U.S. patent application number 16/148957 was filed with the patent office on 2019-04-04 for systems and methods for treatment processes.
The applicant listed for this patent is Theodore K. Jenkins, William Whitfield King, JR., Tyler Kunz, David D. Lauer, Heath E. Murphy. Invention is credited to Theodore K. Jenkins, William Whitfield King, JR., Tyler Kunz, David D. Lauer, Heath E. Murphy.
Application Number | 20190100449 16/148957 |
Document ID | / |
Family ID | 65895927 |
Filed Date | 2019-04-04 |
View All Diagrams
United States Patent
Application |
20190100449 |
Kind Code |
A1 |
Jenkins; Theodore K. ; et
al. |
April 4, 2019 |
SYSTEMS AND METHODS FOR TREATMENT PROCESSES
Abstract
Systems and methods for aeration and mixing processes are
disclosed.
Inventors: |
Jenkins; Theodore K.;
(Charleston, SC) ; Murphy; Heath E.; (Charleston,
SC) ; King, JR.; William Whitfield; (Mt. Pleasant,
SC) ; Kunz; Tyler; (Cedarburg, WI) ; Lauer;
David D.; (Germantown, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Jenkins; Theodore K.
Murphy; Heath E.
King, JR.; William Whitfield
Kunz; Tyler
Lauer; David D. |
Charleston
Charleston
Mt. Pleasant
Cedarburg
Germantown |
SC
SC
SC
WI
WI |
US
US
US
US
US |
|
|
Family ID: |
65895927 |
Appl. No.: |
16/148957 |
Filed: |
October 1, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62565833 |
Sep 29, 2017 |
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C02F 2209/42 20130101;
B01F 2003/04177 20130101; B01F 15/00162 20130101; C02F 3/20
20130101; B01F 15/00344 20130101; C02F 2209/005 20130101; B01F
2003/04148 20130101; C02F 2209/38 20130101; C02F 3/30 20130101;
B01F 3/04248 20130101; B01F 15/00155 20130101; B01F 2215/0052
20130101; B01F 2003/04276 20130101; B01F 2003/04312 20130101; C02F
2209/03 20130101; C02F 3/006 20130101; B01F 15/00253 20130101 |
International
Class: |
C02F 3/00 20060101
C02F003/00; B01F 3/04 20060101 B01F003/04; C02F 3/30 20060101
C02F003/30 |
Claims
1. A wastewater treatment system comprising: one or more supply
lines for providing pressurized gas to wastewater contained in a
containment unit, a nozzle attached to the supply line, wherein the
nozzle comprises at least one opening, and an orifice positioned
within one or more of the supply lines and the nozzles, wherein the
orifice provides a smaller passageway than the supply line or
nozzle within which the orifice is located and limits flow of the
pressurized gas to the nozzle opening.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent
Application No. 62/565,833, filed Sep. 29, 2017, wherein the
contents of the foregoing is incorporated herein in its entirety by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates to control systems and
methods, particularly systems and methods for implementing and
controlling mixing and aeration processes, such as in wastewater
treatment.
BACKGROUND
[0003] Methods and systems for treating wastewater are known in the
art. Such methods may include aerobic, anoxic, and anaerobic
processes.
SUMMARY OF THE INVENTION
[0004] The present invention includes systems and methods as
described herein.
[0005] The present invention may be better understood by reference
to the description and figures that follow. It is to be understood
that the invention is not limited in its application to the
specific details as set forth in the following description and
figures. The invention is capable of other embodiments and of being
practiced or carried out in various ways.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] These and other features, aspects, and advantages of the
present invention are better understood when the following detailed
description is read with reference to the accompanying drawings,
wherein:
[0007] FIG. 1 is a side cut-away view of a basin with mixing and
aeration components for use in conjunction with an embodiment of
the present invention;
[0008] FIG. 2A is a front cutaway view of a controller box for an
exemplary embodiment of the present invention;
[0009] FIG. 2B is a front cutaway view of a controller box for an
alternative exemplary embodiment of the present invention;
[0010] FIG. 3A is a schematic diagram showing components of a
control system an embodiment of a system of the present
invention;
[0011] FIG. 3B is schematic diagram showing components of an
alternative control system an embodiment of a system of the present
invention;
[0012] FIG. 4 is a detailed view of certain components of the
embodiment shown in FIG. 1;
[0013] FIG. 5A is a detailed view of certain components of the
embodiment shown in FIGS. 1 and 4;
[0014] FIG. 5B is a detailed view of certain components of an
alternative embodiment of the configuration shown in FIG. 5A;
[0015] FIGS. 6A-6C are detailed views of an embodiment and its
components of an exemplary nozzle in conjunction with an embodiment
of the present invention;
[0016] FIG. 7 is a schematic view showing the flow of gas through
the nozzle of FIGS. 6A-6C pursuant to an embodiment of the present
invention;
[0017] FIG. 8A is a view of an alternative embodiment of a nozzle
of the present invention;
[0018] FIG. 8B is a top view of the nozzle of FIG. 8A;
[0019] FIG. 9A is a view of a header in communication with a first
line in accordance with an embodiment of the invention;
[0020] FIG. 9B is a view along line A-A of FIG. 9A;
[0021] FIG. 10 is a view of an embodiment of an adjustable nozzle
orifice of the present invention;
[0022] FIGS. 10A-10D are cross-sectional views of various settings
of the adjustable nozzle orifice of FIG. 10 from the perspective of
B-B (at various adjustments of the nozzle shown in FIG. 10);
[0023] FIG. 11A is a view of an alternative embodiment of a basin
with mixing components for use in conjunction with an embodiment of
the present invention;
[0024] FIG. 11B is a view of an additional alternative embodiment
of a basin with mixing components for use in conjunction with an
embodiment of the present invention;
[0025] FIG. 11C is a view of an additional alternative embodiment
of a basin with mixing components for use in conjunction with an
embodiment of the present invention
[0026] FIG. 12 is a schematic view of an embodiment of the present
invention including reservoir tanks; and
[0027] FIG. 13 is a detailed view of certain mixing and aeration
components in an alternative embodiment of the present
invention.
[0028] Repeat use of reference characters in the present
specification and drawings is intended to represent same or
analogous features or elements of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0029] Reference will now be made in detail to various embodiments
of the invention, one or more examples of which are illustrated in
the accompanying drawings. Each example is provided by way of
explanation, not limitation, of the invention. In fact, it will be
apparent to those skilled in the art that modifications and
variations can be made in the present invention without departing
from the scope and spirit thereof. For instance, features
illustrated or described as part of one embodiment may be used on
another embodiment to yield a still further embodiment. Thus, it is
intended that the present invention covers such modifications and
variations as come within the scope of the appended claims and
their equivalents.
[0030] Systems and methods of the present invention may be used in
connection with various treatments or storage of substances. By way
of example, the embodiments of the present invention may be
utilized in the treatment of wastewater, such as in aerobic,
anaerobic, and anoxic wastewater treatment phases. In other
applications, may be used in storing substances. One of ordinary
skill in the art will appreciate that such uses are for
illustrative purposes only and are not intended to limit the full
scope of the invention disclosed herein.
[0031] Referring to FIG. 1, a cut-away perspective view of an
exemplary wastewater treatment mixing system 1 is shown. The system
1 includes a containment unit for wastewater, which is shown in
FIG. 1 as basin 2 having four sidewalls 4 and a bottom 6. One of
ordinary skill in the art will appreciate that alternative types of
containment units, such as tanks, vessels, channels, lagoons and
ditches, are also within the scope of the present invention. The
containment unit may additionally have an inlet through which
wastewater enters and an outlet through which the treated
wastewater exits. In some embodiments, the containment unit may
allow for continuous flow of the wastewater whereas other
embodiments may restrict the flow of the wastewater. In some
embodiments, multiple containment units, of the same type or of
differing types, may be present and connected such that the
wastewater passes through them sequentially or not connected such
that wastewater passes thru them in parallel. The remaining
components of the wastewater treatment mixing system 1 of the
present invention are shown in more detail in additional figures
and described therewith.
[0032] With further reference to FIG. 1, a source of compressed air
is shown outside of basin 2 as a compressor 8, although the
placement of compressor 8 can be in any suitable location for a
particular application. Compressor 8 is connected to supply line
10, which feeds into a controller box 12. A conventional regulator
9 or a throttling valve (not shown) may be placed along the supply
line to regulate the pressure or flow rate of pressurized gas from
the compressor 8. In other embodiments, any suitable pressure or
flow rate control device may be utilized. In the depicted
embodiment, controller box 12 is located outside of basin 2, but it
is understood that the precise placement of controller box 12 may
vary.
[0033] Controller box 12 is shown in further detail in FIG. 2A, in
which, in the particular embodiment depicted, controller box 12
includes eight valves 14 with each having a solenoid valve 16. In
some embodiments, alternative types of valves or flow control
devices may be used as an alternative to solenoid valves 16. Valves
14 are connected with supply line 10. Each valve 14 has an exhaust
pressure sensor 15 that is in communication with a programmable
logic controller (PLC) 20. Each pressure sensor 15 provides a
signal to the PLC 20 each time the valve 14 to which it is attached
opens and closes. If the signals do not fall within a predetermined
range, the PLC 20 generates a fault signal to the plant process
control system (not shown) or to the operator. In this manner,
mixing system 1 includes an alert for certain malfunctions, such as
when a valve 14 is stuck open or stuck closed. PLC 20, which can
include a memory (not shown) and a processor (not shown), is also
capable of selectively opening and closing each valve 14 located in
controller box 12. In other embodiments, systems may also be
utilized in the context of this invention that use manual
manipulation of valves instead of the computerized control system
described above.
[0034] In an alternative embodiment, as shown in FIG. 2B,
controller box 12 is again shown with eight valves 14 with each
having a solenoid valve 16. Valves 14 are connected with supply
line 10. Electronic throttle valve 99 and pressure sensor 95 are
located in connection with supply 10 inside controller box 12. In
addition, pressure sensor 15 is located inside controller box 12 on
a single header 18. In alternative embodiments, a plurality of
headers or all headers may have a pressure sensor 15. In addition,
any components shown inside controller box 12 could alternatively
be located on its exterior.
[0035] As shown in FIG. 3A, each of programmable logic controller
(PLC) 20 and programmable logic controller (PLC) 200 is in
communication with control panel 17. As used herein, reference to
"in communication with" indicates that data and/or signals are
transferrable between the referenced components, and such reference
includes both physical connections and wireless connections. In
addition, "in communication with," whether used in connection with
data or otherwise, also includes embodiments in which the
referenced components are in direct connection (i.e., directly
connected to each other with a cable) as well as indirect
connections, such as when data is transmitted through an
intermediate component and either relayed in the same format or
converted and then relayed to the referenced component.
[0036] In some embodiments, an alternative configuration may be
present other than shown in FIG. 3A. For example, in some
embodiments, a PLC may not be present or may be present in an
alternative configuration. In addition, in some embodiments PLC 20
and control panel 17 may be combined within a single device. For
example, in FIG. 3B, a single control panel 17' is shown that may
optionally include all of the functions discussed herein for
control panel 17, PLC 20, and PLC 200. In addition, in some
embodiments, control panel 17 may not include a PLC. In other
embodiments, more than one control panel 17 and/or more than one
PLC 20 may be present. Although not shown, control panel 17 or
control panel 17' may also be in communication with solenoid valve
16, pressure sensor 15, pressure sensor 95, and/or electronic
throttle valve 99.
[0037] In some embodiments, control panels used for the present
invention may include any machine having processing capacity, such
as, by example, a machine having a processor, a memory, and an
operating system. In some embodiments, control panel 17 may include
an interface for inputting such manual instruction. By way of
example, and without limitation, control panels may include one or
more of a personal computer, handheld computer, microcontroller,
PLC, smartphone, and/or tablet. In still other embodiments, control
panel 17 may be any device capable of controlling the operation of
a mixing system, such as a timer.
[0038] In some embodiments, control panel 17 may be located within
controller box 12, in its proximity, or at a remote location, such
as within a treatment facility or another site. In addition, an
existing facility may have existing PLCs or control panels or
hardware such as mixers and aerators, and the present invention
could be interfaced with those existing systems, such as by loading
software to perform the processes described herein and communicate
with the previously-existing structures. Furthermore, as noted,
control panel 17 may be remotely accessible, and it may be
configured to a network or internet connection. In addition, in
some embodiments, control panel 17 and/or PLC 20 may be connected
to a wireless and/or wired network. In addition, control panel 17
may permit an operator to manually control the processes and system
components, such as manually overriding the automatic control and
activating or deactivating aeration to the wastewater.
[0039] Referring again to FIG. 3A, PLC 20 is also in communication
with and receives input from ORP probe processor 109, nitrate probe
processor 111, ammonia probe processor 113, DO probe processor 115,
and pH probe processor 125. In other embodiments, some or all of
ORP probe 108, nitrate probe 110, ammonia probe 112, DO probe 114,
and pH probe 124 may be in communication with a single probe
processor. Other probes may alternatively or additionally be
utilized, such as, without limitation, level sensors, flow meters,
total suspended solids probes, or any device providing information
about the system and/or content of the containment unit. In other
alternative embodiments, a probe processor may be omitted for some
or all probes and some or all probes may be in direct communication
with PLC 20 without a probe processor. However, as noted above,
alternative configurations may be present in other embodiments.
[0040] Referring again to FIG. 1, system 1 further includes four
supply headers 18 made of polyvinyl chloride (PVC), acrylonitrile
butadiene styrene (ABS), chlorinated polyvinyl chloride (CPVC),
fire retardant polypropylene (FRPP), or stainless steel piping,
wherein each supply header 18 is connected to a valve 14 in
controller box 12. Supply headers 18 extend from controller box 12
toward bottom 6 of basin 2. Supply headers 18 also extend in a
pattern parallel with bottom 6 in an arrangement in which they are
at substantially equally-spaced intervals. As apparent to an
ordinary artisan, supply headers 18 can be made of a single,
continuous component or, in an alternative embodiment, supply
headers 18 can be constructed from multiple components joined by
conventional measures, such as welding, adhesive, threading,
bending, use of a connector, or other known measures or
combinations thereof. In addition, the headers, as well as all of
the piping in this system, can be of any construction and material
that meets the particular needs of the mixing system. For example,
the piping can be made from plastic, galvanized steel, stainless
steel, carbon steel, copper, ABS, PVC, FRPP, CPVC, or any other
material from which piping is typically formed and which meets the
requirements of the particular system. It should also be
appreciated that in other embodiments, the location of supply
headers 18 can be varied. By way of example, headers 18 can run
above basin 2. In addition, one or more headers may be placed in
distinct locations, such as entering basin 2 at different
points.
[0041] In the embodiment depicted in FIG. 1, and as also shown in
more detail in FIGS. 4-5A, each of the supply headers 18 has a
first line 22 that extends substantially perpendicular from each
supply header 18 and that are substantially parallel to bottom 6.
It is understood that first lines 22 can extend at different angles
in other embodiments. As seen in FIGS. 4 and 5A, first lines 22 are
connected to supply header 18 using a T-type connector 19 with cap
21 sealing the unconnected branch, although any conventional means
for connecting can be employed and such means are readily known to
a person having ordinary skill in the art. Alternatively, for
example, supply header 18 can be integral to first line 22 or
welded, bonded, or otherwise connected thereto either with or
without a connector of any suitable type. In still another
embodiment, header 18 and first line 22 may be joined by a
coupling, such as a threaded coupling, wherein such a coupling may
optionally include an orifice as discussed below. In still other
embodiments, as shown in FIG. 5B, a single first line 22 may be
present, optionally having an L-shape in order to provide the same
design as that shown in FIG. 5A but using a single, integral first
line 22 that is bent or curved to provide an L-shape or elbow
instead of connecting first line 22 and second line 24 to obtain
that shape shown in FIG. 5A. Although first lines 22 are depicted
in a staggered layout, i.e., each first line 22 extends in the
opposite direction from the previous and subsequent first lines 22,
other layouts are within the scope of the present invention.
Although, certain advantages may be achieved with the particular
layout depicted in the figures hereof.
[0042] In some embodiments of the present system, first lines 22
and second lines 24 each have an inner diameter that is smaller
than the inner diameter of supply header 18 to which they are in
communication. In some embodiments, first lines 22 have an inner
diameter equal to the inner diameter of the supply header 18 to
which it is connected, and the corresponding second lines 24 has a
smaller inner diameter. In addition, some embodiments may not
include a first line 22, and second line 24 may connect to supply
header 18. As indicated, second line 24 may be a vertical pipe or
line extending from first line 22. However, in some embodiments,
either first line 22 or second line 24 may be omitted or
alternative configurations may be employed without departing from
the scope of the present invention.
[0043] In still other embodiments, headers 18 may extend across a
containment unit, such as basin 2, above the basin, at the surface
level of the basin, immediately under the surface level of the
basin, or near the top area of the basin. In some embodiments,
headers 18 may be submerged within a solution, such as wastewater
in basin 2, and in other embodiments headers 18 may be above such
solution. In similar fashion first lines 22 and/or second lines 24
may be configured accordingly to position nozzles 30 within basin
2, such as at or near bottom 6 of basin 2. In some instances, such
embodiments may offer benefits such as ease of interchangeability
of components (such as nozzles), ease of access to headers for
maintenance or replacement, and other potential benefits.
[0044] By way of example, FIG. 11A illustrates an embodiment in
which headers 18 extend at, near, or above the surface level of
basin 2. Such headers may optionally be secured using any suitable
type of bracings or brackets. In some embodiments, headers located
at, near, or above the surface level of a containment unit may be
located near an edge of such unit, thereby rendering it more easily
accessible First lines 22 extend vertically downward to connect
header 18 to respective nozzles. Valves 28, which may be any
suitable type to control or stop flow, are located on first line
22. In other embodiments, additional lines may be present between
header 18 and a nozzle 30. In some embodiments, first lines 22 may
be removably connected to header 18, and nozzle 30 may be removably
coupled to first line 22. In this manner, by way of example, first
line 22 may be disconnected from header 18 and removed, along with
attached nozzle 30, thereby making first line 22 and nozzle 30
accessible for maintenance, servicing, or any other purpose.
Components for aeration, such as shown in FIG. 1 may also be
present but are not illustrated.
[0045] In alternative embodiments, such as shown in FIG. 11B,
headers 18 may connect, directly or indirectly, to a single nozzle
30. As shown, header 18 is secured to a wall of basin 2 using
brackets 27. Nozzle 30 is connected to header 18 via second line 24
(extending vertically in basin 2) and first line 22 (extending
horizontally in basin 2). In some other embodiments, such as shown
in FIG. 11C, first line 22 may extend vertically downward from a
header to connect to a nozzle without any second line. In such
embodiments such as in FIG. 11C, a vertically downward connector
(not shown) may be present to connect header 18 to first line 22,
and such a connector may have a valve such that flow may be
restricted or stopped to first line 22, such as if were desired to
remove first line 22 for maintenance or service.
[0046] With respect to the embodiments of FIGS. 11B-11C, the
embodiment of FIG. 11B, the connection of a header to a single
nozzle allows in a different manner for localized varying mixing
intensity within a basin, wherein flow to a specific nozzle or
group of nozzles may be controlled in the same manner as described
above. In addition, single nozzles may be isolated and flushed with
liquid, or alternatively pressurized or mechanically rodded, such
as to clear blockages. In addition, in any embodiment relating to
FIG. 11A-11C, a removable cap, such as described above, may be
located near a first line or second line to allow for maintenance
or inspection.
[0047] In some embodiments, headers 18, first lines 22, and/or any
other gas or aeration lines, or any connector associated therewith,
may have a removable cap 25. Such a removable cap, which may be
threaded or otherwise securely attachable and detachable, permits
the removal to access the interior of a pipe or line, such as for
easy cleaning or debris removal from the system. In some
embodiments, such removable caps 25 may be present at one or more
distal ends of a header 18 and/or first line 22. In addition, in
some embodiments a particular header 18 and/or first line 22 may
have more than one removable cap 25. In addition, in some
embodiments, a connector between any of header 18, first lines 22,
or second line 24--such as T-Type connector 19 or T-type connector
23--may have an additional opening (not shown) that has a removable
cap. Exemplary illustrations for positioning removable caps 25 are
shown in FIG. 4.
[0048] Attached to each first line 22 is a second line 24, which
extends in the same general direction as sidewalls 4. As shown in
FIGS. 1 and 3, each second line 24 is connected to a nozzle 30 at
the distal end of second line 24 opposite the supply header 18. The
connection between second line 24 and nozzle 30 can be made by any
conventional measures, such as those discussed above. It is
understood that in other embodiments, the second line 24 can extend
at different angles. In the depicted embodiment, as shown in FIG.
4, first line 22 and second line 24 are connected using a T-type
connector 23 and are generally at a 90.degree. angle with respect
to one another.
[0049] Any suitable types of nozzles may be used in connection with
the present invention. By way of example, nozzles disclosed in U.S.
Pat. No. 8,508,881, which is incorporated herein in its entirety by
reference, may be utilized. An illustrative nozzle is shown in
FIGS. 6A-6C as nozzle 30. As shown in this illustrative embodiment,
nozzle 30 includes nipple 32, which is hollow to permit gas flow,
an upper plate 34, a lower plate 36, and spacer 37. Upper plate 34
and lower plate 36 are parallel to each other and are spaced apart
by spacer 37 such that channel 38 is formed between them, wherein
channel 38 has outlets 40 at each distal end.
[0050] In other embodiments, multiple channels are present, wherein
each channel may have an outlet at each distal end. By way of
example, one embodiment of a nozzle of the present invention has a
nipple that connects with three channels, wherein each channel has
an outlet at each distal end. In yet another exemplary embodiment,
as shown in FIGS. 8A and 8B, a nozzle 30 may have two channels 38
forming a cross configuration with each channel having an outlet 40
at each distal, thus providing four outlets 40. Nozzle 30 may be
constructed in any suitable manner, including optionally in a
similar manner to nozzle 30 by using a nipple 32, an upper plate
34, and a lower plate 36.
[0051] One of ordinary skill in the art will appreciate that
alternative constructions may be used to provide nozzles having
channels and outlets as described herein. By way of example, an
upper plate or lower plate may be an otherwise solid structure
having a channel etched or formed therein, which is covered by an
upper plate or lower plate to form a closed channel without the use
of any spacers. In still other embodiments, a nozzle may be
entirely integrally formed as a single structure having a channel
formed therein as opposed to being constructed from assembled
plates.
[0052] In addition, as shown in the exemplary embodiment shown in
FIGS. 1-2, nozzles 30 are displaced throughout basin 2 in a grid
pattern, with five nozzles in communication with each supply header
by way of a second line 24 and a first line 22, and the nozzles are
shown in a staggered pattern. In other embodiments, more or fewer
nozzles can be in communication with a header. In yet other
embodiments, the arrangement of the nozzles can vary, including
being on the same side of a supply header (as opposed to staggered)
or below the supply header. In addition, in even further
embodiments, the supply header may be of a circular shape or
serpentine shape as opposed to the linear grid depicted in FIG. 1.
The particular arrangement of a mixing system of the present
invention can depend upon the size of a containment unit and the
particular process being performed, and additional and alternative
arrangements are appreciated by a person having ordinary skill in
the art. In some embodiments, the nozzles may be placed
approximately five to ten feet longitudinally along a supply header
and offset approximately one to four feet from the header. In
addition, as shown in the embodiment in FIGS. 1, 3, and 4, nozzles
30 are located on the bottom of the basin. In some embodiments,
nozzles 30 can be attached to the bottom 6 of basin 2. In yet other
embodiments, nozzles 30 are placed above the bottom 6 of basin
2.
[0053] In some embodiments, systems and methods of the present
invention may include a flow control feature. In particular, in
supplying gas to each first line 22 from a header 18, the gas may
distribute unequally to each first line 22 (and the nozzle
associated therewith). By way of example, gas may be supplied more
freely to the first line 22 that is closest to the compressor 8
supplying the gas, and gas may flow less freely to the remaining
first lines 22 and their respective nozzles.
[0054] In some embodiments, to obtain uniform or nearly uniform
flow to all nozzles connected to a particular header, the present
invention may include orifices, which may be located at any
location between a header 18 and a nozzle 30. For example, in some
embodiments an orifice may be configured for each connection point
of header 18 with a first line 22. In some embodiments, an orifice
may be located, alternatively or additionally, in each second line
24. Alternatively or additionally, an orifice could be located in
the nozzle, such as, by way of example, in the portion of the
nozzle connected to or adjacent to a second line. Orifices may be a
relatively smaller passageway that limits flow from the header to
the nozzle. In some embodiments, a check valve (not shown) may be
used in addition to or instead of an orifice. Such check valves
permit flow of gas from the header to the nozzle but do not permit
backflow from the tank to the header. By using an orifice or check
valve as described herein, the gas in the header may be provided in
a generally equalized manner to each nozzle associated with that
header. In addition, check valves offer an additional advantage of
preventing backflow into the system, which could result in clogs
and other problems in the system. The cracking pressure (at which
flow is permitted in the output direction) can be selected for any
particular system. Similar flow control measures may also be
installed, if desirable, within the aeration components.
[0055] By way of example, header 18 may have a diameter, such as
two inches, that is greater in diameter than each first line 22,
such as one inch. In some embodiments, an orifice may be configured
near a connection point where header 18 joins each first line 22,
such that the opening at that junction is at a desired diameter.
For example, if a header 18 has a diameter of two inches and a
first line 22 has a diameter of one inch, an orifice at the
junction of header 18 and first line 22 may have a diameter of
one-half inch. An example of such a configuration is shown for
orifice 33 in the section view of FIG. 9B along the line A-A of
FIG. 9A. The shaded area between first pipe 22 and orifice 33 may
be formed in any suitable manner, such as by an insert or a
modification to first line 22, an insert or modification to header
18 at the junction with first line 22, or the configuration of any
type of connector used to join header 18 to first line 22.
[0056] As noted, such an orifice of any size could additionally or
alternatively be located at other locations. In some embodiments,
such orifices may be configured to provide a particular pressure to
a nozzle and the orifice size may be configured to provide such a
desired pressure based upon the particular specifications of a
system, either through calculation or trial and error. In some
embodiments, orifice configurations of the present invention may be
replaceable or interchangeable, such that the orifice size may be
changed. In still other embodiments, orifices of the present
invention may be adjustable, such as during installation.
[0057] In some embodiments of the present invention, an orifice
size may be altered as a function of the distance from the air
source. In this regard, the orifice size may be increased or
decreased for supply air to nozzles farther away from the source of
air relative to nozzles that are located closer to the air source.
Such deviations may promote, in some embodiments, a more uniform
distribution of gas for mixing to the nozzles.
[0058] An illustrative embodiment of an adjustable orifice
positioned at a nozzle is shown in FIG. 10. As shown, nozzle 30 is
partially obstructed and partially open, and orifice 33 is disposed
on nipple 32. As shown, orifice 33 is shown as a half-moon shape,
although other shapes and orifice sizes may be utilized in a
particular embodiment. Connector 35 is connected to nipple 32 and
connector 35 is capable of rotation about nipple 32. Such rotation
results in increasing or decreasing the exposed portion of orifice
33, thereby controlling the amount of pressurized gas that may pass
through orifice 33 during operation. FIGS. 10A-10D illustrate
various exemplary adjustments that alter the size of orifice 33,
thereby regulating gas flow to the associated nozzle. Such
adjustments may be made during installation of a system or
subsequent to installation of the system. In addition, although
shown in FIG. 10 in the context of a nipple, an adjustable orifice
of this configuration or similar configurations may also be
positioned at any location between a header pipe and a nozzle. For
example, an orifice may be positioned in a first line 22 and a
connector 35 may be disposed between a header 18 and such first
line 22, thereby providing an adjustable orifice.
[0059] In some embodiments, systems of the present invention may
also utilize receiver tanks. In operation, gas velocity in supply
line 10 and receiver tank 5 may be low, but air velocity between
receiver tank 5 and the containment unit, such as basin 2, may be
high. A receiver tank, as described herein, may minimize piping
headloss and the need to oversize piping. In this regard, such
receiver tanks may be employed to negate any hydraulic differential
between containment units and may facilitate the use of a common
compressor for two or more containment units with different tank
levels, volumes, or amount of substance therein.
[0060] With reference to in FIG. 12, an exemplary embodiment
utilizing receiver tanks is shown. As shown, compressor 8 is
connected to and providing air to one or more aeration basins 2 and
one or more sludge holding tanks 2' by way of supply lines 10. In
the depicted embodiment, supply line 10 connects compressor 8 to
receiver tanks 5. Receiver tanks may be located at any point
between a compressor and a control panel for valves as described
above. In some embodiments, a receiver tank may be positioned in
close proximity to the valves controlling entry of air into headers
18. As one of ordinary skill in the art would appreciate,
alternative mixing systems, such as mechanical mixers, submersible
mixers, surface mixers, agitators, static mixers, and hyperbolic
mixers, may be used with basin 2 or any containment unit for
wastewater and are within the scope of certain embodiments of the
present invention. Similarly, the number of mixing components and
layout of the mixing components may vary within the scope of the
present invention. In addition, the number and arrangement of
mixing components may vary in other embodiments of the present
invention. Furthermore, as used herein, the terms "connected" and
"attached," and variations of those terms, includes, unless
indicated otherwise by the context, components that are in direct
connection and components that are indirectly connected by way of
other components.
[0061] In some embodiments of the present invention, basin 2 may
also be equipped for aeration. For example, as shown in FIG. 1,
embodiments of the present invention may include diffuser heads 100
as the aerators, and each diffuser head 100 is serially connected
to a diffuser pipe 102. Each depicted diffuser pipe 102 is then
connected with header pipe 104, and header pipe 104 is connected
with supply pipe 106. Supply pipe 106 is connected to blower 108,
which delivers air or oxygen under pressure to each diffuser head
100 by way of supply pipe 106, header 104, and diffuser pipe 102.
Valve 109 is connected with blower 108 to control the flow of air
to supply pipe 106. In addition, valve 109 is in communication with
PLC 20', which may control its opening and closing.
[0062] Various modifications to the illustrative embodiment are
included within the scope of the present invention. In some
embodiments, diffuser heads 100 may be located in proximity to
bottom 6 but are not flush with bottom 6. In addition, diffuser
pipe 102 may be secured to bottom 6 or located above bottom 6 and
supply pipe 106 may be secured to a side 4 of basin 2. In some
alternate embodiments, a system may include multiple supply pipes
106, wherein each supply pipe 106 may be connected to a valve
109.
[0063] Whether a single or multiple supply pipes, in the same
manner as described above in the context of mixing, a control panel
and/or PLC may optionally be used in connection with the valves to
selectively control the supply of air or oxygen to each diffuser
pipe. In such circumstances, the same PLC 20 and control panel 17
used for controlling mixing may also be used to control aeration,
or a separate PLC or control panel may be used.
[0064] In an alternative embodiment of the invention, as shown in
FIG. 13, diffuser pipe 102 may abut or be adjacent to or attached
to supply header 18. In such embodiments, diffuser pipe 102 may be
secured to header 18 by any suitable means, such as cable ties,
clamps, or other mechanisms. Such diffuser pipes may be configured
to release air above or below any adjacent or attached supply
header.
[0065] The depicted aeration components herein are illustrative
only, and it will be readily apparent to one of ordinary skill in
the art that alternative types of aeration systems, aerators, and
aeration components are within the scope of the present invention.
By way of example, alternative aerators for use in embodiments of
the present invention may include fine bubble (or fine pore)
diffusers or course bubble diffusers, mechanical aerators,
centrifugal blowers, turbo blowers, screw compressors, jet
aerators, and positive displacement blowers. In addition, the
layout and number of aeration devices may vary in alternative
embodiments of the present invention. For instance, in some
embodiments, the number or arrangement of diffuser heads 100 may
vary.
[0066] In operation, wastewater treatment mixing system 1 functions
to mix the contents of basin 2 and/or to aerate the contents of
basin 2. For mixing, system 1 operates by compressor 8 providing
pressurized gas into supply line 10. A conventional regulator or a
throttle valve may be utilized to control the pressure or flow of
the pressurized gas. The pressurized gas is generally a gas or
fluid that has a lower density than the wastewater mixture
(including any added compounds) that is present in basin 2. The
pressurized gas flows through supply line 10 to the valves 14 in
controller box 12. Each valve 14 is capable of opening and closing
to selectively and controllably allow the pressurized gas to flow
into the supply header 18 corresponding to that particular valve
14. When a valve 14 is opened, the pressurized gas flows into the
respective header 18 for that valve. In one embodiment, the opening
and closing of the valve can be controlled by the programmable
logic controller 20. In others, the opening and closing of the
valve(s) can be controlled manually or by other components
described herein.
[0067] In one embodiment, no more than one valve 14 within control
box 12 is open at any given time. In alternative embodiments, a
plurality of valves 14 may be simultaneously open. When a valve 14
is open, the pressurized gas flows into and through a header 18
corresponding with that particular valve 14. As sufficient
pressurized gas flows into header 18, it will also fill first line
22 and second line 24. The gas flow continues into nozzle 30. The
flow of gas in nozzle 30 of FIG. 6 is shown by arrows in FIG. 7. As
shown, the gas flows into nozzle 30 by entering nipple 32 and then
continues to channel 38 and toward outlets 40. In general
operation, valves 14 are opened in short, cyclic intervals.
[0068] In this regard, with reference to FIGS. 1 and 2A or FIGS. 1
and 2B, control panel 17 can send a signal to PLC 20 indicating to
activate or deactivate the mixing system, such as the flow of air
to nozzle 30 via header 18, first line 22, and second line 24. In
that instance, PLC 20 may transmit a signal to controller box 12,
and controller box 12 would actuate one or more control valves 14,
optionally by way of PLC 20, based upon the signal to begin or end
the mixing by controlling the supply of air to nozzle 30. Such
operation may be carried out for the embodiment shown in FIG. 3B by
control panel 17'. As a result of the bursts of gas exiting nozzle
30 through outlets 40 and entering basin 2, nozzle 30 generates a
displacement of the substance in basin 2, which is generally larger
in size than the displacement introduced into the system by
conventional aerators used in an aeration process for treating
wastewater. Due to the displacement of the substance within basin
2, mixing occurs. In addition, because the pressurized gas is less
dense than the surrounding liquid composition in basin 2, the gas
may rise in basin 2 and currents may be formed in the
substance.
[0069] The burst of gas from the nozzle and the resulting
displacement of the substance in basin 2 may vary in size, and
various parameters may influence the burst and displacement, such
as the size of channel 38 and outlets 40, the flow rate of the
pressurized gas, and the density of the pressurized gas. In some
embodiments, nozzles 30 do not create any bubbles that exceed a
diameter of six inches. In addition, in other embodiments, other
types of mixers, such as mechanical mixers, a signal may be
supplied, such as from a control panel or PLC, to either supply or
terminate power to the mixer.
[0070] In alternative embodiments, control panel 17 can also
transmit a signal to the mixing system to control the rate or
intensity of mixing. For instance, with reference to the embodiment
shown in FIG. 1 and with reference to FIG. 2A, control panel 17 may
send a signal to PLC 20, and PLC 20 may transmit a signal to
controller box 12 to adjust the number of valves open or their
degree of opening, thereby controlling the mixing rate. The
actuator may control the flow rate by permitting or obstructing the
flow of air, or the rate of air flow, to one or more of headers 18.
In other embodiments in which other types of mixers are used, such
as mechanical mixers, control panel 17 and PLC 20 may transmit
signals to control the speed of the mixer. In still other
embodiments, control panel 17 and PLC 20 may send signals to
deactivate some of a plurality of mixers, thereby decreasing the
overall mixing rate.
[0071] For instance, in some treatment processes, it is unnecessary
to continuously mix the wastewater, and mixing may only be
conducted during certain treatment processes or when certain
conditions are met. Therefore, in some embodiments of the present
invention, control panel 17 may indicate to activate or deactivate
a mixing system or an aeration system, or to control the rate,
duration, or intensity of mixing or aeration, such as based on the
dynamic condition or parameters of the wastewater or the system. By
way of example, probes for a single parameter (such as multiple ORP
probes 108, nitrate probes 110, ammonia probes 112, DO probes 114,
and pH probes 124 or for any other parameters, including, without
limitation, devices indicating level, pressure, or flow) may be
displaced within a containment unit, such as basin 2, and control
panel 17 may monitor the measurements for a parameter within basin
2 and activate or deactivate mixing based upon those parameters.
Furthermore, multiple probes for a single parameter may be located
throughout the basin, and mixing or aeration may be activated in a
particular area based upon the measurements from such probes in
that area. Embodiments concerning mixing and aerating using such
probes for dynamic measurements and operation are further disclosed
in U.S. Pat. No. 9,567,245, which is incorporated by reference
herein in its entirety. In addition, as used herein, the term
"measured" and "measurements" include detected parameters,
directly-measured values of parameters, and parameter values
calculated or otherwise determined from the direct measurement or
detection of one or more other parameters, either alone or in
combination with additional data or measurements.
[0072] In some embodiments, system 1 may operate to provide
sequence variability in mixing. By way of example, as described
above, one or more headers (and their associated nozzles) may be
selectively activated and deactivated. In some embodiments, the
particular header(s) activated may be randomly, pseudo-randomly, or
quasi-randomly selected, and such random cycles of mixing may
advantageously avoid stagnation in the substance in the basin and
disrupt steady state flow patterns in the substance. In addition,
such random cycles may avoid accumulation of surface materials by
dispersing such materials, thereby providing both potential
aesthetic and utility benefits. In other embodiments, individual
nozzles may be selected for activation and deactivation. In such
embodiments, each nozzle may have a valve in communication with the
control panel, which can transmit signals for opening or closing
the nozzle valve or the degree it is opened or closed. In yet
another embodiment, the activation and deactivation of the headers,
or alternatively nozzles, may be conducted in a pre-selected
pattern or based upon dynamic measurements of parameters in or
relating to the basin.
[0073] In either the random or cyclic mixing processes, valves may
control both the amount of gas permitted to enter a header, thereby
controlling the intensity of gas introduced from that header to the
substance, as well as the duration of gas permitted to the header.
Alternatively, if a valve controlled by the control panel is
included in the nozzle, the degree a valve is opened may be
controlled to determine the intensity of the mixing from that
nozzle. Similarly, the duration of time that gas is released to a
header or a nozzle may also be controlled.
[0074] Pressure sensor 95 may be utilized in some embodiments as a
system check for proper operation. In operation, with reference to
FIG. 2B, pressure sensor 95 monitors the pressure of a header 18.
As a result, the pressure required to open valve can indicate if
the system is functioning properly or if there is an actual or
potential malfunction, such as if the valves are not properly
opening or if there is a clog. If a pressure measurement detected
by a pressure sensor is an anomaly from normal operating
conditions, the system may indicate that a valve or multiple valves
or nozzles are not functioning or are clogged or that inspection is
required. In such instances, the control panel may generate an
alert, such as a sound, light, message, text message, email, or any
other suitable indication. Alternatively, an automatic corrective
action, such as a maintenance purge described below, could be
initiated. In some embodiments, a paddle switch may be used instead
of, or in addition to, pressure sensor 95, wherein the paddle
switch measures air flow (as opposed to the pressure measured by
pressure sensor 95).
[0075] In some embodiments, the present invention may also include
tank level monitoring and control equipment, which may be utilized
in the operation of the system. For example, again with reference
to FIG. 2B, pressure sensor 15 may be utilized to control mixing
and/or aeration of the substance of the basin based upon the
amount, or level, of substance in the tank (also referenced herein
as the tank level). In particular, upon installation, pressure
sensor 15 may be calibrated such that the pressure in headers 18
serves as a proxy for the substance level in the basin, whereby the
approximate tank level may be calculated from the measured pressure
when nozzles in connection with the header associated with pressure
sensor 15 are not in operation. In some instances, tank level may
be used in determining the activation, deactivation, duration, or
intensity of mixing or aeration in the system. By way of example,
given that a decreased tank level may indicate more dense
wastewater (or other substance depending on the application) in the
basin and an increased tank level, such as after storms or heavy
rain, may increase less dense and more diluted wastewater (or other
substance depending on the application), the system may control the
mixing frequency and/or intensity based upon such measured tank
level. In some embodiments, the water level may also be used to
control the frequency and intensity of aerating the substance in
basin 2. Similarly, the tank level may be used to determine which
and how many mixers should be activated in the tank at a given
time. In addition, the use of pressure sensor 15 permits placement
of the sensor outside of the basin such that it is more accessible
and easily installed as opposed to other means of measuring
substance level that require the installation and maintenance of
hardware components within the basin itself. In some embodiments,
the water level may also be used to control the frequency and
intensity of aerating the substance in basin 2 in this same
manner.
[0076] In addition, some embodiments of the present invention may
allow for proportional mixing and aeration controls. For example,
desired mixing parameters for a system, such as the amount and
duration of gas supplied to a nozzle under certain conditions, may
be calibrated, such as by adjusting valve operations, during the
installation process for a particular tank level. As the tank level
varies, it may be desirable in some applications to maintain a
consistent impact on the system. Thus, the mixing parameters,
including the duration and intensity of mixing from a nozzle (or
for all nozzles connected to a particular header) may be adjusted
proportionately (as dictated by the control panel) based upon the
measured tank level so that the impact on the system remains
proportionately consistent during dynamically-changing operating
conditions. Thus, as the tank level increases or decreases, the
system may modify the mixing duration, frequency, and/or intensity
in a manner that it proportionallly remains at that the desired
level as applied to a particular tank level. Appropriate data for
such operations can be stored in a memory in or connected to the
control panel or may be determined by using the processor in the
control panel. As explained above, such adjustments may be
completed by adjusting which valves are opened, the duration of
their opening, and/or the sequencing of their opening to allow air
to flow to particular headers. In similar fashion, the aeration of
the system may be similarly controlled based upon tank level. In
some embodiments, tank level may be one of multiple factors
considered in mixing or aerating a substance.
[0077] With respect to aeration, the disclosed embodiments of
control panels and/or PLCs may also control the flow of air to
diffuser heads 100, including based upon parameters dynamically
measured from the wastewater. In some embodiments, the same control
panel and/or PLC may be used for aeration and mixing, and in other
embodiments a different control panel and/or PLC may be used. In
either scenario, a control panel and/or a PLC may activate and
deactivate the flow of air to diffuser heads 100, thereby
controlling the aeration of the contents of basin 2. In other
embodiments, the control panel and PLC may also control the rate of
air flow to diffuser heads 100. As explained further herein, this
system and process allow for automated control between wastewater
treatment processes, such as aerobic, anaerobic, and anoxic
treatment processes, and that control may optionally be based upon
dynamically-measured parameters of the wastewater.
[0078] In some embodiments, other types of aeration devices may be
utilized, such as mechanical aerators or blowers without variable
speed drives that can only be turned on or off and the oxygen flow
not regulated. In such embodiments, a control panel may signal to
deactivate less than all of a plurality of devices used to compress
atmospheric air for purposes of oxygenation, such as, without
limitation, positive displacement blowers, centrifugal blowers,
turbo blowers, screw compressors, or rotary disc surface aerators,
in order to decrease the overall oxygen flow to the wastewater
without regulating the specific output of each blower. In this
manner, by selective activation and deactivation, the overall
aeration and rate of aeration to the entire system may also be
controlled.
[0079] In some embodiments of the present invention, the mixing
systems and/or aeration systems described herein may also include a
maintenance cycle. By way of example, a maintenance cycle may be
manually initiated by a user or automatically initiated by the
control panel, such as after a period without operation or upon
detection of parameters indicated that cleaning is needed (such as
an indication in a pressure sensor indicated that a system may be
clogged). In operation, a maintenance cycle can discharge gas
through the mixing system or aeration system to purge it, which may
remove any undesired entry of substance from the tank into the
mixing or aeration components. Such purging may be completed
selectively for headers of the system or simultaneously for all
mixers. In addition, such maintenance cycles may limit periods of
inactivity of the system.
[0080] Although the foregoing description has been provided in the
context of wastewater treatment, other types of wastewater
treatment and also applications unrelated to wastewater treatment
are within the scope the present invention. By way of example,
embodiments of the present invention could include treatments in
oxidation ditches, sludge treatment, other wastewater treatment
processes, water storage, chemical storage, sequencing batch
reactors, pumping stations, and food and beverage processing
tanks.
[0081] As such, the foregoing description of illustrative
embodiments of the invention has been presented only for the
purpose of illustration and description and is not intended to be
exhaustive or to limit the invention to the precise forms
disclosed. Numerous modifications and adaptations thereof will be
apparent to those of ordinary skill in the art without departing
from the scope of the present invention.
[0082] It will be understood that each of the elements described
above, or two or more together, may also find utility in
applications differing from the types described. While the
invention has been illustrated and described in the general context
of wastewater treatment, it is not intended to be limited to the
details shown, since various modifications and substitutions can be
made without departing in any way from the spirit and scope of the
present invention. As such, further modifications and equivalents
of the invention herein disclosed may occur to persons skilled in
the art using no more than routine experimentation, and all such
modifications and equivalents are believed to be within the spirit
and scope of the invention as described herein.
* * * * *