On site generation of alkalinity boost for ware washing applications

• US 9,045,835 B2
• Filed: 09/11/2013
• Issued: 06/02/2015
• Est. Priority Date: 07/26/2011
• Status: Active Grant

• Current Assignee: Ecolab USA Incorporated (Ecolab, Inc.)
• Original Assignee: Ecolab USA Incorporated (Ecolab, Inc.)
• Inventors: Sanville, Katherine M., Hunt, Clinton Jr., Taylor, Barry R.
• Primary Examiner(s): Hendricks, Keith
• Assistant Examiner(s): Friday, Steven A.
• Application Number:
  US14/023,517
• Publication Number:
  US 20140014526A1
• Time in Patent Office: 629 Days
• Field of Search: 205/510, 205/516, 205/687, 205/746, 205/769, 205/770, 510/179, 510/197, 510218-237
• US Class Current: 1/1
• CPC Class Codes: C11D 11/00 Special methods for preparing compositions containing mixtures of detergents
• CPC Class Codes: C11D 3/044 Hydroxides or bases
• CPC Class Codes: C11D 3/10 Carbonates ; Bicarbonates
• CPC Class Codes: C11D 7/06 Hydroxides
• CPC Class Codes: C11D 7/12 Carbonates bicarbonates
• CPC Class Codes: C25B 1/16 Hydroxides by simultaneous production of alkali metal hydroxides and chlorine, oxyacids or salts of chlorine C25B1/34

Abstract

Methods for enhancing alkalinity and performance of ash-based detergents are disclosed. Nonhazardous ash-based detergent alkalinity is enhanced through increasing the ratio of sodium hydroxide to ash-based alkalinity. Methods according to the invention do not require the addition of chemical ingredients, do not generate additional waste streams and use the entirety of the ash-based detergent. The methods according to the invention provide alkalinity-enhanced detergent use solutions that are sufficiently concentrated for adequate cleaning capability while only requiring minimal amounts of the use solution to be dispensed for an in situ cleaning process.

Claims

1. A method of electrochemically increasing alkalinity of a detergent comprising:

providing an alkali metal carbonate, bicarbonate or sesquicarbonate source to an anode chamber of an electrolytic cell, wherein said electrolytic cell comprises said anode chamber and a cathode chamber;

causing the alkali metal carbonate, bicarbonate or sesquicarbonate source to undergo electrolysis, wherein said electrolysis increases hydroxide concentration in the alkali metal carbonate, bicarbonate or sesquicarbonate source;

removing carbon dioxide from said alkali metal carbonate, bicarbonate or sesquicarbonate source, wherein the resulting decrease in carbon dioxide in the alkali metal carbonate, bicarbonate or sesquicarbonate source and the increase in hydroxide concentration in the alkali metal carbonate, bicarbonate or sesquicarbonate source produces increased hydroxide alkalinity in the alkali metal carbonate, bicarbonate or sesquicarbonate source;

recirculating the contents of the anode chamber directly into the cathode chamber; and

generating a detergent use solution having increased hydroxide alkalinity compared to the original alkali metal carbonate, bicarbonate or sesquicarbonate source provided to the electrolytic cell.

2. The method of claim 1 wherein said alkali metal carbonate source is a sodium carbonate detergent.

3. The method of claim 2 wherein water is provided to a cathode chamber.

4. The method of claim 2 wherein said sodium carbonate detergent further comprises polymers and other ingredients and further comprising the step of adding an exhausted sodium carbonate detergent into said detergent use solution.

5. The method of claim 1 wherein the ratio of ash to hydroxide alkalinity generated in the detergent use solution is from about 90:

10 to about 80;

20.

6. The method of claim 1 wherein the ratio of ash to hydroxide alkalinity generated in the detergent use solution is from about 80:

20 to about 70;

30.

7. The method of claim 1 wherein said alkali metal carbonate source is solid sodium carbonate detergent that is dispensed directly into said electrolytic cell in the form of a concentrated detergent solution.

8. The method of claim 1 wherein the contents of the anode chamber are recirculated into the cathode chamber for additional electrolysis within the electrolytic cell until an ash to hydroxide alkalinity ratio of from about 90:

10 to about 85;

15 is obtained in the detergent use solution.

9. The method of claim 1 wherein the generation of the detergent use solution is a continuous or batch mode.

10. The method of claim 1 wherein said detergent use solution provides essentially the same detergency as a caustic detergent.

11. A method of increasing alkalinity of a detergent use solution on site comprising:

causing an alkali metal carbonate, bicarbonate or sesquicarbonate source to undergo electrolysis in an anode chamber of an electrolytic cell, wherein said electrolytic cell comprises said anode chamber and a cathode chamber, wherein the alkali metal carbonate, bicarbonate or sesquicarbonate detergent source is a concentrated detergent solution from a dispenser;

recirculating the contents of the anode chamber directly into the cathode chamber;

decreasing the ratio of ash to hydroxide alkalinity from about 100;

0 to between about 95;

5 to about 70;

30 in a detergent use solution generated from the output of said electrolytic cell; and

providing said detergent use solution to an onsite cleaning application.

13. The method of claim 11 wherein said alkali metal carbonate, bicarbonate or sesquicarbonate source is provided to both the anode chamber and the cathode chamber of the electrolytic cell.

14. The method of claim 11 wherein the ratio of ash to hydroxide alkalinity is from about 80:

20 to about 70;

30.

15. The method of claim 11 wherein an exhausted detergent source is added directly into said detergent use solution.

16. The method of claim 11 wherein the contents of the anode chamber are recirculated into the cathode chamber for additional electrolysis within the electrolytic cell until an ash to hydroxide alkalinity concentration of from about 90:

10 to about 85;

15 is obtained in the detergent use solution.

17. The method of claim 11 wherein the generation of the detergent use solution is a continuous or batch mode.

18. The method of claim 11 wherein said detergent use solution provides essentially the same detergency as a caustic detergent.

19. The method of claim 11 wherein the detergent use solution further comprises a surfactant and chelating agent, wherein said surfactant and chelating agent is present in the detergent use solution between about 10-30 wt %.

20. The method of claim 11 wherein the providing the detergent use solution does not generate additional waste streams.

12. The method of 11 wherein water is provided to the cathode chamber of the electrolytic cell.