U.S. patent application number 15/464125 was filed with the patent office on 2017-07-27 for systems and methods for extracting sand from raw slurry material.
The applicant listed for this patent is Daritech, Inc.. Invention is credited to David DeWaard.
Application Number | 20170209818 15/464125 |
Document ID | / |
Family ID | 43924262 |
Filed Date | 2017-07-27 |
United States Patent
Application |
20170209818 |
Kind Code |
A1 |
DeWaard; David |
July 27, 2017 |
Systems and Methods for Extracting Sand from Raw Slurry
Material
Abstract
A processing system for processing raw slurry material
comprising at least liquid, sand, and contaminates comprises a
barrel member, at least one transport member, at least one
separator member, and a drive system. As the drive system rotates
the barrel member about the barrel longitudinal axis, a portion of
the raw slurry material is transported through a pre-processing
portion of the processing chamber. At least a portion of the liquid
and at least a portion of the contaminates in the raw slurry
material flows back down the pre-processing portion of the
processing chamber towards a barrel inlet. At least one
intermediate opening is arranged such that at least a portion of
the contaminates in the raw slurry material flowing down through
the pre-processing portion of the processing chamber passes through
the at least one intermediate opening.
Inventors: |
DeWaard; David; (Lynden,
WA) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Daritech, Inc. |
Lynden |
WA |
US |
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|
Family ID: |
43924262 |
Appl. No.: |
15/464125 |
Filed: |
March 20, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14542951 |
Nov 17, 2014 |
9597618 |
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15464125 |
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13926640 |
Jun 25, 2013 |
8889016 |
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14542951 |
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12917728 |
Nov 2, 2010 |
8470183 |
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13926640 |
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61258467 |
Nov 5, 2009 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65G 33/12 20130101;
B01D 21/2461 20130101; B01D 33/06 20130101; B01D 33/76 20130101;
B65G 2201/045 20130101; B01D 33/72 20130101 |
International
Class: |
B01D 33/06 20060101
B01D033/06; B01D 21/24 20060101 B01D021/24; B65G 33/12 20060101
B65G033/12; B01D 33/76 20060101 B01D033/76 |
Claims
1. A processing system for processing raw slurry material
comprising at least liquid, sand, and contaminates, the processing
system comprising: a main trough; an inlet conduit arranged to
introduce the raw slurry material into the trough; an upper trough
in fluid communication with an upper portion of the main trough; an
outlet conduit arranged to allow liquid to flow out of the upper
trough; a barrel member defining a barrel inlet, a barrel outlet,
and a barrel longitudinal axis, where the barrel member defines a
processing chamber and at least one intermediate opening, the
processing chamber defines a pre-processing portion and a separator
portion, and the barrel inlet is arranged within the main trough;
at least one transport member arranged within the pre-processing
portion of the processing chamber; at least one separator member
arranged within the separator portion of the processing chamber and
configured to define at least one separator gap; and a drive system
for rotating the barrel member about the barrel longitudinal axis;
wherein as the drive system rotates the barrel member about the
barrel longitudinal axis, the at least one transport member
transports at least a portion of the raw slurry material away from
the barrel inlet and through the pre-processing portion of the
processing chamber, the at least one separator member transports at
least a portion of the sand in the raw slurry material through the
separator portion of the processing chamber and out of the barrel
outlet, at least a portion of the liquid and at least a portion of
the contaminates in the raw slurry material flows back down the
pre-processing portion of the processing chamber towards the barrel
inlet, and the at least one intermediate opening is arranged such
that at least a portion of the contaminates in the raw slurry
material flowing down through the pre-processing portion of the
processing chamber passes through the at least one intermediate
opening.
2. A processing system as recited in claim 1, in which the at least
one transport member and the at least one separator member extend
inwardly from an interior wall of the barrel member.
3. A processing system as recited in claim 1, in which a portion of
the pre-processing member extends out of the barrel member through
the barrel inlet.
4. A processing system as recited in claim 3, in which the at least
one intermediate opening comprises a plurality of intermediate
openings.
5. A processing system as recited in claim 3, in which the at least
one intermediate opening comprises a plurality of intermediate
openings. spaced around a diameter of the barrel member.
6. A processing system as recited in claim 1, in which the at least
one intermediate opening comprises a plurality of intermediate
openings spaced along the longitudinal axis of the barrel
member.
7. A processing system as recited in claim 1, in which the at least
one intermediate opening comprises a plurality of intermediate
openings spaced around a diameter of the barrel member and along
the longitudinal axis of the barrel member.
8. A processing system as recited in claim 1, in which the at least
one separator member defines a plurality of separator gaps.
9. A processing system as recited in claim 1, further comprising at
least one of: a first processing conduit arranged to introduce
rinse fluid into the processing chamber such that rinse fluid flows
into the pre-processing portion of the processing chamber; and a
second processing conduit arranged to introduce rinse fluid into
the processing chamber such that rinse fluid flows into the
separator portion of the pre-processing chamber and then into the
pre-processing portion of the processing chamber.
10. A processing system for processing raw slurry material
comprising at least liquid, sand, and contaminates, the processing
system comprising: a main trough; an inlet conduit arranged to
introduce the raw slurry material into the trough; an upper trough
in fluid communication with an upper portion of the main trough; an
outlet conduit arranged to allow liquid to flow out of the upper
trough; a barrel member defining an inlet, and outlet, and a barrel
longitudinal axis, where the barrel member defines a processing
chamber and at least one intermediate opening, and the processing
chamber defines a pre-processing portion and a separator portion; a
continuous helical member arranged within the pre-processing
portion of the processing chamber; a plurality of discontinuous
helical members arranged within the separator portion of the
processing chamber such that the discontinuous helical members
define at least one separator gap; and a drive system for rotating
the barrel member about the barrel longitudinal axis; wherein as
the drive system rotates the barrel member about the barrel
longitudinal axis, the continuous helical member transports at
least a portion of the raw slurry material away from the barrel
inlet and through the pre-processing portion of the processing
chamber, the plurality of discontinuous helical members at least a
portion of the sand in the raw slurry material through the
separator portion of the processing chamber and out of the barrel
outlet, at least a portion of the liquid and at least a portion of
the contaminates in the raw slurry material flows back down the
pre-processing portion of the processing chamber towards the barrel
inlet, and the at least one intermediate opening is arranged such
that at least a portion of the contaminates in the raw slurry
material flowing down through the pre-processing portion of the
processing chamber passes through the at least one intermediate
opening.
11. A processing system as recited in claim 10, in which the at
least one continuous helical member and the at least one
discontinuous helical member extend inwardly from an interior wall
of the barrel member.
12. A processing system as recited in claim 10, in which in which a
portion of the pre-processing member extends out of the barrel
member through the barrel inlet.
13. A processing system as recited in claim 10, in which the at
least one intermediate opening comprises a plurality of
intermediate openings.
14. A processing system as recited in claim 10, in which the at
least one intermediate opening comprises a plurality of
intermediate openings spaced around a diameter of the barrel
member.
15. A processing system as recited in claim 10, in which the at
least one intermediate opening comprises a plurality of
intermediate openings spaced along the longitudinal axis of the
barrel member.
16. A processing system as recited in claim 10, in which the at
least one intermediate opening comprises a plurality of
intermediate openings spaced around a diameter of the barrel member
and along a longitudinal axis of the barrel member.
17. A processing system as recited in claim 10, in which the
plurality of discontinuous helical members define a plurality of
separator gaps.
18. A processing system as recited in claim 10, further comprising
at least one of: a first processing conduit arranged to introduce
rinse fluid into the processing chamber such that rinse fluid flows
into the pre-processing portion of the processing chamber; and a
second processing conduit arranged to introduce rinse fluid into
the processing chamber such that rinse fluid flows into the
separator portion of the pre-processing chamber and then into the
pre-processing portion of the processing chamber.
19. A method of processing raw slurry material comprising at least
liquid, sand, and contaminates, the method comprising the steps of:
providing a barrel member defining a barrel inlet, a barrel outlet,
a processing chamber, at least one intermediate opening, and a
longitudinal axis; arranging at least one transport member within a
pre-processing portion of the processing chamber; arranging at
least one separator member within a separator portion of the
processing chamber such that the at least one separator member
defines at least one separator gap; arranging the barrel member
such that the barrel inlet is within a main trough; arranging an
upper trough be in fluid communication with an upper portion of the
main trough; introducing the raw slurry material into the main
chamber; and rotating the barrel member such that the at least one
transport member transports at least a portion of the raw slurry
material away from the barrel inlet and through the pre-processing
portion of the processing chamber, the at least one separator
member transports at least a portion of the sand in the raw slurry
material through the separator portion of the processing chamber
and out of the barrel outlet, at least a portion of the liquid and
at least a portion of the contaminates in the raw slurry material
flows back down the pre-processing portion of the processing
chamber towards the barrel inlet, and at least a portion of the
contaminates in the raw slurry material flowing down through the
pre-processing portion of the processing chamber passes through the
at least one intermediate opening.
Description
RELATED APPLICATIONS
[0001] This application (Attorney's Ref. No. P219026) is a
continuation of U.S. patent application Ser. No. 14/542,951 filed
Nov. 17, 2014, currently pending.
[0002] U.S. patent application Ser. No. 14/542,951 is a
continuation of U.S. patent application Ser. No. 13/926,640 filed
Jun. 25, 2013, now U.S. Pat. No. 8,889,016, which issued on Nov.
18, 2014.
[0003] U.S. patent application Ser. No. 13/926,640 is a
continuation of U.S. patent application Ser. No. 12/917,728 filed
Nov. 2, 2010, now U.S. Pat. No. 8,470,183, which issued on Jun. 25,
2013.
[0004] U.S. patent application Ser. No. 12/917,728 claims priority
benefit of U.S. Provisional Application Ser. No. 61/258,467 filed
Nov. 5, 2009, now expired.
[0005] The contents of all related applications listed above are
incorporated herein by reference.
TECHNICAL FIELD
[0006] The present invention relates to the extraction of solid
particulates from raw slurry material and, in particular, to the
extraction of sand from raw slurry material comprising at least
water, animal waste, and sand.
BACKGROUND
[0007] Modern animal husbandry operations such as dairy farms often
require the handling of relatively large numbers of animals in
indoor facilities. For example, cows in a dairy operation are kept
at least part of the day in stalls defining a stall resting
surface. From a cow's perspective, the stall resting surface should
be covered with bedding material that is comfortable to lie on,
provide uniform support, be cool in the summer, be non-abrasive,
and provide confident footing during reclining and rising
maneuvers. From the perspective of the operator of the dairy,
bedding material should not be detrimental to the health of the
cows or the quality of the milk produced by the cows. Sand has been
proven to be advantageous as a bedding material and is commonly
used in modern dairy operations.
[0008] When used as a bedding material, sand often becomes mixed
with manure and possibly other contaminants. When cleaning systems
are used to remove manure from a diary facility, raw slurry
material is formed containing rinse liquids, liquid manure, solids,
sand, and possibly other contaminants. If possible, it is desirable
to convert components of the raw slurry mixture to usable materials
and/or reuse the components of the raw slurry mixture.
[0009] The present invention relates to the removal of particulate
material such as sand from raw slurry mixtures so that the sand may
be reused. Removal of sand from the raw slurry material further
forms a processed slurry (low sand content) that is more
appropriate for further processing operations such as extraction of
water, composting, and/or digesting.
SUMMARY
[0010] The present invention may be embodied as a processing system
for processing raw slurry material comprising at least liquid,
sand, and contaminates. The processing system comprises a main
trough, an inlet conduit, an upper trough, an outlet conduit, a
barrel member, at least one transport member, at least on separator
member, and a drive system. The inlet conduit is arranged to
introduce the raw slurry material into the trough.
[0011] The upper trough is in fluid communication with an upper
portion of the main trough. The outlet conduit is arranged to allow
liquid to flow out of the upper trough. The barrel member defines a
barrel inlet, a barrel outlet, and a barrel longitudinal axis. The
barrel member defines a processing chamber and at least one
intermediate opening. The processing chamber defines a
pre-processing portion and a separator portion. The barrel inlet is
arranged within the main trough. The at least one transport member
is arranged within the pre-processing portion of the processing
chamber. The at least one separator member is arranged within the
separator portion of the processing chamber and configured to
define at least one separator gap. The drive system rotates the
barrel member about the barrel longitudinal axis. As the drive
system rotates the barrel member about the barrel longitudinal
axis, the at least one transport member transports at least a
portion of the raw slurry material away from the barrel inlet and
through the pre-processing portion of the processing chamber, the
at least one separator member transports at least a portion of the
sand in the raw slurry material through the separator portion of
the processing chamber and out of the barrel outlet, at least a
portion of the liquid and at least a portion of the contaminates in
the raw slurry material flows back down the pre-processing portion
of the processing chamber towards the barrel inlet, and the at
least one intermediate opening is arranged such that at least a
portion of the contaminates in the raw slurry material flowing down
through the pre-processing portion of the processing chamber passes
through the at least one intermediate opening.
[0012] The present invention may also be embodied as a processing
system for processing raw slurry material comprising at least
liquid, sand, and contaminates, the processing system comprising a
main trough, an inlet conduit, an upper trough, an outlet conduit,
a barrel member, a continuous helical member, a plurality of
discontinuous helical members, and a drive system. The inlet
conduit is arranged to introduce the raw slurry material into the
trough. The upper trough is in fluid communication with an upper
portion of the main trough. The outlet conduit is arranged to allow
liquid to flow out of the upper trough. The barrel member defines
an inlet, and outlet, and a barrel longitudinal axis. The barrel
member defines a processing chamber and at least one intermediate
opening, and the processing chamber defines a pre-processing
portion and a separator portion. The continuous helical member is
arranged within the pre-processing portion of the processing
chamber. The plurality of discontinuous helical members is arranged
within the separator portion of the processing chamber such that
the discontinuous helical members define at least one separator
gap. The drive system for rotating the barrel member about the
barrel longitudinal axis. As the drive system rotates the barrel
member about the barrel longitudinal axis, the continuous helical
member transports at least a portion of the raw slurry material
away from the barrel inlet and through the pre-processing portion
of the processing chamber, the plurality of discontinuous helical
members at least a portion of the sand in the raw slurry material
through the separator portion of the processing chamber and out of
the barrel outlet, at least a portion of the liquid and at least a
portion of the contaminates in the raw slurry material flows back
down the pre-processing portion of the processing chamber towards
the barrel inlet, and the at least one intermediate opening is
arranged such that at least a portion of the contaminates in the
raw slurry material flowing down through the pre-processing portion
of the processing chamber passes through the at least one
intermediate opening.
[0013] The present invention may also be embodied as a method of
processing raw slurry material comprising at least liquid, sand,
and contaminates, the method comprising the following steps. A
barrel member defining a barrel inlet, a barrel outlet, a
processing chamber, at least one intermediate opening, and a
longitudinal axis is provided. At least one transport member is
arranged within a pre-processing portion of the processing chamber.
At least one separator member is arranged within a separator
portion of the processing chamber such that the at least one
separator member defines at least one separator gap. The barrel
member is arranged such that the barrel inlet is within a main
trough. An upper trough is arranged be in fluid communication with
an upper portion of the main trough.
[0014] The raw slurry material is introduced into the main chamber.
The barrel member is rotated such that the at least one transport
member transports at least a portion of the raw slurry material
away from the barrel inlet and through the pre-processing portion
of the processing chamber, the at least one separator member
transports at least a portion of the sand in the raw slurry
material through the separator portion of the processing chamber
and out of the barrel outlet, at least a portion of the liquid and
at least a portion of the contaminates in the raw slurry material
flows back down the pre-processing portion of the processing
chamber towards the barrel inlet, and at least a portion of the
contaminates in the raw slurry material flowing down through the
pre-processing portion of the processing chamber passes through the
at least one intermediate opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view of a first example sand
separator system;
[0016] FIG. 2 is a side elevation view of the first example sand
separator system;
[0017] FIG. 3 is an enlarged portion of FIG. 2;
[0018] FIG. 4 is an enlarged portion of FIG. 2;
[0019] FIG. 5 is a partial cutaway, end elevation view of the first
example sand separator system;
[0020] FIG. 6 is an end perspective view taken along lines 6-6 in
FIG. 2;
[0021] FIGS. 6A and 6B are section views taken along lines 6A-6A in
FIG. 2 illustrating the separation of the raw slurry material into
a thinned portion and a thickened portion;
[0022] FIG. 6C is a section view taken along lines 6C-6C in FIG.
6B;
[0023] FIG. 6D is a section view similar to FIG. 6C without the raw
slurry material;
[0024] FIG. 7 is a cutaway view taken along lines 7-7 in FIG.
2;
[0025] FIG. 8 is a perspective view of a second example sand
separator system;
[0026] FIG. 9 is a side elevation view of the second example sand
separator system;
[0027] FIG. 10 is a perspective view of a proximal end of a barrel
member of the sand separator member illustrating a portion of the
pre-processing member thereof;
[0028] FIG. 11 is an enlarged portion of FIG. 9;
[0029] FIG. 12 is a perspective view of a distal end of a barrel
member of the sand separator member illustrating a portion of the
separator members;
[0030] FIG. 13 is a perspective view of the distal end of a barrel
member of the sand separator member illustrating portions of the
separator members;
[0031] FIG. 14 is a cutaway view taken along lines 14-14 in FIG. 9;
and
[0032] FIG. 15 is a perspective view of a third example sand
separator system.
DETAILED DESCRIPTION
[0033] Referring initially to FIG. 1 of the drawing, depicted at 20
therein is a first example sand separator system constructed in
accordance with, and embodying, the principles of the present
invention. The first example sand separator system comprises a
support frame 22, a processing system 24, a trough system 26, and a
drive system 28.
[0034] In general, the support frame 22 supports the processing
system relative to the trough system 26 such that slurry material
within the trough system 26 is fed into the processing system 24.
The drive system 28 rotates at least a portion of the processing
system 24 such that particulate material such as sand is extracted
from the slurry material fed into and through the processing system
24.
[0035] The example support frame 22 defines a surface engaging
portion 30, a support portion 32, cradle portions 34, a bearing
surface 36, and a motor platform 38. The surface engaging portion
30 defines a reference plane P1, and the support portion 32 defines
a support plane P2 that extends at an angle to the reference plane
P1 (FIG. 2). The surface engaging portion 30 is adapted to be
supported on a support surface such that the reference plane P1 is
substantially horizontal. Accordingly, the reference plane P2
extends at an angle with respect to horizontal.
[0036] The purpose of the support frame 22 is to support the
processing system 24 at a particular angle with respect to
horizontal and in a desired position with respect to the trough
system 26. Any structure that supports one or all of the
processing, trough, and/or drive systems 24, 26, and 28 relative to
horizontal and with respect to each other as generally described
herein may be used in place of the example support frame 22.
[0037] FIG. 1 further shows that the example processing system 24
comprises a processing structure 40, a first processing conduit 42,
and a second processing conduit 44. As perhaps best shown in FIG.
2, the processing structure 40 defines a processing axis Al and a
processing chamber 46. The example cradle portions 34 are
configured to support trough system 26. The bearing surface 36 and
motor platform 38 are arranged and configured such that the
processing axis Al is substantially parallel to the support plane
P2 as will be described in further detail below. The processing
axis A1 thus extends at an angle with respect to horizontal.
[0038] The example trough system 26 comprises a main trough 50, an
inlet conduit 52, and an upper trough 54. A divider surface 56
separates the main trough 50 from the upper trough 54. A baffle 58
divides the main trough 50 into an inlet portion 50a and a feed
portion 50b. The inlet conduit 52 is arranged deposit raw slurry
material into the inlet portion 50a. Raw slurry material in the
inlet portion 50a must flow down and under the baffle 58 before
flowing into the feed portion 50b.
[0039] The example drive system 28 comprises a drive shaft 60 (FIG.
3), a shaft bearing assembly 62, a transmission assembly 64, a
drive motor assembly 66, and a plurality (two or more) bearing
wheel assemblies 68 (FIG. 7). The drive motor assembly 66 rotates
the drive shaft 60 through the transmission assembly 64. The
example drive shaft 60 is connected to the processing structure 40
such that rotation of the drive shaft 60 causes rotation of the
processing structure 40 about the processing axis Al. The shaft
bearing assembly 62 is arranged to support the drive shaft 60 and
thus an end of the processing structure 40. The bearing wheel
assemblies 68 are configured to support a portion of the processing
structure 40 for rotation about the processing axis A1.
[0040] The example processing structure 40 comprises a barrel
member 70, a guide member 72, an auger member 74, a pre-processing
member 76, and a plurality (two or more) separator members 78. The
example barrel member 70 is an elongate cylinder made of material
capable of maintaining this cylindrical shape while supporting the
guide member 72, auger member 74, pre-processing member 76, and
separator members 78 as will be described below. The example barrel
member 70 is made of steel, but other materials such as plastic or
composites may be used under certain circumstances.
[0041] The barrel member 70 defines both the processing chamber 46
and the processing axis A1. The processing chamber 46 defines a
feed portion 80, a pre-processing portion 82, a separator portion
84, and an outlet portion 86.
[0042] The pre-processing member 76 and separator members 78 extend
into the processing chamber 46 from the interior wall of the barrel
member 70. In particular, the pre-processing member 76 extends
substantially radially inwardly from the barrel member 70 into part
of the feed portion 80 and throughout the pre-processing portion 82
of the processing chamber 46. The example pre-processing member 76
follows a predetermined helical path defined by the diameter of the
barrel member 70 and the distance between axially spaced portions
of the pre-processing member 76. In the following discussion, each
portion or segment of the pre-processing member 76 extending
through one rotation along the helical path defines a course. These
discrete portions or sections of the pre-processing member 76 may
thus be referred to as courses.
[0043] The guide member 72 is rigidly secured to an inner edge 76a
of the portion of the pre-processing member 76 within the feed
portion 80 such that a longitudinal axis of the guide member 72 is
aligned with the processing axis A1. The auger member 74 is rigidly
secured to the guide member 72 such that the auger member 74
extends from the guide member 72 outside of the processing chamber
46. The example auger member 74 further follows substantially the
same predetermined helical path as the pre-processing member 76. A
notch 70a is formed in the barrel member 70 to create a path from
the feed portion 50b of the main trough 50 into the processing
chamber 46 around the auger member 74 and through the
pre-processing member 76.
[0044] The separator members 78 extend generally radially inwardly
from the barrel member 70 and generally follow the predetermined
helical path defined by the pre-processing member 76. However, the
separator members 78 are spaced from each other along the
predetermined helical path and/or deviate from the predetermined
helical path such that separator gaps 88 are formed between
adjacent separator members 78.
[0045] In particular, first and second example separator members
78a and 78b are shown in FIG. 6D. As generally described above, the
processing axis A1 extends at an angle with respect to horizontal;
the processing axis A1 thus defines up and down directions as
represented by arrows labeled UP and DOWN in drawing FIGS. 1-4, 6C,
and 6D. In the context of any given pair of separator members, the
uppermost separator member will be referred to as the as the
leading separator member, while the lowermost separator member will
be referred to as the trailing separator member. Using similar
terminology, each separator member defines to radially aligned
edges, and the uppermost of these edges will be referred to as the
leading edge, while the lower most of these edges will be referred
to as the trailing edge.
[0046] Accordingly, the first example separator member 78a is the
leading separator member of this pair of separating members and
defines a leading edge 90a and a trailing edge 92a. The second
example separator member 78b is the trailing separator member in
this pair and defines a leading edge 90b and a trailing edge
92b.
[0047] Using this terminology, FIG. 6D shows that the leading edge
90b of the trailing separator member 78b is above the trailing edge
92a of the leading separator member 78a by a distance D1. FIG. 6D
also shows that the leading edge 90b of the trailing separator
member 78b is circumferentially spaced from the trailing edge 92a
of the leading separator member 78a by a distance D2. At least one
of these distances D1 and D2 must be greater than zero to define
the separator gap 88.
[0048] The example separator members 78 are in the shape of
segments of the predetermined helical path but each helical
separator member is offset from the predetermined helical path
relative to the helical separators adjacent thereto. Another way of
forming the separator gaps 88 is to arrange non-helical separator
members along the predetermined helical path. Additionally,
non-helical separator members may be offset from the predetermined
helical path to form the separator gaps 88.
[0049] The example processing structure 40 further comprises
cleaning blades 94 formed on the outer surface thereof. Main trough
outlets 96 are formed in the main trough 50, while upper trough
outlets 98 are formed in the upper trough 54.
[0050] The first example sand separator system 20 operates as
follows. Raw slurry material is forced through the inlet conduit 52
into the inlet portion 50a of the main trough 50. The example sand
separator system 20 is designed to process raw slurry material a
liquid portion comprising at least rinse liquid, such as water, and
manure and a particulate portion comprising particulate material
such as sand.
[0051] The baffle 58 forces the raw slurry material to flow down to
the bottom of the main trough 50 before entering the feed portion
50b of that trough 50. The main trough 50 thus functions like a
gravity separator in which heavier particulate material such as
sand sinks to the bottom and the liquid portion rises to the top.
The flow path under the baffle 58 forces particulate material to
flow to a lower portion of the trough 50 before entering the upper
trough 54 as will be described in further detail below.
[0052] The support frame 22 supports the processing structure 40
such that the feed portion 80 of the processing chamber 46 is
within the feed portion 50b of the main trough 50. The auger member
74 extends into the bottom of the main trough 50 with the drive
shaft 60 partly within the guide member 72. In particular, the
drive shaft 60 is coupled to the guide member 72 such that axial
rotation of the drive shaft 60 rotates the guide member 72 about
the processing axis A1. And because the guide member 72 supports
the auger member 74 and pre-processing member 76, the auger member
74 and pre-processing member 76 also rotate about the processing
axis A1. Similarly, the pre-processing member 76 supports the
barrel member 70, so the barrel member 70 also rotates about the
processing axis A1. And axial rotation of the barrel member 70
causes the separator members 78 also to rotate about the processing
axis A1.
[0053] As the auger member 74 rotates about the processing axis A1,
a leading surface of the auger member 74 acts on the raw slurry
material within the main trough 50 to displace this raw slurry
material up towards the processing chamber 46. At about the notch
70a formed in the barrel member 70, the raw slurry material
displaced by the auger member 74 enters the pre-processing portion
82 of the processing chamber, where the raw slurry material is
displaced through the pre-processing portion 82 by a leading
surface of the pre-processing member 76.
[0054] As the pre-processing member displaces the raw slurry
material up along the processing axis A1 through the pre-processing
portion of the processing chamber, the particulate portion of the
raw slurry material sinks in the liquid portion of the raw slurry
material, separating the raw slurry material into a thickened
portion and a thinned portion. The thickened portion is relatively
close to the inner wall of the barrel member 70, while the thinned
portion is away from this inner wall. The thickened portion has a
relatively high concentration of particulate material, while the
thinned portion has a relatively lower concentration of the
particulate material. The concentration of particulate material in
the thickened portion increases as the raw slurry material proceeds
up through the pre-processing portion 82 of the processing chamber
46.
[0055] Towards the lower end of the pre-processing portion 82 of
the processing chamber 46, the thinned portion of the raw slurry
material flows over the inner edge 76a of the pre-processing member
76 from one course of the pre-processing member 76 back down to the
course below. This process begins to concentrate the particulate
material within the thickened portion. At some point along the
pre-processing portion 82, the thinned portion of the raw slurry
material no longer flows over the inner edge 76a.
[0056] After this point, the slurry material continues to separate,
with the lighter, leading portion thereof being pushed in front
(i.e., in the direction opposite the direction of rotation of the
barrel member) and the heavier lagging portion behind (i.e., in the
direction of rotation of the barrel member).
[0057] Accordingly, by the time the raw slurry material reaches the
separator portion 84, the slurry material has been thickened and
separated into a leading portion and a lagging portion. The leading
portion will contain a lower concentration of particulate, while
the lagging portion will contain a higher concentration of
particulate.
[0058] FIGS. 6A, 6B, and 6C illustrate what happens as the slurry
passes through the separator portion 84 of the processing chamber
46. FIGS. 6A and 6C show the leading portion 99a of the slurry
material, while FIGS. 6A, 6B, and 6C show both the leading portion
99a and the lagging portion 99b. As generally described above,
rotation of the barrel member 70 causes the leading portion 99a to
cross the separator gaps 88. The more fluid leading portion 99a
passes through the gaps 88 to the course below. The less fluid
lagging portion 99b, however, projects across the separator gap
onto the next separator member 78. Accordingly, as the slurry
material moves across the successive separator gaps 88 formed by
the separator members 78 in the separator region, more and more of
the more fluid portion flows back down through the processing
chamber. The processing system 24 thus separates the particulate
portion of the raw slurry material from the liquid portion of the
raw slurry material.
[0059] The portion of the material raw slurry material that reaches
the outlet portion 86 of the separator chamber comprises a very
high proportion of the particulate portion in comparison to the
proportion of the particulate material in the raw slurry material
entering the feed portion 80.
[0060] In addition to separating the particulate portion from the
liquid portion of the raw slurry material, the first example sand
separating system 20 may be configured to clean the particulate
portion and/or dilute the liquid portion. In particular, one or
both of the first and second example processing conduits of the
first example processing system 24 may be configured to arrange
rinse liquids within the processing chamber 46.
[0061] In the example processing system 24, the first processing
conduit 42 is arranged to deposit a first rinse fluid at a first
location 42a within the processing chamber 46. The second
processing conduit 44 is arranged to deposit a second rinse fluid
at a second location 44a within the processing chamber 46. The
processing system 24 may thus be operated without a supplemental
rinse fluid, with either the first rinse fluid or the second rinse
fluid, or with both the first and second rinse fluids.
[0062] Typically, the first location 42a at which the first rinse
fluid is introduced is below the second location 44a at which the
second rinse fluid. In the example processing system 24, the first
location 42a is between the second location 44a and the feed
portion 80, approximately at the junction of the pre-processing
portion 82 and the separator portion 84. The second location is
between the first location 42a and the outlet portion 86 of the
processing chamber 46.
[0063] In this configuration, the second rinse fluid may be a
relatively pure or clean liquid such as water while the first rinse
fluid may be a relatively impure fluid that is a byproduct of the
stall rinse system. The first rinse fluid will provide a fresh
volume of low contaminant liquid material to facilitate separation
of the particulate portion from the liquid portion of the raw
slurry material. The second rinse fluid will provide a fresh volume
of uncontaminated liquid material to rinse contaminants from the
particulate portion of the raw slurry material. Additives such as
lubricants, defoamers, disinfectants, or the like may be added to
one or both of the first and second rinse fluids.
[0064] The liquid portion of the raw slurry material flows back
down through the processing chamber 46 and collects in the feed
portion 50b of the main trough 50. This liquid portion will collect
in the upper portion of the main trough 50 and will eventually flow
over the divider surface 56, into upper trough 54, and out of the
system 20 through the upper trough outlets 98. The main trough
outlets 96 allow material to be removed from the bottom of the main
trough 50 when necessary.
[0065] Referring now to FIGS. 9-14 of the drawing, depicted at 120
therein is a second example sand separator system constructed in
accordance with, and embodying, the principles of the present
invention. The second example sand separator system comprises a
support frame 122, a processing system 124, a trough system 126,
and a drive system 128.
[0066] In general, the support frame 122 supports the processing
system relative to the trough system 126 such that slurry material
within the trough system 126 is fed into the processing system 124.
The drive system 128 rotates at least a portion of the processing
system 124 such that particulate material such as sand is extracted
from the slurry material fed into and through the processing system
124.
[0067] The example support frame 122 defines a surface engaging
portion 130, a support portion 132, a bearing surface 134, a motor
platform 136, and brace assembly 138. The surface engaging portion
130 defines a reference plane P1, and the support portion 132
defines a support plane P2 that extends at an angle to the
reference plane P1 (FIG. 12). The surface engaging portion 130 is
adapted to be supported on a support surface such that the
reference plane P1 is substantially horizontal. Accordingly, the
reference plane P2 extends at an angle with respect to
horizontal.
[0068] The purpose of the support frame 122 is to support the
processing system 124 at a particular angle with respect to
horizontal and in a desired position with respect to the trough
system 126.
[0069] FIG. 1 further shows that the example processing system 124
comprises a processing structure 140, a first processing conduit
142, and a second processing conduit 144. As perhaps best shown in
FIG. 12, the processing structure 140 defines a processing axis Al
and a processing chamber 146. The bearing surface 134 and motor
platform 136 are arranged and configured such that the processing
axis A1 is substantially parallel to the support plane P2 as will
be described in further detail below. The processing axis A1 thus
extends at an angle with respect to horizontal.
[0070] The example trough system 126 comprises a main trough 150,
an inlet conduit 152, and an upper trough 154. A divider surface
156 separates the main trough 150 from the upper trough 154. The
inlet conduit 152 is arranged deposit raw slurry material into the
main trough 150. An outlet conduit 158 allows fluid to flow out of
the upper trough 154.
[0071] The example drive system 128 comprises a drive motor 160, a
drive member 162 such as a belt or chain, a drive surface 164 such
as a sprocket, and bearing wheel assemblies 166. The drive motor
160 causes rotation of the processing structure 140 through the
drive member 162 and the drive surface 164. The bearing wheel
assemblies 166 support the processing structure 140 for rotation
about the processing axis A1.
[0072] The example processing structure 140 comprises a barrel
member 170, a pre-processing member 172, a plurality (two or more)
separator members 174, an inlet member 176, and an extension
portion 178. The example barrel member 170 is an elongate cylinder
made of material capable of maintaining this cylindrical shape
while supporting the pre-processing member 172 and separator
members 174 as will be described below. The example barrel member
170 is made of steel, but other materials such as plastic or
composites may be used under certain circumstances.
[0073] The barrel member 170 defines both the processing chamber
146 and the processing axis A1. The processing chamber 146 defines
a feed portion 180, a pre-processing portion 182, a separator
portion 184, and an outlet portion 186. Part of the pre-processing
member 172 extends out of the processing chamber 146 and to define
the feed portion of the processing chamber 146. The inlet member
176 is arranged adjacent to the feed portion of the processing
chamber 146 and defines an inlet surface that facilitates the entry
of the raw slurry material into the processing chamber 146. Part of
the last separator member 174 extends out through the outlet
opening 186 such that particulate material does not drop back into
the separator portion 184 of the processing chamber 146.
[0074] The pre-processing member 172 and separator members 174
extend into the processing chamber 146 from the interior wall of
the barrel member 170. In particular, the pre-processing member 172
extends substantially radially inwardly from the barrel member 170
into part of the feed portion 180 and throughout the pre-processing
portion 182 of the processing chamber 146. The example
pre-processing member 172 follows a predetermined helical path
defined by the diameter of the barrel member 170 and the distance
between axially spaced portions of the pre-processing member 172.
In the following discussion, each portion or segment of the
pre-processing member 172 extending through one rotation along the
helical path defines a course. These discrete portions or sections
of the pre-processing member 172 may thus be referred to as
courses.
[0075] The separator members 174 extend generally radially inwardly
from the barrel member 170 and generally follow the predetermined
helical path defined by the pre-processing member 172. However, the
separator members 174 are spaced from each other along the
predetermined helical path and/or deviate from the predetermined
helical path such that separator gaps 188 are formed between
adjacent separator members 174.
[0076] The example processing structure 140 further comprises
cleaning blades formed on the outer surface thereof. The upper
trough conduit 158 allows fluid to flow out of the upper trough
154.
[0077] The second example sand separator system 120 operates in a
manner that is generally similar to that of the first example sand
separator 20 described above. Raw slurry material is forced through
the inlet conduit 152 into the main trough 150. The example sand
separator system 120 is designed to process raw slurry material a
liquid portion comprising at least rinse liquid, such as water, and
manure and a particulate portion comprising particulate material
such as sand. The main trough 150 functions like a gravity
separator in which heavier particulate material such as sand sinks
to the bottom and the liquid portion rises to the top.
[0078] The support frame 122 supports the processing structure 140
such that the feed portion 180 of the processing chamber 146 is
within the main trough 150. Rotation of the barrel member 170
causes the particulate portion of the raw slurry material to move
up through the processing chamber 146 and out of the outlet portion
186. As generally described above, the portion of the material raw
slurry material that reaches the outlet portion 186 of the
separator chamber comprises a very high proportion of the
particulate portion in comparison to the proportion of the
particulate material in the raw slurry material entering the feed
portion 180.
[0079] In addition to separating the particulate portion from the
liquid portion of the raw slurry material, the second example sand
separating system 120 may be configured to clean the particulate
portion and/or dilute the liquid portion. In particular, one or
both of the first and second example processing conduits of the
second example processing system 124 may be configured to arrange
rinse liquids within the processing chamber 146.
[0080] In the example processing system 124, the first processing
conduit 142 is arranged to deposit a first rinse fluid at a first
location 142a within the processing chamber 146. The second
processing conduit 144 is arranged to deposit a second rinse fluid
at a second location 144a within the processing chamber 146. The
processing system 124 may thus be operated without a supplemental
rinse fluid, with either the first rinse fluid or the second rinse
fluid, or with both the first and second rinse fluids.
[0081] Typically, the first location 142a at which the first rinse
fluid is introduced is below the second location 144a at which the
second rinse fluid. In the example processing system 124, the first
location 142a is between the second location 144a and the feed
portion 180, approximately at the junction of the pre-processing
portion 182 and the separator portion 184. The second location is
between the first location 142a and the outlet portion 186 of the
processing chamber 146.
[0082] In this configuration, the second rinse fluid may be a
relatively pure or clean liquid such as water while the first rinse
fluid may be a relatively impure fluid that is a byproduct of the
stall rinse system. The first rinse fluid will provide a fresh
volume of low contaminant liquid material to facilitate separation
of the particulate portion from the liquid portion of the raw
slurry material. The second rinse fluid will provide a fresh volume
of uncontaminated liquid material to rinse contaminants from the
particulate portion of the raw slurry material. Additives such as
lubricants, defoamers, disinfectants, or the like may be added to
one or both of the first and second rinse fluids.
[0083] The liquid portion of the raw slurry material flows back
down through the processing chamber 146 and collects in the main
trough 150. This liquid portion will collect in the upper portion
of the main trough 150 and will eventually flow over the divider
surface 156, into upper trough 154, and out of the system 120
through the upper trough outlet 158. FIG. 8 further illustrates
that intermediate openings 196 are formed in the barrel member 170
of the processing system 124. The intermediate openings 196 are
arranged to allow at least a portion the raw slurry material to the
processing chamber through these intermediate openings 196. As
shown in FIG. 8, the intermediate openings 196 are spaced around a
diameter of the barrel member 170 and along a longitudinal axis of
the barrel member 170.
[0084] Referring now to FIG. 15 of the drawing, depicted at 220
therein is a second example sand separator system constructed in
accordance with, and embodying, the principles of the present
invention. The second example sand separator system 220 comprises a
support frame 222, a processing system 224, a trough system 226,
and a drive system 228. The processing system 224 and drive system
228 are or may be the same as the processing system 124 and drive
system 128 described above and will not be described herein in
detail.
[0085] The example trough system 226 comprises a main trough 250,
an inlet conduit 252, and an upper trough 254. A divider surface
256 separates the main trough 250 from the upper trough 254. The
inlet conduit 252 is arranged deposit raw slurry material into the
main trough 250. An outlet conduit 258 allows fluid to flow out of
the upper trough 254. In the example trough system 226, the inlet
conduit 252 is arranged such that the main trough 250 is gravity
fed. Raw slurry material entering the main trough flows down and
around a conical surface defined by the main trough 250 so that the
particulate material has time to sink to the bottom of the main
trough 250 and be taken in by the processing system 224.
[0086] FIG. 15 further illustrates that intermediate openings 260a
and 260b are formed in a barrel member 262 of the processing system
224. FIG. 15 also shows that the intermediate openings 260a and
260b are arranged to allow at least a portion the raw slurry
material to the processing chamber through these intermediate
opening 260a and 260b. FIG. 15 also clearly shows that the
intermediate openings 260a and 260b are spaced around a diameter of
the barrel member 262 and along a longitudinal axis of the barrel
member 262.
* * * * *