Max, cellular, satellite, RF, bluetooth, and other wireless pathways) and media related interfaces (e.g., CD, DVD, and other media related interfaces). The control panel 500 optionally includes the ability to connect to a network or other device including the internet. In addition, the control panel 500 optionally includes a position determination system (including but not limited to cellular, satellite, etc.). The location determination system may provide information that causes the location of the control panel 500 to be communicated to another device or network. In addition, the control panel 500 can use this information to alter the required concentration, additive mix, etc. according to the determined location. For example, controlThe panel 500 may provide more additive according to one location as opposed to less additive according to another location. Alternatively, it may provide its location based on user input or a location sent remotely thereto.

In one example, PLC 216 can process operations independent of HMI 214. In other cases, PLC 216 may be replaced by HMI 214 alone. Further, the PLC may be networked with a computer or computing system to allow communication therebetween and/or download new information to the PLC 216. For example, the central command center may instruct PLC 216 at each location to increase the amount of chemicals/solvents/solutes/slurries compared to the others. Also, a network (e.g., the internet or other network) of PLCs 216 may allow firmware updates or data uploads regarding usage and other metrics. In addition, the data retention function may provide reports or requests to the network regarding data retention and/or ordering of more materials.

Additionally, the network of PLCs 216 may allow for remote operation of the system. For example, one person may operate one HMI to control two or more mixers 102.

The report, in turn, may provide a quantitative measure of the solution or other output produced and/or the time required to make the solution or other mixture. These reports may be output in one or more forms, including a form suitable for storage in a database (SQL, Microsoft Access, etc.).

The control panel effects regulation of the flow of solvent into the first section of the mixer 102. The solvent concentration and/or actual temperature compensation concentration may be monitored and if the concentration is outside the tolerance of the target concentration, the solution will be returned to the mixer 102. Alternatively, the solution may be diluted on the way out of the mixer 102 to meet the desired concentration level. The solution of the desired concentration may be processed into a holding tank. As shown, the PLC, conductivity analyzer, and other electronic controls may be mounted in an electrical enclosure on the back side of the panel. The main panel of the control panel may include valve indicia and valve functions. The information displayed on the screen may include the concentration of the solution actually produced in terms of weight percent concentration, the number of gallons of solvent used to make the solution, the self-diagnostics of the conductivity sensor, the self-diagnostics of the electro-valve (indicating whether and which valve is not functioning properly), the state of the valve being open or closed, and the state of the machine along with the state of the electrical components. In one embodiment, the display is multi-colored with a green screen indicating that the system is normal, a red screen indicating machine failure and an orange screen indicating set parameters.

The one or more reservoirs may be filled individually or in an order specified by the control panel or HMI. For example, the first holding tank may be designated as the location of the output of the solution maker 100 or the mixer 102. Then, after the first reservoir is filled (based on a predetermined amount of solution dispensed or a sensor in the reservoir), another reservoir can be filled. The control panel can be programmed to fill several slots and then stop the dispensing and/or mixing process.

The solution maker may be configured to be self-diagnostic. Thus, the valves and sensors may be in operable communication with the controller to determine the current state. In the event of a component failure, the system may be configured to shut down and provide information about the particular failure along with a method of correction, including how to manually override the problem and part number failure.

Fig. 14 shows a flow of a solution maker according to an embodiment of the invention. As shown, a solvent 402, such as water, enters a mixer 102404. In the mixer 102404, the solvent is mixed with a chemical such as a salt to form a solution such as brine. Solution 406 exits mixer 102404. Conductivity sensor 408 measures the conductivity of exiting solution 406 to determine the concentration of solution 406. If the concentration is within the desired range, the solution 406 continues to a reservoir 410. The additive 412 may be added to the solvent 406 as needed after the solution 406 is determined to be at an acceptable concentration. If the solution 406 is not at the desired concentration, it is returned 414 to the mixer 102404. This process will be described more precisely below.

In operation, a chemical (e.g., rock salt) is deposited in the first container 104 of the mixer 102. The pump 124 is initially in the "off" state, while the solvent valve 136 is in the "on" position. The operator enters the desired target solution concentration, the volume of solution to be produced and the additive ratio in the finished product (if needed) at the HMI 214. Upon entering this information, the operator activates a start switch which initiates the PLC program into an operational mode. The operational mode initiates the flow of solvent from the valve 136 into the mixer 102104. The first container 104 of the mixer 102 receives solvent from the spray head 178 via the solvent inlet 138, the actuation valve 136, the conduit 200, the valve 186, the valve 158, and the conduit 176. The solvent dissolves the chemicals and the resulting solution passes through the strainer 142 into the second container 106 of the mixer 102. The solvent continues to enter the mixer 102 through the spray head 178 until the third level sensor 122 detects that the mixer 102 is full of liquid and activates the solvent valve 136 to the "off" position so that the mixer 102 does not overflow.

Although the mixer 102 receives the solvent, the second level sensor 120 detects whether there is a sufficient amount of solvent in the mixer 102. When there is a sufficient amount of solvent in the mixer 102, the pump 124 is actuated to a "run" position. The pump 124 is locked into the "run" position until the batch is complete or the first level sensor 118 detects a low level.

The pump 124 conveys the solution from the second container 106 of the mixer 102 through the first straw 164, the conduit 188, the valve 154, the conduit, the dilution inlet 146, and into the suction side inlet of the pump 124. The pump 124 may be configured to pump approximately 5000 gallons of solution per hour and have a dynamic head of 45 feet.

The solution sensor 132 senses the conductivity and temperature of the solution delivered by the pump 124 from the mixer 102106. The solution sensor 132 measures the resistance of the solution flowing through the solution sensor 132. This measurement may be made by the probe of the solution sensor 132 and the conductivity analyzer. The resistance can be compared to the temperature of the solution and these two variables are scaled to form a temperature compensated conductivity reading. This reading can be converted to a chemical concentration curve, which in turn expresses the solution reading as a temperature compensated gravimetric concentration. A concentration curve relating temperature compensated conductivity to concentration may be developed for any chemical in solution. Thus, for example, in a brine maker, a sodium chloride (and/or other salt) concentration profile is employed.

If the solution is too concentrated, the conductivity analyzer communicates with the PLC 216, and the PLC 216 in turn opens the dilution valve 134 to allow the solvent to dilute the over-concentrated solution exiting the mixer 102106 to the target concentration. When the dilution valve 134 is activated, solvent passes from the solvent inlet 138 through the dilution valve 134 into the dilution inlet 146 and mixes with the solution delivered to the pump 124 from the second container 106 of the mixer 102. The dilution valve 134 remains activated until the solution reaches the target concentration. The over-concentrated solution is diverted from the pump 124 by the diverter valve 130 and enters the first container 104 of the mixer 102 through the return line 126 via the conduit 180, the valve 156, and the agitation nozzle 166.

If the solution concentration is low, the low concentration solution is diverted from the pump 124 by the diverter valve 130 and enters the first container 104 of the mixer 102 through the return pipe 126 via the valve 156, the conduit 180, and the agitation nozzle 166.

If the solution is within a tolerance level of the target concentration, the solution is diverted from the pump 124 by the diverter valve 130 and enters a storage tank (not shown) through the product line 128. Alternatively, if a truck is loaded with solution during operation of the solution maker, solution within a tolerance level of the target concentration may be delivered directly to the truck via the truck fill pipe. When the solution is transferred to the reservoir, an electrical plug wire harness (removable electric plug wire) may be provided to stop filling of the reservoir when full. Thus, the sensing device may be arranged for sensing the state of the reservoir.

As the solution within the tolerance level of the target concentration is sent to the reservoir, the liquid level in the mixer 102 falls over time. First, if the solution maker 100 is in the operational mode, the level sensor 118 detects that the water level in the mixer 102 is low and turns the pump 124 to the "off" state. Alternatively, the solvent and chemicals may be supplied continuously to the solution maker. In a semi-continuous embodiment, the solution maker 100 continuously produces a solution of a desired concentration. Thus, the solution maker 100 can be used for continuous batch processing. Continuous batch processing allows for the production of more solution per unit time of operation of the solution maker.

The configuration of the solution maker thus provides a downward flow design. In the first vessel 104 of the mixer 102, the solvent flows downward through the chemicals to form a solution. An upward flow design is well known in the art, but should also include a pump to counteract gravity, which assists the downward flow design. It should be appreciated that aspects described herein include both upward and downward flow designs.

The solution passes through the filter grid 142 into the second container 106. The solution with the highest concentration settles to the bottom of the second vessel 106 where the solvent is removed for disposal.

A data log may be generated by the solution maker to record how much solvent was produced and the amount of ingredients (chemicals and solvents) used.

Fig. 3, 5 and 20 further illustrate the ease of cleaning of the solution maker.

Fig. 3, 5 and 21 show the slope and mud tank of the second vessel 106 of the mixer 102. Due to the slope, the sediment passing through the grate 142 is concentrated at the bottom of the second section in the area adjacent to the sludge tank outlet 108. Any suitable number of ramps may be used. In the illustrated embodiment, a first ramp 150, a second ramp 152, and a third ramp 202 are provided. Thus, the sediment passing through the screen 142 is concentrated on the bottom of the second container 106 of the mixer 102 in the area formed by the first, second and third inclined surfaces 150, 152 and 202. The mud tank outlet 108 allows the sediment to be flushed from the mixer 102 using the spray bar 402 and nozzles 162 as described above.

Fig. 2-4 illustrate the mixer 102. The mixer 102 includes a first vessel 104 and a second vessel 106. The nozzle 162 is disposed on the second container 106. The spray nozzles 162 spray the liquid substantially in the direction of the mud tank outlet 108 disposed in the second container 106. In one embodiment, the liquid sprayed by the nozzle 162 is water. Thus, the liquid is discharged from the nozzle 162 and directed toward the sediment that accumulates adjacent to the sludge tank outlet 108. The force from the spray forces the sediment through the mud tank outlet 108. Of course, any suitable means for forcing the sediment through the outlet of the mud tank may be used.

As further shown in fig. 19 and 20, the first container 104 of the mixer 102 may include a spray head 178. Alternatively, the first container 104 may include multiple spray heads. The spray head 178 receives solvent from the solvent inlet 138 via the solvent valve 136.

Fig. 6 and 9 show a plurality of spray bars 402 (only one side shown) located on opposite sides of the second container 106 of the mixer 102. The spray bar 402 sprays the liquid, forcing the sediment toward the mud tank outlet 108.

As described above, during use of the solution maker, the precipitate may pass through the filter grid 142 into the second container 106 of the mixer 102. Sediment resting on the first and second ramps 150, 152 is forced downward toward the bottom of the second container 106 via the spray bars 402 disposed along the first and second ramps 150, 152. Spray bar 402 is supplied with liquid through liquid source 138, conduit 200, water inlet 186, flush valve 160, and conduit 174. Sediment at the bottom of the second vessel 106 is forced out of the sludge tank outlet 108 of the second vessel 106 via the nozzle 162. Liquid is provided to the nozzle 162 via the liquid source 138, conduit 200, water inlet 162, and conduit 172.

The chemicals are supported within the first container 104 by a grate 142. Thus, the sediment may be flushed from the mixer 102 while the chemical is in the first container 104 of the mixer 102. Alternatively, the precipitate may be flushed from the mixer 102 when the first container 104 of the mixer 102 is substantially free of the chemical.

Fig. 12 shows a control panel for a solution maker, in which additives may be provided to a solution. Thus, the solution maker can be used to inject the additives in the required proportions to the required solution concentration. For example, when the solution maker is used to make brine, additives that operate brine at lower temperatures or reduce the corrosiveness of brine are beneficial.

Typically, brine is used at or above about 20 degrees fahrenheit. By mixing the additive with the brine, the effective temperature of the brine used can be reduced to about 0 degrees Fahrenheit, thereby providing a solution that melts snow and ice at a lower temperature. Salt water is naturally corrosive, and the corrosiveness of salt water causes corrosion of bridge decks, vehicles, and road surfaces. At least one additive is mixed into the brine in a predetermined ratio to reduce the corrosivity and reduce the freezing point of the brine to be beneficial to the environment. Generally, these additives are expensive compared to the cost of the brine solution. The system may optionally include the ability to add the required amount of additive to the solution when needed thus reducing costs and enabling the production of concentrated products when needed.

With the embodiment of fig. 12, the user enters the required percentage of the total volume in which the additive will be processed to the tank of the stored finished product via HMI 214. When brine is produced and delivered to the storage tank, a predetermined proportion of additive is placed into conduit 128 by pump 210 controlled by PLC 216 and connected to a supply tank (not shown) for the additive. The pump 210 delivers the solution. Flow meter 206 communicates with PLC 216 and measures the additive volume. The actuated valve for shutting off flow is controlled by PLC 216.

Thus, in the embodiment shown in fig. 12, a solution of a desired concentration can be produced, and additives in a desired ratio can be mixed with the solution according to the volume of the solution when the solution is transferred to the holding tank. This ratio may be between 0 and 100% as desired. The solution maker thus produces brine and has the ability to mix and inject any proportion of additives into the solution.

Fig. 16 shows a perspective view of the floatation assembly on the mixer 102.

Figure 17 shows the addition of solvent to the first container 104 of the solution maker via spray head 178,

fig. 18 shows the solvent mixed with a quantity of chemicals in the first container 104 of the solution maker.

Fig. 19 shows the first container 104 with the spray head 178 on the grate 142 prior to adding any bulk chemical to the first container 104.

Fig. 20 shows the first container 104 being sprayed with solvent from a spray head 178 over a mass of material.

Fig. 21 shows the second container 106 having a first ramp 150 and a third ramp 202, showing solution formed and flowing toward the brine outlet valve 154.

Fig. 22-25B illustrate various processes that may be used in conjunction with the solution maker 100 and additional components.

Fig. 22 illustrates a process of forming a mixture of solute and solvent. Although a single solute and a single solvent are typically mixed to form a slurry, aspects of the present invention are not limited thereto. A variety of solutes and solvents can be slurried. For example, in fig. 22, solvent 2201 and solvent 2202 are mixed with solid chemical 2203 and solid chemical 2204 to produce a new slurry 2206. Although solid chemicals are used in this example, liquids may also be used. For example, slurry 2205 can also be added to solvents 2201 and 2202 to produce slurry 2206. In the case where the slurry 2205 is the only chemical added to the solvent, the solution maker may be used as a diluter.

As described above, the solution maker can be used to ensure that the slurry 2206 is at or above or below a desired concentration. At step 2208, the concentration of the slurry 2206 is tested by any suitable means, including measuring the refractive index, specific gravity, and/or electrical conductivity. As described above, the temperature can also be measured to more accurately correlate the conductivity/specific gravity/refractive index to the actual concentration of the chemical species in the slurry. For example, in some cases, the concentration may be tested by a sensor at the location of the mixer 102. In other cases, the actual sensor may be located separate from the physical location of the mixer 102. For example, in cold climates, the sensors may be located in a heated house with the mixer 102 outside to protect the sensors and associated processing/control equipment.

If the slurry 2206 is not sufficiently concentrated, solutes or slurries 2203, 2204, and 2205 can be added to the slurry 2206. If the slurry 2206 is too concentrated, a solvent 2201 and/or 2202 may be added to the slurry 2206 in step 2207.

Once the desired concentration is achieved, as measured at step 2208, the slurry 2206 can be selectively released into one or more storage tanks 2209 and/or other containers 2212, as indicated by the dashed lines in fig. 22. Alternatively, the process may continue to produce more slurry 2206 until the mixer 102 is full. The amount of solution delivered to holding tank 2209 and/or other container 2212 is determined in steps 2210 and 2213. This amount may be recorded in the data log 2211 along with other information about the product such as delivery times, chemicals and solvents used, concentration settings, etc.

Data log 2211 can be used to maintain records of the contents of slots 2209 and/or other containers 2212. Likewise, the data log can be used to remember the amount of raw material solute/solvent/chemical/slurry used. This information can be used to facilitate order processing of alternative chemicals and supplies.

Although holding tanks and other containers are shown in fig. 22, the solution may be released as part of a continuous process. For example, instead of filling only a discrete number of holding tanks or other containers, the solution may be continuously or nearly continuously supplied to any receiving container, such as a pipeline of a waiting truck or other process that uses the produced solution.

As described above, the release of the slurry 2206 to another vessel is optional. In some cases, it may be advantageous to operate in a winterization mode. In this mode, the mixer 102 is located outdoors or in a location where the ingredients or solution may freeze. The control panel is located outdoors or indoors. When in winterization mode, the slurry 2206 can be circulated periodically or continuously, even without the addition of solvents or solutes. This may help ensure that the solution is uniformly mixed, help prevent precipitate formation, and help prevent any partial solidification of the slurry or solution. Continuous mixing also allows conductivity to be measured more accurately, since the temperature of the solution will be kept more uniform, and conductivity measurement is dependent on the concentration and temperature of the solute.

Additive agent

Fig. 23 shows three possible processes for mixing additives to the produced solution. In fig. 23A, the volume of the solution is determined at step 2301. The amount of additive required is calculated from the volume at step 2302. Alternatively, the volume of the additive may be determined first, and then the volume of solution required may be calculated from the volume of additive to be used. The solution and additives are mixed at step 2303.

Fig. 23B shows the logic required to automate the mixing of the additive with the solution. First, the total volume (amount) of mixing of the additive and the solution is determined in step 2304. The total volume (e.g., amount) may be, for example, the volume of the container in which the mixture is located. This container may be the same container as the solution or additive, or it may be a third container 2307. If the requested volume is greater than the total space available in the container 2307 or container in which the mixture is to be placed as determined in step 2308, an alert 2312 will be given. If mixing is continued, the container will overflow. Alternatively, the volume of the mixture to be produced may be adjusted below the required volume and the process may continue assuming there are no other reasons for the alarm.

The desired volume of the mixture of solution and additive 2304 can be used to calculate the desired volume of solution and the desired volume of additive. If neither is sufficient as determined at steps 2309 and 2310, step 2312 must give an alarm. The process may optionally proceed by producing a volume less than the desired volume at step 2304.

The steps 2309 and 2310 of measuring the volume of the solution and additive may be performed using a pressure transducer. The transducer sensor may be mounted at the bottom of the container. The pressure reading may be proportional to the weight of the solution or additive in the cylinder on the transducer sensor. The volume stored in the container can then be calculated using the size of the container and the specific gravity of the solution or additive.

Each of the above-described steps 2305, 2306, 2307, 2308, 2309, and 2310 is optional, as any of the steps 2308, 2309, and 2310 is sufficient to trigger an alarm. Alternatively, only some of the above steps may be used in situations where it is desirable to construct a solution manufacturing system with fewer sensors or steps. If an alarm is triggered, the process will not be able to produce the required volume 2304, regardless of the results of the other steps. On the other hand, if there is sufficient room for mixing as determined in step 2308 and sufficient solution and additives as determined in steps 2309 and 2310, then the desired volume of the mixture of solution and additives may be produced at step 2311.

Fig. 23C shows the logic for mixing the additive and solution in a continuous process. Unlike fig. 23A and 23B, the required volume is not required. Instead, the solution is released regardless of the final amount to be produced. The flow rate of the solution is determined at step 2313. This can be achieved in many ways. For example, the flow rate of the solution flow turning the turbine may be measured. Another technique may determine the flow rate for each time interval. In this example, a valve opening of 15 seconds at a flow rate of 4 gallons per minute may result in dispensing 1 gallon.

Once the flow rate of the solution is known, the flow rate of the additive required to form the desired mixture is determined in step 2314. At step 2315, the flow rate of the additive is adjusted according to the calculations of step 2314 to produce the desired mixture. Alternatively, the flow rate of the additive may be measured and the flow rate of the solution adjusted. Or both may be adjusted to achieve the desired flow rate of the final mixture. Proportional-integral-derivative (PID) circuits known in the art may be used to dynamically calculate the flow rate of the additive, solution, or both, even if the flow rate is not constant.

Dispensing

Fig. 24 shows control logic for filling a container, such as a drum or truck that is pulled into a filling station, with a solution generated by a solution maker. The container may be filled from a tank for the production solution, as in step 2208 of fig. 22, or from a holding tank or other container, such as the containers in steps 2209 and 2212 of fig. 22. Once the fill command is received, the product is placed in the container at step 2401. This may occur when a user presses a button or when a truck to be filled enters a weight sensitive loading bay. Step 2402 illustrates calculating and measuring a flow rate of the product delivered to the container. As discussed with reference to fig. 23, the amount of product dispensed, along with any other information useful about the product, may be recorded in a data log at step 2403. For example, if the truck is filled, the time and amount of product dispensed may be used to send a bill to the truck owner. As in step 2402, product will flow into the container to be filled until the storage container is full (step 2405), a command is received to stop pumping product (step 2506), or no more product can be delivered due to a supply shortage or any kind of malfunction (step 2407). Upon detection of any of the above events, aspiration ceases and the valve closes (step 2408).

FIG. 25A illustrates control logic for another aspect of the present invention. The control logic may be used to dispense a desired amount of the solution, the mixture (the solution containing the additive), or both. At step 2501, the required amount of solution or mixture to produce is determined. The required amount may be entered by an operator or may come from a predetermined setting, such as a known size of the container to be filled. It may also be automatically determined or defined by the needs of the process of end use of the dispensed solution or mixture.

At step 2502, the amount of solution or mixture that has been available is determined. If the amount is equal to or greater than the amount to be dispensed, the required amount 2501 is dispensed at step 2506. The volume (or other indication of the quantity) dispensed at step 2506 is recorded in a log or database at step 2507. This log can be used to remember various aspects of the machine's work and to automate auxiliary tasks, as described above with reference to data log 2211. In step 2508, the dispensed amount is checked. This may be accomplished by measuring the flow rate, determining the volume of solution or mixture in the container from which the solution or mixture was dispensed (if present), determining the volume of solution or mixture in the container from which the solution was dispensed, or any other suitable method. If the required amount has not been allocated, the allocation and checking continues. Once the required amount has been dispensed, the process stops (step 2510).

When the amount of solution or mixture available is determined at step 2502, there may not be enough solution or mixture available for dispensing the required amount. In this case, more solution should be produced. If there are materials available to produce the desired solution or mixture (step 2504), a solution or mixture is formed in step 2505 and dispensed in step 2506.

If there is not enough material available to produce the desired amount of solution or mixture (step 2511), an alarm is given at step 2512 and the process stops (step 2510).

Steps 2503 (solution/mixture available) and 2505 (production solution/mixture) may occur simultaneously: a stock quantity of solution or mixture may be maintained. The stock amount of solution or mixture should always be available or in the process of being replenished during normal operation. Operating in this manner may increase efficiency by reducing the delay between inputting the required amount and dispensing that amount. In this case, the alarm 2512 is an alarm that cannot dispense the required amount, but it may also be an alarm that cannot maintain the required solution stock level due to lack of raw material.

Finally, while performing any of the steps described above, the machine may monitor its own functions at step 2513 to detect usage of raw materials and abnormal operation. If an error is detected (step 2514), the machine may stop dispensing solution to ensure safety and/or accuracy. As a non-limiting example, the error may include a detected sudden high or low level of the solution or material, which may indicate a leak or improper dispense.

The step of producing the desired solution or mixture for dispensing 2505 may include the entire process indicated in fig. 25A. This process occurs if the desired amount of mixture is produced in step 2501. The mixture is a mixture of the additive and the solution. In step 2505, a mixture can be produced by mixing the solution and the additive. The amount of solution required to be mixed with the additive can be considered the desired amount 2501. The process of dispensing the solution can thus be included in step 2505 in the process of dispensing the mixture.

Fig. 25B is similar to fig. 25A, but it shows that pre-made and available solutions or mixtures are not necessary and need not be provided. In this aspect of the invention, the amount of material required to make the solution or mixture is checked in step 2515 after the required amount is entered (step 2501). If sufficient quantity is available to produce the required quantity (step 2517), the quantity is produced (step 2505) and dispensed (step 2506). If not enough material is available (step 2516), an alarm occurs (step 2512) and the process stops. The design of fig. 25B is advantageous in situations where it is more difficult or more expensive to pre-form the solution or mixture due to space constraints, for example.

Finally, although the cell of the present invention is used with a control system that regulates the mixing of chemicals, the cell may be used separately from the control system, and the control system may be used separately from the cell or in conjunction with other cells.

Chemical substance, solution and solvent

Various chemicals, solutions, and solvents may be used and formed using aspects of the present invention. Examples include calcium magnesium acetate, calcium chloride, magnesium chloride, potassium acetate, potassium formate, sodium formate, magnesium acetate, diammonium phosphate, urea, ethyl glycol, propylene glycol, and other materials.

Modifying

In various aspects, one or more structures, systems, methods, etc., may be used in combination with others. Further, the structure of the solution maker may include additional modifications as follows. First, one or more components of the solution maker, for example, may be made of a non-plastic material. For example, the filter grid 142 may be made at least partially or entirely of a non-plastic material. Similarly, at least one of the first container 104 and the second container 106 may be constructed at least partially of a non-plastic material. Plastics have a number of advantages over other materials. However, plastics are not as beneficial as other materials in all situations. For example, plastics become brittle at cold temperatures or when exposed to various chemicals or ultraviolet light. In this regard, stainless steel, aluminum, or other metals are beneficial for use in various environments. In one example, stainless steel has the advantage of high corrosion resistance, while other materials are corroded. Alternatively, rubber may be used in place of plastic to enhance the flexibility, elasticity, and movement of one or more components of the solution maker 100 and/or associated piping. In addition, concrete or other materials may be used because concrete is both durable and cost effective.

Second, the water inlet of the solution maker 100 may be a simple inlet valve or may be an active device that changes the solvent supply spray pattern to more completely dissolve the chemical into solution. For example, the inlet valve may have a rotating spray pattern, an oscillating spray pattern, and any other spray pattern that prevents undesirable accumulation of chemical species on the grate 142. Similarly, the inlet valve of the second container 106 may similarly be replaced with one or more valves that change its spray pattern.

Third, mixer 102 can be eliminated and replaced with a flow control and mixing valve that provides a mixing environment to achieve mixing of various chemicals and solvents without the need for a mixing tank.

Fourth, the solution maker 100 may include a modified structure as shown in fig. 26. Fig. 26 shows a first portion 2601 and a second portion 2602. Instead of a permeable grate, the bottom of the first portion 2601 is an impermeable layer 2603. Solvent 2609 enters first portion 2601 through inlet 2610. Solvent 2611 then fills first portion 2601, as shown as volume 2611. It should be appreciated that the port 2610 may be located on either side of the portion 2601 (including the top and bottom plates).

On top of portion 2602 is a permeable grate 2604. Chemicals to be dissolved in solvent 2609 can be added through one or more sides (or top conduits, not shown) via pathway 2605 and optionally 2607 in the direction of arrows 2606 and 2608. The dissolved chemicals are deposited on grid 2604 as shown as chemical 2612. Solvent 2611 then travels along conduit 2614 from first portion 2601 into conduit 2602. Solvent 2611 is then sprayed up through the grid or directly between grid 2604 and impermeable layer 2603. When chemical 2612 dissolves into solvent 2611, the mixture passes through grate 2604 as shown as solution 2616. Solution 2616 may then be further processed as described herein.

It should be appreciated that the chemical 2612 may be a solid material, a liquid, or a slurry. For example, the chemical 2612 may be a salt, a salt solution, or a liquid chemical (such as ethylene glycol or fertilizer) that is mixed with a solvent 2611 such as water or other compound in which the chemical 2612 is dissolved.

Fifth, other aspects of the mixing system 102 may be modified such that no storage tank is present. Fig. 27 shows the mixing system 102 without a storage tank. The first supply line 2701 provides a concentrated solution 2703. A second supply line 2702 provides a solvent 2704. Concentrated solution 2703 and solvent 2704 are mixed at location 2705. The concentration is determined at position 2706. The results of the concentration determination 2706 control the diverter 2707 so that a mixed solution of a desired concentration passes through the diverter port 2708 and is output at 2709. Too high a concentration passes through the diverter port 2710 and is output back to the concentrate supply 2703 using the optional control valve 2711. Too low a concentration passes through the diverter port 2712 and is output back to the concentrate supply 2704 using the optional control valve 2713. When the mixture has too high a concentration, feeding the mixture to the concentrated solution 2703 reduces the concentration of the mixture at location 2705 due to the previously added solvent. The result is a reduced concentration at position 2705. Similarly, when the concentration of the mixture is too low, feeding the mixture to solvent 2704 increases the concentration of the mixture at location 2705 due to the previously added concentration 2703. The result is an increase in the concentration of the mixture at position 2705.

Examples and applications

Aspects of the present invention may be used in various applications, as divided into the following examples.

In a first embodiment, aspects of the present invention may be used in corrosive environments such as mixed brines for deicing applications. Brine used for deicing is very corrosive. It is important to minimize the number of precision instruments that come into contact with the saline. For example, adding a rotary flow meter to a solution can create serious maintenance problems due to constant failure of the meter. Although flow meters can be used in such corrosive environments, the cost of the flow meter is high, making the entire solution maker expensive. One advantage of using this type of flow meter, however, is that it can provide highly accurate measurements of the material flowing through it.

In a second embodiment, aspects of the present invention may be used in the saltwater industry with less corrosive environments. For example, aspects of the invention may be used in the cheese, beverage, or meat processing industries. Here, the food may be immersed in a saline solution having a salinity lower than that of the deicing environment.

In a third embodiment, aspects of the present invention may be used in an industrial water supply environment where large quantities of water or other liquid chemicals need to be mixed before being provided for subsequent processing or use. For example, hospitals, processing plants, energy generation plants, and the like may require large amounts of treated water or other materials. Aspects of the present invention may be used to assist in mixing solutions for these applications.

In a fourth embodiment, aspects of the present invention may be used to blend other chemicals or slurries, including but not limited to various oils, solutions for water cutting or grit blasting, production of compound fertilizers, and grinding, among others.

Although the present invention has been described with reference to embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.

Claims (16)

1. A solution manufacturing system for mixing a solvent and a chemical, the system comprising:

a first location receiving the solvent;

a second location receiving a solution of the solvent and the chemical;

a concentration sensor that outputs a signal;

a processor that determines a concentration of the solution from the signal;

a first return path that returns the solution to the first location when the concentration of the solution is below a desired concentration;

a second return path for returning the solution to the second location when the concentration of the solution is above the desired concentration, the second return path including an inlet through which additional solvent is added to the solution;

an outlet that outputs the solution having the desired concentration.

2. The solution manufacturing system according to claim 1, wherein said desired concentration is a concentration range.

3. The solution manufacturing system according to claim 1, wherein said chemical substance is a solid.

4. The solution manufacturing system according to claim 1, wherein said chemical substance is a slurry.

5. The solution manufacturing system according to claim 1, further comprising:

an additive container containing an additive;

a mixing location where the additive is mixed with the solution;

wherein the processor determines whether the additive and the solution are mixed to one of a desired concentration and a desired volume and controls the mixing of the additive and the solution to form at least one of the desired concentration and the desired volume.

6. The solution manufacturing system according to claim 5, further comprising:

a sensor associated with the additive container, the sensor outputting a signal;

wherein the processor utilizes the signal to determine a volume of additive in the additive container.

7. The solution manufacturing system according to claim 5, further comprising:

a sensor associated with a solution container containing the solution, the sensor outputting a signal;

wherein the processor utilizes the signal to determine a volume of solution in the solution container.

8. The solution manufacturing system according to claim 5, further comprising:

a sensor associated with the output receptacle, the sensor outputting a signal;

wherein the processor utilizes the signal to determine an available volume in the output container to hold an output mixture of the solution and the additive.

9. The solution manufacturing system according to claim 5, further comprising:

a sensor that outputs a signal to the processor,

wherein the processor uses the signal for the determination.

10. The solution manufacturing system according to claim 1, wherein said concentration sensor is a conductivity sensor.

11. The solution manufacturing system according to claim 1, wherein said concentration sensor is a specific gravity sensor.

12. The solution manufacturing system according to claim 1, wherein said concentration sensor is a refractometer sensor.

13. The solution manufacturing system according to claim 1, further comprising an opening at said first location that receives said chemical.

14. The solution manufacturing system according to claim 1, further comprising an opening at said second location that receives said chemical.

15. The solution manufacturing system of claim 1, further comprising a purging system.

16. The solution manufacturing system of claim 1, wherein said solution manufacturing system is devoid of a purging system.