U.S. patent application number 17/096226 was filed with the patent office on 2021-05-06 for disc filter pre-screen dual media disc filter.
This patent application is currently assigned to Evoqua Water Technologies LLC. The applicant listed for this patent is Evoqua Water Technologies LLC. Invention is credited to Harry Bryant, Patrick Harden.
Application Number | 20210129059 17/096226 |
Document ID | / |
Family ID | 1000005329160 |
Filed Date | 2021-05-06 |
United States Patent
Application |
20210129059 |
Kind Code |
A1 |
Harden; Patrick ; et
al. |
May 6, 2021 |
DISC FILTER PRE-SCREEN DUAL MEDIA DISC FILTER
Abstract
According to various aspects and embodiments, a system and
method for two-stage filtration is provided. The system includes an
inlet fluidly connectable with wastewater, a first stage filter
assembly that is fluidly connectable with the inlet and has a
rotary drum with a filter surface configured for radially inward
fluid flow, a second stage filter assembly that is fluidly
connectable with the first stage filter and has a plurality of
filter discs configured for radially outward fluid flow, and an
outlet fluidly connectable with filtrate generated by the second
stage disc filter assembly.
Inventors: |
Harden; Patrick;
(Thomasvilie, GA) ; Bryant; Harry; (Thomasvilie,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Evoqua Water Technologies LLC |
Pittsburgh |
PA |
US |
|
|
Assignee: |
Evoqua Water Technologies
LLC
Pittsburgh
PA
|
Family ID: |
1000005329160 |
Appl. No.: |
17/096226 |
Filed: |
November 12, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16320011 |
Jan 23, 2019 |
10888807 |
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PCT/US2017/046496 |
Aug 11, 2017 |
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17096226 |
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62374097 |
Aug 12, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C02F 2301/08 20130101;
B01D 33/41 20130101; B01D 33/23 20130101; B01D 33/50 20130101; B01D
33/39 20130101; C02F 2303/16 20130101; B01D 36/04 20130101; B01D
33/073 20130101; B01D 33/807 20130101; C02F 2209/42 20130101; C02F
1/004 20130101; B01D 33/466 20130101; B01D 2201/184 20130101; B01D
36/02 20130101 |
International
Class: |
B01D 36/02 20060101
B01D036/02; B01D 33/23 20060101 B01D033/23; B01D 33/50 20060101
B01D033/50; B01D 33/073 20060101 B01D033/073; B01D 33/46 20060101
B01D033/46; C02F 1/00 20060101 C02F001/00; B01D 33/39 20060101
B01D033/39; B01D 33/41 20060101 B01D033/41; B01D 33/80 20060101
B01D033/80; B01D 36/04 20060101 B01D036/04 |
Claims
1. A filter device for filtering wastewater, the filter device
comprising: a drum filter including a rotary drum with a filter
surface having a first side facing an interior of the drum and a
second side facing an exterior of the rotary drum and being fluidly
connectable with a source of wastewater; and a disc filter having
an inlet fluidly connectable with the first side of the filter
surface of the rotary drum.
2. The filter device of claim 1, wherein the disc filter includes a
plurality of disc-shaped filter members attached to a central drum
that are configured to receive filtered wastewater passed through
the filter surface of the drum filter and to filter the filtered
wastewater.
3. The filter device of claim 2, wherein the inlet of the disc
filter is fluidly connectable with an interior of the central drum
of the disc filter.
4. The filter device of claim 2, wherein the rotary drum of the
drum filter and the central drum of the disc filter are positioned
along a common longitudinal axis.
5. The filter device of claim 4, wherein the rotary drum of the
drum filter is coupled to the central drum of the disc filter.
6. The filter device of claim 5, further comprising a housing that
at least partially surrounds the drum filter and the disc filter,
the housing having an inlet trough fluidly connectable with the
wastewater and the second side of the filter surface of the rotary
drum filter, an outlet trough fluidly connectable with filtrate,
and a sealing plate configured to separate the inlet trough from
the outlet trough.
7. The filter device of claim 6, further comprising a drum filter
collection trough fluidly connectable with the exterior of the
rotary drum.
8. The filter device of claim 7, further comprising a backwashing
system comprising: a first plurality of spray nozzles configured to
spray filtrate onto the plurality of disc-shaped filter members; a
disc filter backwash trough configured to collect backwashed
filtrate from the plurality of disc-shaped filter members; and a
second plurality of spray nozzles configured to spray filtrate onto
the first side of the filter surface of the rotary drum, wherein
the drum filter collection trough is configured to collect backwash
from the filter surface of the rotary drum.
9. The filter device of claim 1, wherein the filter surface of the
rotary drum is configured to retain solids on the second side while
permitting the wastewater to filter through the filter material to
the first side of the filter material and the interior of the
rotary drum as filtered wastewater.
10. The filter device of claim 1, wherein the filter surface of the
drum filter has openings with a diameter in a range of about 20
microns to about 800 microns.
11. The filter device of claim 10, wherein the filter surface of
the drum filter comprises one of wedge wire screen material or
woven filter media material.
12. The filter device of claim 10, wherein the plurality of
disc-shaped filter members include a filter media with openings
having a diameter in a range of about 6 microns to about 300
microns.
13. The filter device of claim 1, wherein the wastewater is from
one of a secondary or primary treatment process.
14. A two-stage filtration system for filtering wastewater, the
system comprising: an inlet fluidly connectable with the
wastewater; a first stage filter assembly fluidly connectable with
the inlet and having a rotary drum with a filter surface configured
for radially inward fluid flow; a second stage filter assembly
fluidly connectable with the first stage filter assembly and having
a plurality of filter discs configured for radially outward fluid
flow; and an outlet fluidly connectable with filtrate generated by
the second stage filter assembly.
15. The two-stage filtration system of claim 14, wherein the
plurality of filter discs are attached to a central drum that is
fluidly connectable with an interior of the rotary drum of the
first stage filter assembly.
16. The two-stage filtration system of claim 14, wherein the first
stage filter assembly and the second stage filter assembly are
rotatable around a common longitudinal axis, and the system further
comprises a drive assembly coupled to the first stage filter
assembly and the second stage filter assembly.
17. The two-stage filtration system of claim 16, further comprising
a backwashing system having a first plurality of spray nozzles
configured to spray the filtrate onto the plurality of filter discs
and a second plurality of spray nozzles configured to spray the
filtrate onto an inwardly facing side of the filter surface of the
rotary drum.
18. The two-stage filtration system of claim 17, further comprising
a level sensor configured to provide measurements of a level of
wastewater provided by the inlet to the first stage filter
assembly.
19. The two-stage filtration system of claim 18, further comprising
a controller operatively coupled to the level sensor, the drive
assembly, and the backwashing system, the controller configured to
control at least one of the drive assembly and the backwashing
system based on measurements from the level sensor.
20. The two-stage filtration system of claim 14, wherein the filter
surface of the drum filter has openings with a diameter in a range
of about 20 microns to about 800 microns.
21. The two-stage filtration system of claim 20, wherein the filter
discs include a filter media with openings having a diameter in a
range of about 6 microns to about 300 microns.
22. The two-stage filtration system of claim 14, wherein the inlet
is fluidly connectable with a secondary clarifier of a secondary
treatment process.
23. The two-stage filtration system of claim 14, wherein the inlet
is fluidly connectable with influent to a primary treatment
process.
24. The two-stage filtration system of claim 14, wherein the second
stage disc filter assembly comprises: a central drum configured to
receive filtered wastewater from the first stage filter assembly,
the central drum including a plurality of drum apertures; a frame
comprising a plurality of frame supports each having an attachment
portion coupled to the central drum and a radial strut portion
extending from the attachment portion, each of the plurality of
frame supports defining a single frame aperture that extends
through the attachment portion and along an entire length of the
radial strut portion to correspond with the shape of the frame
support; and a plurality of adjacent filter segments positioned
around the central drum, each of the plurality of adjacent filter
segments defining a cavity in fluid communication with at least one
of the plurality of drum apertures and supported at a first side by
a first frame support and at a second side by a second frame
support, the plurality of frame apertures and cavities arranged to
form a circumferential open fluid channel extending continuously
around the central drum to enable the filtered wastewater to pass
substantially unimpeded through the plurality of drum apertures and
through the plurality of adjacent filter segments.
25. The two-stage filtration system of claim 24, wherein the single
frame aperture forms an inverted substantially T-shaped
configuration.
26. A method of treating wastewater, comprising: introducing the
wastewater to a first-stage filtration operation comprising a
barrier filter to produce filtered wastewater; and introducing the
filtered wastewater to a second-stage filtration operation
comprising a disc filter to produce treated water.
27. The method of claim 26, further comprising measuring a level of
the wastewater introduced to the barrier filter of the first stage
filtration operation.
28. The method of claim 27, further comprising backwashing a filter
surface of the barrier filter based on the measured level of
wastewater.
29. The method of claim 26, wherein the barrier filter comprises a
rotary drum configured for radially inward fluid flow.
30. The method of claim 29, wherein the disc filter is configured
for radially outward fluid flow.
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Application Ser. No. 62/374,097, titled
"DISC FILTER PRE-SCREEN DUAL MEDIA DISC FILTER," filed on Aug. 12,
2016, which is herein incorporated by reference in its
entirety.
BACKGROUND
Technical Field
[0002] The technical field relates generally to wastewater
treatment processes, and more particularly, to media filtration in
wastewater treatment processes.
Background Discussion
[0003] Water filtration processes typically include primary,
secondary, and tertiary processes to treat wastewater to remove
contaminants, such as suspended solids, biodegradable organics,
phosphorous, nitrogen, microbiological contaminants, and the like,
to provide a clean effluent.
[0004] The first or primary treatment process typically involves
mechanically separating large solids and other suspended matter in
the wastewater from the less dense solids and liquid in the
wastewater. Primary treatment processes are typically done in
sedimentation tanks using gravity and provide a primary
effluent.
[0005] Secondary treatment typically includes biological treatment
of the primary effluent. The biological treatment units or vessels
used for secondary treatment typically include bacteria that break
down components of the wastewater, such as organic components. The
biological treatment processes in the biological treatment units or
vessels may reduce the total organic content and/or biochemical
oxygen demand of the wastewater. This is typically done by
promoting the consumption of the carbonaceous and nutrient material
by bacteria and other types of beneficial organisms already present
in the wastewater or mixed into the wastewater.
[0006] Tertiary processes typically involve removing suspended
solids and any remaining contaminants or pollutants from the
wastewater so that the remaining water can be either reused or
disposed of safely in the environment. Tertiary processes can
include filtration and/or the addition of any one or more of
chemicals, UV light, and ozone.
[0007] Many wastewater treatment plants utilize a disc filter
system to filter water. Such systems typically include a plurality
of discs that each comprise a plurality of filter segments. Each
filter segment includes a pair of filter panels which are spaced
apart and arranged on an outer surface of a central drum. A cap is
attached to the top of each pair of filter panels to form a pocket
shaped filter segment for receiving water. Each filter panel
includes filter media, such as finely woven cloth, for filtering
water.
[0008] Each filter panel is attached to the drum by a filter
support arrangement. Each filter support includes a plurality of
support openings which provide fluid communication between adjacent
filter segments. This enables water and air to flow
circumferentially between adjacent filter segments as the drum
rotates.
[0009] In operation, the drum is rotated and the water to be
filtered is introduced into the drum. The water then exits through
ducts in the drum and flows into filter segments inside the filter
support. The water in the filter support is then filtered through
the media of the filter panels to provide filtered water. The
filtered water is then collected in a chamber and exits the disc
filter through an effluent pipe. Particulates which are filtered
out by the filter panels remain within the filter segments on the
inside surface of the filter media of the filter panels. A spray
device is used to spray the panels with water to dislodge the
particulates and clean the filter media. The particulates are then
collected onto a trough and removed from the disc filter
system.
[0010] Openings in the central drum that function to provide a
passageway for the water to be transferred into the interior of the
filter discs are typically larger than the openings of the filter
media on the filter panels. Influent wastewater having high Total
Suspended Solids (TTS) levels will therefore clog the filter media
more quickly, which reduces throughput.
[0011] Furthermore, objects in the wastewater, such as rags and
other large objects may flow through the openings in the drum into
the interior of the filter panels and become trapped. This results
in the loss of effective filter panel filtration area and thus a
loss of efficiency. For example, in order to remove these large
objects, the disc filter has to be taken offline and the filter
panels have to be removed and cleaned, which is both labor
intensive and time consuming.
SUMMARY
[0012] Aspects and embodiments are directed to a two-stage
filtration system for filtering wastewater that includes a first
stage filter assembly that is disposed sequentially to and upstream
from a second stage filter assembly.
[0013] According to an aspect of the present disclosure, a filter
device for filtering wastewater is provided. The filter device
comprises a drum filter including a rotary drum with a filter
surface having a first side facing an interior of the drum and a
second side facing an exterior of the rotary drum and being fluidly
connectable with a source of wastewater, and a disc filter having
an inlet fluidly connectable with the first side of the filter
surface of the rotary drum.
[0014] In some embodiments, the disc filter includes a plurality of
disc-shaped filter members attached to a central drum that are
configured to receive filtered wastewater passed through the filter
surface of the drum filter and to filter the filtered wastewater.
In one embodiment, the inlet of the disc filter is fluidly
connectable with an interior of the central drum of the disc
filter. In another embodiment, the rotary drum of the drum filter
and the central drum of the disc filter are positioned along a
common longitudinal axis. In some embodiments, the rotary drum of
the drum filter is coupled to the central drum of the disc
filter.
[0015] According to a another embodiment, the disc filter further
comprises a housing that at least partially surrounds the drum
filter and the disc filter, the housing having an inlet trough
fluidly connectable with the wastewater and the second side of the
filter surface of the rotary drum filter, an outlet trough fluidly
connectable with filtrate, and a sealing plate configured to
separate the inlet trough from the outlet trough.
[0016] In some embodiments, the disc filter further comprises a
drum filter collection trough fluidly connectable with the exterior
of the rotary drum.
[0017] In some embodiments, the disc filter further comprises a
backwashing system. According to one embodiment, the backwashing
system comprises a first plurality of spray nozzles configured to
spray filtrate onto the plurality of disc-shaped filter members, a
disc filter backwash trough configured to collect backwashed
filtrate from the plurality of disc-shaped filter members, and a
second plurality of spray nozzles configured to spray filtrate onto
the first side of the filter surface of the rotary drum, wherein
the drum filter collection trough is configured to collect backwash
from the filter surface of the rotary drum.
[0018] According to at least one embodiment, the filter surface of
the rotary drum is configured to retain solids on the second side
while permitting the wastewater to filter through the filter
material to the first side of the filter material and the interior
of the rotary drum as filtered wastewater. In some embodiments, the
filter surface of the drum filter has openings with a diameter in a
range of about 20 microns to about 800 microns. According to
certain embodiments, the filter surface of the drum filter
comprises one of wedge wire screen material or woven filter media
material. In one embodiment, the plurality of disc-shaped filter
members include a filter media with openings having a diameter in a
range of about 6 microns to about 300 microns.
[0019] According to some embodiments, the wastewater is from one of
a secondary or primary treatment process.
[0020] According to another aspect of the present disclosure, a
two-stage filtration system for filtering wastewater is provided
that includes an inlet fluidly connectable with the wastewater, a
first stage filter assembly fluidly connectable with the inlet and
having a rotary drum with a filter surface configured for radially
inward fluid flow, a second stage filter assembly fluidly
connectable with the first stage filter assembly and having a
plurality of filter discs configured for radially outward fluid
flow, and an outlet fluidly connectable with filtrate generated by
the second stage filter assembly.
[0021] In some embodiments, the plurality of filter discs are
attached to a central drum that is fluidly connectable with an
interior of the rotary drum of the first stage filter assembly.
[0022] According to at least one embodiment, the first stage filter
assembly and the second stage filter assembly are rotatable around
a common longitudinal axis, and the system further comprises a
drive assembly coupled to the first stage filter assembly and the
second stage filter assembly. In another embodiment, the two-stage
filtration system further includes a backwashing system having a
first plurality of spray nozzles configured to spray the filtrate
onto the plurality of filter discs and a second plurality of spray
nozzles configured to spray the filtrate onto an inwardly facing
side of the filter surface of the rotary drum.
[0023] In another embodiment, the two-stage filtration system
further includes a level sensor configured to provide measurements
of a level of wastewater provided by the inlet to the first stage
filter assembly. In a further embodiment, the two-stage filtration
system further includes a controller operatively coupled to the
level sensor, the drive assembly, and the backwashing system, the
controller configured to control at least one of the drive assembly
and the backwashing system based on measurements from the level
sensor. In some embodiments, the filter surface of the drum filter
has openings with a diameter in a range of about 20 microns to
about 800 microns. In some embodiments, the filter discs include a
filter media with openings having a diameter in a range of about 6
microns to about 300 microns.
[0024] In some embodiments, the inlet of the two-stage filtration
system is fluidly connectable with a secondary clarifier of a
secondary treatment process. In other embodiments, the inlet is
fluidly connectable with influent to a primary treatment
process.
[0025] According to one embodiment, the second stage disc filter
assembly includes a central drum configured to receive filtered
wastewater from the first stage filter assembly, the central drum
including a plurality of drum apertures, a frame comprising a
plurality of frame supports each having an attachment portion
coupled to the central drum and a radial strut portion extending
from the attachment portion, each of the plurality of frame
supports defining a single frame aperture that extends through the
attachment portion and along an entire length of the radial strut
portion to correspond with the shape of the frame support, and a
plurality of adjacent filter segments positioned around the central
drum, each of the plurality of adjacent filter segments defining a
cavity in fluid communication with at least one of the plurality of
drum apertures and supported at a first side by a first frame
support and at a second side by a second frame support, the
plurality of frame apertures and cavities arranged to form a
circumferential open fluid channel extending continuously around
the central drum to enable the filtered wastewater to pass
substantially unimpeded through the plurality of drum apertures and
through the plurality of adjacent filter segments. In some
embodiments, the single frame aperture forms an inverted
substantially T-shaped configuration.
[0026] According to another aspect of the present disclosure, a
method of treating wastewater is provided. The method includes
introducing the wastewater to a first-stage filtration operation
comprising a barrier filter to produce filtered wastewater, and
introducing the filtered wastewater to a second-stage filtration
operation comprising a disc filter to produce treated water.
[0027] In some embodiments, the method further includes measuring a
level of the wastewater introduced to the barrier filter of the
first stage filtration operation. In another embodiment, the method
further includes backwashing a filter surface of the barrier filter
based on the measured level of wastewater. In some embodiments, the
barrier filter comprises a rotary drum configured for radially
inward fluid flow. In some embodiments, the disc filter is
configured for radially outward fluid flow.
[0028] Still other aspects, embodiments, and advantages of these
example aspects and embodiments, are discussed in detail below.
Moreover, it is to be understood that both the foregoing
information and the following detailed description are merely
illustrative examples of various aspects and embodiments, and are
intended to provide an overview or framework for understanding the
nature and character of the claimed aspects and embodiments.
Embodiments disclosed herein may be combined with other
embodiments, and references to "an embodiment," "an example," "some
embodiments," "some examples," "an alternate embodiment," "various
embodiments," "one embodiment," "at least one embodiment," "this
and other embodiments," "certain embodiments," or the like are not
necessarily mutually exclusive and are intended to indicate that a
particular feature, structure, or characteristic described may be
included in at least one embodiment. The appearances of such terms
herein are not necessarily all referring to the same
embodiment.
BRIEF DESCRIPTION OF DRAWINGS
[0029] Various aspects of at least one embodiment are discussed
below with reference to the accompanying figures, which are not
intended to be drawn to scale. The figures are included to provide
an illustration and a further understanding of the various aspects
and embodiments, and are incorporated in and constitute a part of
this specification, but are not intended as a definition of the
limits of any particular embodiment. The drawings, together with
the remainder of the specification, serve to explain principles and
operations of the described and claimed aspects and embodiments.
For purposes of clarity, not every component may be labeled in
every figure. In the figures:
[0030] FIG. 1A is a partial cut-away perspective view of a disc
filter in accordance with one or more aspects of the invention;
[0031] FIG. 1B is a cross-sectional side view of the disc filter of
FIG. 1A taken along section line 1B;
[0032] FIG. 2A is a perspective view of a drum typically used in
the disc filter of FIGS. 1A and 1B;
[0033] FIG. 2B is a side view of the drum of FIG. 2A;
[0034] FIG. 3 is a side view of a portion of a disc filter;
[0035] FIG. 4A is a front view of a filter panel in a support frame
attached to a central drum in a disc filter;
[0036] FIG. 4B is a perspective view of the filter panel of FIG.
4A;
[0037] FIG. 4C is a side view of the filter panel of FIG. 4A with a
portion of a support structure removed;
[0038] FIG. 5A is a perspective view of two-stage filtration system
in accordance with one or more aspects of the invention;
[0039] FIG. 5B is a cross-sectional side view of a two-stage
filtration system in accordance with one or more aspects of the
invention;
[0040] FIG. 6A is a side schematic view of a drum filter in
accordance with one or more aspects of the invention;
[0041] FIG. 6B is an enlarged view of the circled portion (labeled
"6B") of FIG. 5A;
[0042] FIG. 6C is a photograph of a drum filter attached to a disc
filter in accordance with one or more aspects of the invention;
[0043] FIG. 7A is a schematic front view of a drum filter in
accordance with one or more aspects of the invention;
[0044] FIG. 7B is an enlarged view of the circled portion (labeled
"7B") of FIG. 7A;
[0045] FIG. 8 is a partial perspective view of a top portion of a
drum filter in accordance with one or more aspects of the
invention;
[0046] FIG. 9 is a photograph of a drum filter attached to a disc
filter in accordance with one or more aspects of the invention;
[0047] FIG. 10 is a schematic flow diagram of a wastewater
treatment process that includes a two-stage filtration system in
accordance with one or more aspects of the invention;
[0048] FIG. 11 is a schematic view of a backwash system in
accordance with one or more aspects of the invention;
[0049] FIG. 12A is a perspective view of a frame support;
[0050] FIG. 12B is a perspective view of the frame support shown in
FIG. 12A attached to a central drum;
[0051] FIG. 12C is an end view of the frame support of FIG. 12A
attached to a central drum;
[0052] FIG. 12D is a side view of a filter disc including several
filter panels and frame supports;
[0053] FIG. 12E is a perspective view of a filter disc including a
number of filter panels;
[0054] FIG. 13 is a schematic diagram of a two-stage filtration
system;
[0055] FIG. 14 is a schematic of a pilot plant used in accordance
with one or more aspects of the invention;
[0056] FIG. 15 is a schematic flow diagram of a test site and
placement of the pilot plant of FIG. 14;
[0057] FIG. 16 is a graph showing results of one test performed
using a two-stage filtration system in accordance with one or more
aspects of the invention;
[0058] FIG. 17 is a graph showing results of another test performed
using a two-stage filtration system in accordance with one or more
aspects of the invention;
[0059] FIG. 18A is a graph showing results of another test
performed using a two-stage filtration system in accordance with
one or more aspects of the invention; and
[0060] FIG. 18B is a graph showing results of another test
performed using a two-stage filtration system in accordance with
one or more aspects of the invention.
DETAILED DESCRIPTION
[0061] The aspects disclosed herein in accordance with the present
invention, are not limited in their application to the details of
construction and the arrangement of components set forth in the
following description or illustrated in the accompanying drawings.
These aspects are capable of assuming other embodiments and of
being practiced or of being carried out in various ways. Examples
of specific implementations are provided herein for illustrative
purposes only and are not intended to be limiting. In particular,
acts, components, elements, and features discussed in connection
with any one or more embodiments are not intended to be excluded
from a similar role in any other embodiments. For example, the
teachings of this invention apply not only to an "outside-in" type
drum filter connected to an "inside-out" disc filter, but also
apply to other types of filter configurations, including an
"inside-out" type drum filter connected to an "outside-in" disc
filter.
[0062] Also, the phraseology and terminology used herein is for the
purpose of description and should not be regarded as limiting. Any
references to examples, embodiments, components, elements or acts
of the systems and methods herein referred to in the singular may
also embrace embodiments including a plurality, and any references
in plural to any embodiment, component, element or act herein may
also embrace embodiments including only a singularity. References
in the singular or plural form are not intended to limit the
presently disclosed systems or methods, their components, acts, or
elements. The use herein of "including," "comprising," "having,"
"containing," "involving," and variations thereof is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. References to "or" may be construed as
inclusive so that any terms described using "or" may indicate any
of a single, more than one, and all of the described terms. In
addition, in the event of inconsistent usages of terms between this
document and documents incorporated herein by reference, the term
usage in the incorporated reference is supplementary to that of
this document; for irreconcilable inconsistencies, the term usage
in this document controls.
[0063] While the invention illustrated herein is described as being
employed in a wastewater treatment setting, and particularly as a
tertiary treatment system, other uses and arrangements are
possible. For example, the invention may be used as a primary
wastewater treatment system. Other wastewater treatment
applications include use as a secondary clarifier in a municipal
wastewater treatment plant. In addition to wastewater treatment
uses, the present invention can also be used for filtering water
used in industrial and manufacturing processes, such as wood,
paper, and food industries, as well as production facilities.
[0064] As discussed above, rotary disc filters may be used to
remove suspended solids from water. Examples of suitable disc
filters that may be used in accordance with aspects of the
invention are discussed in PCT Application Nos. PCT/US2007/017847
and PCT/US2008/008671, each of which is incorporated herein by
reference in its entirety. FIGS. 1A and 1B illustrate a possible
rotary disc filter 115, also referred to herein as simply a "disc
filter" or "disc filter assembly." Suitable examples of disc
filters for use with the invention include the Forty-X.TM. disc
filters manufactured by Evoqua Water Technologies, although other
disc filters may be used.
[0065] The disc filter 115 configuration shown in FIGS. 1A and 1B
employs a filter media 118 that is pleated filter media. The filter
media 118 may be woven or non-woven. In addition, pile cloth,
needle felt, microfiltration, nanofiltration, reverse osmosis, or
other membranes may be employed as media constructions.
Non-limiting examples of materials for use in making filter media
include polyester, metal-coated polyester, antimicrobial-coated
polyester, polypropylene, nylon, stainless steel wire, glass fiber,
alumina fiber, glass filled polypropylene (e.g., 17%), glass-filled
acetal, glass-filled nylon, or any combination thereof. It should
also be noted that the term "filter media" should be interpreted
broadly to cover any component that filters a fluid. Other terms
included within the definition of filter media include membrane,
element, filter device, and the like. As such, the term "filter
media" should not be narrowly interpreted to exclude any component
that filters fluid.
[0066] Referring back to FIGS. 1A and 1B, disc filter 115 comprises
a housing 125, such as a metal tank that substantially encloses a
central drum 119 that is configured to rotate and supports a
plurality of disc-shaped filter members or filter discs 117. It
will be appreciated that variations on this design, including those
employing a frame intended to facilitate mounting of the unit in a
concrete tank, may also be used.
[0067] The disc filter 115 also includes a drive assembly 170. The
drive assembly 170 includes at least two bearings that support the
central drum 119 for rotation. A driven sprocket 50 is coupled to
the central drum 119 and a drive sprocket 45 is coupled to a motor
55 or other prime mover. In the illustrated construction, a belt
engages the drive sprocket 45 and the driven sprocket 50 such that
rotation of the motor 55 produces a corresponding rotation of the
central drum 119. In preferred constructions, the sprockets 45, 50
are sized to produce a significant speed reduction. However, some
constructions may employ a slow speed drive with no speed reduction
if desired. While the illustrated construction employs a belt
drive, other constructions may employ gears, shafts, chains, direct
drive, or other means for transferring the rotation of the motor 55
to the central drum 119.
[0068] The disc filter 115 also includes an influent pipe 155 (also
referred to herein as an inlet to the housing) that directs
influent into an interior 65 (see FIG. 4A) of the central drum 119,
an effluent pipe 160 (also referred to herein as an outlet to the
housing) that directs filtered fluid from an outlet trough or
chamber 135 defined within the housing 125 out of the disc filter
115. The disc filter 115 may also include a spray water pipe 80
that provides high-pressure water to a plurality of spray nozzles
147 (see FIG. 11) that is periodically used to clean the filter
media 118. A backwash pipe 90 transports the spray water after use
and directs it out of the disc filter 115.
[0069] The spray bars 190 may be positioned between adjacent filter
discs 117 and at the ends of the disc filter 115 to enable the
spraying of high-pressure water in a reverse flow direction through
the pleated filter media 118 to provide backwashing of the filter
media 118. Because the filter media 118 is pleated and thus angled
with respect to the plane of the filter discs 117, the use of
nozzles (147) that are similarly angled may provide for more
efficient backwash cycles. Thus, the nozzles are angled
approximately 45 degrees off of a normal direction to the planes of
the filter discs 117. In addition, two nozzles may be provided at
each spray point, with the nozzles angled with respect to one
another at about 90 degrees such that both sides of the pleats are
sprayed directly during the backwashing. In some instances, a
straight on direct spray may be utilized. In addition, bouncing
spray off the filter media at an angle improves the cleaning effect
and efficiency for a given amount of backwash flow and spray
velocity.
[0070] The disc filter 115 of FIGS. 1A and 1B employs a plurality
of filter discs 117 to increase the overall filter area. The number
and size of the filter discs 117 can be varied depending on the
flow requirements of the system. For example, additional filter
discs 117 can be attached to the central drum 119 to increase the
capacity of the disc filter 115 without having to pass additional
flow through any of the already existing filter discs 117.
According to various embodiments, the disc filter 115 is configured
as an "inside-out" configuration, meaning that water to be filtered
enters the central drum 119 and flows from the central drum 119
into the filter discs 117, and from there outwardly through the
filter media 118, as described further below. This type of
configuration may also be referred to herein as radially outward
fluid flow.
[0071] FIGS. 2A and 2B illustrate a possible central drum 119
configuration that may be used in accordance with one or more
embodiments. The central drum 119 includes an outer surface 95 and
two end surfaces 156 that cooperate to define an interior space.
One end is open to permit flow and the other end is sealed against
flow. Several drum apertures 158 are arranged in a series of axial
rows with each row including a number of drum apertures 158 that
extend circumferentially around a portion of the outer surface 95.
The drum apertures 158 are rectangular although it is understood
that other shapes may be suitable. Attachment apertures 159 are
positioned on either side of each drum aperture 156. Each drum
aperture 158 is associated with a set of attachment apertures 159.
As illustrated in FIG. 2A, the outer surface 95 of the central drum
119 includes a number of flat planar surfaces that contact one
another to define a polygonal cross section. It is to be
appreciated that a circular cross section or a cylindrical or other
shape is also within the scope of this disclosure.
[0072] Referring to FIG. 3, a side view of one of the filter discs
117 of FIGS. 1A and 1B is shown. Each filter disc 117 includes a
plurality of filter panel sets 300. Each filter panel set 300
includes two associated filter panels 116. In FIG. 3, one of the
filter panels 116 from each panel set 300 is shown. The filter disc
117 in FIG. 3 depicts twelve filter panels 116 and thus filter disc
117 includes a total of twenty four filter panels 116. However, it
is to be appreciated that other constructions may employ more or
fewer filter panels 116 as desired.
[0073] After filtering, and during rotation of the central drum
119, the filter panels 116 exit the liquid and pass the spray bars
190. During a backwash cycle, spray nozzles 147 (see FIG. 11) are
used to spray the filter panels 116 with high-pressure water or
chemicals to dislodge the particulates and clean the filter media
118 as the central drum 119 rotates. The water droplet impact
vibration and penetration of the filter media 118 by a portion of
the water removes debris that is caught on the upstream surface of
the pleated filter media 118. The debris and water are collected in
the trough 142 and transported out of the disc filter 115 by
backwash pipe 90.
[0074] FIGS. 4A and 4B illustrate possible arrangements of the
filter panels 116. FIG. 4A illustrates the panel 116 mounted in the
support structure 121. FIG. 4B illustrates a pleated panel. The
filter panels 116 include a pleated filter media 118, a perimeter
frame 210, and several support gussets or stringers 215. In some
constructions, the stringers 215 are molded as an integral part of
the frame 210 with other attachment means also being suitable for
use. In some constructions, the pleated filter media 118 is formed
from a single piece of material that is sized and shaped to fit
within the perimeter frame 210. In the illustrated constructions,
the pleats extend in a substantially radial direction with other
orientations also being possible. In one construction, a stainless
steel screen is employed as the filter media 118. Other
constructions may employ woven polyester, cloth, or other
materials. The materials used and the size of the openings (also
referred to herein as pore size) are chosen based on the likely
contaminates in the effluent, the flow rate of the effluent, as
well as other factors. In one embodiment, the openings are in a
range of 10 and 30 microns in diameter. Smaller and larger openings
are also within the scope of this disclosure. For example, in some
applications, the filter media may have openings that are in a
range of 6 to 300 microns in diameter. According to another
example, the filter media has openings that are about 100, 150, or
200 microns in diameter. As indicated in the examples discussed
below, according to some embodiments, the filtrate 122 generated by
the disc filter may have a TSS concentration of less than 5
mg/L.
[0075] As illustrated in FIG. 4B, one construction of the frame 210
is formed with a cross section of an angled member that includes a
flow-parallel leg 230 and a flow-transverse leg 235. The
flow-transverse leg 235 receives the respective inner diameter seal
165 as illustrated in FIG. 4C, and provides additional stiffness to
the flow-parallel legs 230. The flow-parallel legs 230 are sized to
substantially match the peak-to-peak height of the pleated filter
media 118. The frame 210 also includes two substantially parallel
sides 236 and two non-parallel sides 237 that are arranged such
that they are substantially radial with respect to the central drum
119.
[0076] Referring to FIG. 4C, one of the filter panel sets 300 is
shown. FIG. 4C is a side view of FIG. 4A with a right portion of a
support structure 121 (see FIG. 4A) removed. The filter panels 116
are mounted in the support structure 121 such that the filter
panels are spaced apart from each other. An attachment plate 123
having an aperture 146 engages the attachment apertures 159 around
a drum aperture 158 to attach the support structure 121 to the
central drum 119. A cap 175 is located over a top portion of the
filter panels 116. The filter panels 116, the support structure 121
in which they are mounted, the cap 175, and the attachment plate
123 define a partially enclosed space 180. The partially enclosed
space 180 extends circumferentially around the central drum 119
through each filter panel set 300 on the filter disc 117. Fluid is
able to pass from within the central drum 119, through the drum
aperture 158 and aperture 146 in the attachment plate 123 and into
the enclosed space 180 to enable fluid to flow circumferentially
within each filter panel set in the filter disc 117. A perimeter
seal 165 is located on a perimeter 161 of each filter panel 116 and
serves to inhibit leakage of water from around the filter panel
116.
[0077] Referring to FIG. 1B in conjunction with FIG. 3, the spray
water pipe 80 extends the full length of the disc filter 115 and
defines a distribution manifold 185. A spray bar 190 is positioned
between adjacent filter discs 117 and at each end of the disc
filter 115. A distribution pipe 195 extends between the manifold
185 and the spray bar 190 to provide for fluid communication of
high-pressure water to the spray bar 190. The spray bar 190
includes nozzles that spray water onto the filter panels 116 to
periodically clean the filter panels 116 as described in greater
detail below with reference to FIG. 11.
[0078] A disc filter backwash trough 142 is positioned beneath the
spray bar 190 between adjacent filter discs 117 to catch the spray
water or backwash, including any particulate matter removed from
the filter panels 116. The backwash and particles are then removed
from the disc filter 115 via the backwash pipe 90.
[0079] As mentioned above, openings in the central drum 119 (e.g.,
apertures 158) provide a passageway for water to be sent into the
interior of the filter panels (e.g., enclosed space 180). Since the
openings or pore size of the filter media 118 is smaller than these
openings, solids that are larger than the pore size opening become
attached to the filter media. In addition, larger objects such as
rags can also flow through the drum openings and become trapped in
the interior of the filter panels, which not only reduces filter
panel filtration area but also decreases efficiency since the disc
filter has to be taken offline to remove these larger trapped
objects since the backwash process is ineffective at removing such
large objects.
[0080] In accordance with one or more embodiments, a two-stage
filtration system for filtering wastewater is provided that
addresses the problems discussed above related to the trapped
solids. The two-stage filtration system includes a drum filter,
also referred to herein as a "barrier filter" that functions as a
first stage filtration process that is positioned upstream from a
disc filter that functions as a second stage filtration process.
The drum filter functions as a preceding filter or a pre-filter
which provides a certain degree of filtering to a second stage
filtration process such as the disc filter. For instance, the drum
filter may be configured to remove material that is larger than 100
microns, including large debris from plant upsets caused by storm
surges, etc. The drum filter may be directly attached to the disc
filter such that the drum filter acts as an extension of the disc
filter and functions to protect the disc filter from large debris
and foreign objects. Influent wastewater passes through the drum
filter first, as a first stage filtration operation. The drum
filter removes larger particulates and generates filtered
wastewater that is then directed through the disc filter. The disc
filter functions as a second state filtration operation by removing
finer particulates from the filtered wastewater that passed through
the drum filter to generate filtrate.
[0081] FIG. 5A is a perspective view of one embodiment of a
two-stage filtration system 100, also referred to herein as a
"filter device." The filter device 100 includes a drum filter 105,
also referred to herein as a "first stage filter assembly" or a
"first stage drum filter assembly," and a disc filter 115, also
referred to herein as a "second stage filter assembly" or a "second
stage disc filter assembly." The drum filter 105 includes a rotary
drum 110 and the disc filter 115 includes a central drum 119. The
rotary drum 110 and the central drum 119 are positioned along a
common longitudinal axis 120. The drum filter 105 and the disc
filter 115 are disposed within a housing 125 that at least
partially surrounds the drum filter 105 and the disc filter 115.
The configuration shown in FIG. 5A has a front panel of the housing
125 that is removed to show the drum filter 105 and other features
of the filtration system 100. Referring back to the disc filter 115
FIG. 1B, the drum filter 105 may be positioned in the space defined
by the inlet trough 130 of the housing 125.
[0082] FIG. 5B is a side view of a two-stage filtration system 100.
The housing 125 includes an inlet 155 for receiving wastewater 102
to be filtered that collects in an inlet trough 130 that is in
fluid communication or otherwise fluidly connectable with the
rotary drum 110 of the drum filter 105. As discussed in further
detail below, the wastewater 102 passes through the filter surface
112 of the drum filter 105 as filtered wastewater 104. The filtered
wastewater 104 that has been filtered by the drum filter 105 enters
one or more openings 150 in the central drum 119 of the disc filter
115 to the interior of the central drum 119 where it is then
transferred to the filter discs 117 of the disc filter 115. The
filtered wastewater 104 then passes through the filter media 118 of
the filter discs 117 and collects in an outlet trough 135 of the
housing 125 as filtrate 122. An outlet 160 of the housing 125
allows for filtrate 122 to exit the system. The two-stage
filtration system 100 may also include a sealing plate 126 that is
configured to separate the inlet trough 130 from the outlet trough
135 and a drive assembly 170 that functions to rotate the rotary
drum 110 of the drum filter 105 and the central drum 119 of the
disc filter 115.
[0083] The housing 125 includes an inlet 155 that is in fluid
communication or otherwise fluidly connectable with wastewater to
be filtered 102. The wastewater to be filtered 102 may be piped to
the inlet from any one of a number of various sources. In some
embodiments, the wastewater 102 is from a previous wastewater
treatment process, including any one of a primary, secondary, or
tertiary treatment process. According to one embodiment, the
wastewater 102 is from a secondary treatment process, and the
two-stage filtration system 100 may function as at least a portion
of a tertiary treatment process. For example, the wastewater 102
may be sourced from a secondary clarifier of a secondary treatment
process, as shown in FIG. 10. According to other embodiments, the
wastewater 102 may be influent to a primary treatment system (i.e.,
"wastewater influent" in FIG. 10), and the two-stage filtration
system 100 may function as at least a portion of a primary
treatment process.
[0084] According to some embodiments, the wastewater 102 has a
concentration of total suspended solids (TSS), also referred to
herein as simply "suspended solids" in a range of approximately
10-30 mg/L. In other embodiments, the wastewater 102 has a TSS
concentration that is greater than 30 mg/L, for example, in primary
filtration applications and in instances where the wastewater 102
includes storm water runoff or effluent from a clarifier "burping"
process, the wastewater 102 may have a concentration in a range of
approximately 100-500 mg/L.
[0085] The drum filter 105 includes a rotary drum 110 with a filter
surface 112 that has a first side 114a that faces an interior of
the rotary drum 110 and a second side 114b that faces an exterior
of the rotary drum. According to the embodiments discussed herein,
the drum filter 105 is configured as an "outside-in" filter, such
that wastewater to be filtered 102 (see FIG. 6A) is passed through
the filter surface 112 from the second side 114b (exterior of the
rotary drum) to the first side 114a (interior of the rotary drum)
to generate a filtered wastewater. This type of configuration may
also be referred to herein as radially inward fluid flow.
[0086] The filter surface 112 of the rotary drum 110 may be any one
of a number of different types of filtration media that have
openings or pores that allow water to pass through the filter
surface but retain solids or other undesirable substances. The size
of the openings may depend on the characteristics of the incoming
wastewater 102 and/or the type of filter surface 112 used. In some
embodiments, the filter surface 112 has openings that are in a
range of approximately 1-1000 microns in diameter, and according to
one embodiment, the openings in the filter surface 112 have a
diameter that is in a range of approximately 20-800 microns,
although smaller and larger sized openings for the filter surface
of the drum filter are within the scope of this disclosure.
[0087] The filter surface 112 may be constructed from any corrosion
resistant metal material. In some embodiments, the filter surface
112 is a metal mesh material. Non-limiting examples of metal mesh
material include stainless steel, nickel alloys, other metal
alloys, brass, bronze, titanium, or any combination thereof. In one
embodiment, the filter surface 112 is a wedge wire screen material.
In other embodiments, the filter surface 112 is a polymer material.
In some embodiments, the filter surface 112 is a woven filter media
material.
[0088] FIG. 6A shows one example of a filtration operation using
the drum filter 105. Wastewater to be filtered 102 enters the inlet
trough 130 of the housing 125 through the inlet 155. At least a
portion of the rotary drum 110 rests in the wastewater 102. For
example, in accordance with one embodiment, a portion of the drum
area remains above the water level (see example shown in FIG. 7B
indicated a maximum water level) for purposes of accommodating
spray nozzles (discussed below and refer to FIGS. 7A and 7B) that
spray the filter surface 112 of the rotary drum 110 from the inside
out. However, as will be appreciated, according to other designs,
the rotary drum 110 may be fully immersed in the wastewater 102.
This type of configuration may be useful for removing floatable
materials entrained within the wastewater 102.
[0089] Referring back to FIG. 6A, at least a portion of the second
side 114b of the filter surface 112 is in fluid communication or
otherwise fluidly connectable with the wastewater 102. During
operation, the drive assembly 170 applies a driving force to the
rotary drum 110 to rotate the rotary drum 110 through the
wastewater 102. As shown by the arrow in FIG. 6A, the configuration
of the drum filter 105 of FIG. 6A indicates that the rotary drum
rotates in a counter-clockwise direction, although it is to be
appreciated that clockwise rotation is also within the scope of
this disclosure.
[0090] According to one embodiment, the wastewater 102 flows
through the second side 114b of the filter surface 112 to the first
side 114a as filtered wastewater 104. Wastewater 102 is forced
through the filter surface 112 of the rotary drum 110 by a pressure
differential caused by a difference in water height between a high
pressure source (water at a higher level) on the outside of the
rotary drum 110 (i.e., the presence of the wastewater 102 in the
inlet trough 130 that the rotary drum 110 is at least partially
immersed in) and the inside of the rotary drum 110, which is at a
lower pressure (and lower height water level). The high pressure
source on the outside of the rotary drum 110 pushes the wastewater
102 through the filter surface 112 to the inner chamber of the
rotary drum 110. The filtered wastewater 104 then flows through one
or more openings 150 in the central drum 119 of the disc filter via
gravitational forces (see arrows in FIG. 6A). The openings 150 may
therefore function as an inlet to the disc filter 119, including
the interior of the central drum 119. Referring to the photograph
shown in FIG. 6C, a flange 152 or other attachment mechanism may be
used to attach the rotary drum 110 of the drum filter 105 to the
central drum 119 of the disc filter 115. In some embodiments, the
openings 150 in the central drum 119 may be slots, such as those
shown in FIG. 6C. The filtered wastewater 102 passes through the
openings 150 in the central drum 119 where it is then transferred
to the filter discs 117.
[0091] Solids 106 too large to pass through the openings in the
filter surface 112 adhere to the exterior (second side 114b) of the
filter surface 112. A doctor blade 162 or other scraping device
functions to scrape off or otherwise remove the filtered-out solid
substances 106 from the from the second side 114b of the filter
surface 112 as the rotary drum 110 rotates, which is shown in FIG.
6B. For instance, a scraping edge of the doctor blade 162 rests
against the outer surface of the rotary drum 110 and scrapes the
solids 106 off of the outer surface of the filter surface 112 as
the rotary drum 110 rotates. The scraped solids 106 pass along a
top surface of the doctor blade 162, for example, by the force of
gravity, and are collected in a drum filter collection trough 140,
which is shown in FIGS. 5A, 6B, 7A, and 7B. The drum filter
collection trough 140 is therefore in fluid communication or
otherwise fluidly connectable with the exterior of the rotary drum
110. A portion of the drum filter collection trough 140 may be at
least partially enclosed by an enclosure 141 (see FIG. 6B) that
helps confine the solids 106 and direct them to the collection
trough 140. The doctor blade 162 may be mounted to an internal
portion of the enclosure 141 and may be spring-loaded or have some
other tension adjustment. The enclosure 141 may also include an
access point, such as a door, as shown in FIG. 6B, which may be
used to manually remove trapped solids and/or to access the doctor
blade 162.
[0092] In accordance with at least one embodiment, the filter
device 100 also includes a backwash system. The backwash system
functions to clean the filter media 118 of the disc filters 117 and
the filter surface 112 of the rotary drum 110 at periodic or
predetermined intervals. A schematic of a backwash system 145 is
shown in FIG. 11. The backwash system 145 includes a first
plurality of spray nozzles 147 that are configured to spray
filtrate 122 onto the plurality of filter discs 117. During
cleaning, the drive assembly 170 turns the filter discs 117 at a
low speed (e.g., 1-3 rpm) and filtrate 122 or any other backwash
fluid is pumped from the outlet trough 135 of the housing 125 (or
any other source of filtrate) to the first plurality of spray
nozzles 147 that are positioned at the top of the disc filters 117.
The first plurality of nozzles 147 functions to clean the filtered
solids off the filter media 118. The configuration shown in FIG. 11
includes spray nozzles 147 that are positioned between two adjacent
discs 117 such that both sides of each disc are sprayed from the
"clean" side. The filtrate 122 penetrates through the filter media
118 and washes away the collected solids. A disc filter backwash
trough 142 is used to collect the collected solids (particulate
matter removed from the filter media 118) and used spray water
(backwashed filtrate), which is collectively referred to herein as
backwash effluent, and transports the backwash effluent out of the
disc filter 115, as shown by the arrow in FIG. 11. According to one
embodiment, the disc filter backwash trough 142 (also shown in FIG.
5B) is positioned within the central drum 119 of the disc filter
115.
[0093] The backwash system 145 also includes a second plurality of
spray nozzles 149 configured spray filtrate 122 onto the filter
surface 112 of the rotary drum 110. The second plurality of spray
nozzles 149 functions in a similar manner as the first plurality of
spray nozzles 147. The second plurality of spray nozzles 149 are
also shown in FIG. 6B. As shown, the second plurality of spray
nozzles 149 are disposed on the interior of the rotary drum 110 and
are positioned to spray the "clean" side (first side 114a) of the
filter surface 112. While the rotary drum 110 is being rotated
(also at a slow speed during backwash), the filtrate 122 or other
backwash fluid is pumped to the second plurality of spray nozzles
149 and sprayed onto the first side 114a of the filter surface 112.
The filtrate 122 passes through the filter surface 112 to the
second side 114b and particulate matter removed from the filter
surface 112 and used spray water is collected in the drum filter
collection trough 140, which transports the backwash effluent out
of the drum filter 105.
[0094] According to some embodiments, the first plurality of spray
nozzles 147 and/or the second plurality of spray nozzles 149 may
include one or more features or elements that minimize or reduce
clogging. For instance, the spray nozzles may include a retractable
element that includes a split spray tip or other element that is
configured to retract into an orifice of the housing of the spray
nozzle during non-backwashing operations. When retracted, the split
spray tip "splits" outwardly such that debris that would otherwise
clog the orifice of the spray nozzle is released. Once pressurized,
the retractable element extends outward from the opening and the
split spray tip merges back together to form a spray pattern.
Suitable nozzles having these features include the MOMOJet.RTM.
nozzles available from Ikeuchi USA, Inc.
[0095] As shown in FIG. 6B, The second plurality of spray nozzles
149 are angled and positioned such that the outwardly-directed
spray pattern results in the backwash effluent being directed into
the drum filter collection trough 140. According to one embodiment,
the spray nozzles 149 are positioned to be aligned adjacent to one
another across the width of the rotary drum 110. The spray nozzles
149 may also be positioned and angled to coincide with the doctor
blade 162 such that the spray nozzles 149 spray at the filter
surface 112 in such a way that the doctor blade 162 is more readily
able to scrape waste off into the drum filter collection trough
140. In some instances, the angled orientation of the spray nozzles
149 may be 90 degrees to the filter surface 112, but in other
configurations, the spray nozzles 149 may not be oriented at 90
degrees. FIG. 7A indicates one potential position for the spray
nozzles 149, and FIG. 7B is an enlarged view of the circled portion
of FIG. 7A that indicates the placement and approximate spray
direction. In this instance, the drum filter collection trough 140
is positioned external to the rotary drum 110, but it is to be
appreciated that other locations are also within the scope of this
disclosure, including the interior of the rotary drum 110.
[0096] FIG. 8 is a view of a top portion of the drum filter 105 as
installed within the housing 125 (the front panel of the housing
125 is shown in FIG. 8). According to various aspects, the drum
filter 105 is configured to be sealed to prevent wastewater 102
from inadvertently entering the disc filter 115. The embodiment
shown in FIG. 8 includes a seal 164, such as a v-ring seal that
seals the drum filter 105 to a portion of the housing 125, and a
band clamp 166 to prevent the v-ring seal 164 from moving. A second
sealing mechanism, such as a seal and band clamp, may also be
positioned on the other side of the drum filter 105 where the
central drum 119 penetrates through the sealing plate 126, which
can be seen in the photograph of FIG. 9). The sealing plate 126, as
discussed above, also prevents the wastewater 102 in the inlet
trough 130 from entering and contaminating the filtrate 122 in the
outlet trough 135. FIG. 9 is a photograph of the drum filter 105
attached to the central drum 119 of the disc filter 115. The
sealing plate 126 is also visible in FIG. 9.
[0097] The size of the drum filter 105 may depend on several
factors, including the area and opening size of the filter panel
116 of the drum filter 10, and the flow rate of the wastewater for
a given head loss.
[0098] Referring now to FIG. 12A, a frame support 245 (also
referred to herein as a filter support), for a disc filter 115 in
accordance with at least one embodiment is shown. The frame support
245 serves to support a portion of a side 255 and bottom portion
250 of a pair of filter panels 116 (see FIG. 4B). The frame support
245 includes an attachment portion 260 and a transversely oriented
strut portion 270. The attachment portion 260 includes a first
section 265 which extends from an end 267 of the strut portion 270.
The attachment portion 260 also includes a second section 269 which
extends from the end 267 in a direction opposite to the first
section 265 to thus form an inverted T-shaped frame support 245.
The attachment portion 260 further includes a single aperture 275
which extends along the first 265 and second 269 sections of the
attachment portion 260 and along the strut portion 270 to thus form
a substantially inverted T-shaped aperture which corresponds to the
shape of the frame support 245.
[0099] Referring to FIG. 12B, the frame support 245 is shown
positioned on the central drum 119. The attachment portion 260 is
designed to be maintained in alignment with drum aperture 158 such
that the aperture 275 is in fluid communication or otherwise
fluidly connectable with an associated drum aperture 158 in the
central drum 119. The aperture 275 is substantially the same size
or larger than the drum aperture 158. In another embodiment, the
frame support 245 is positioned on the central drum 119 such that
the attachment portion 260 straddles a support section of the
central drum 119 located in between adjacent drum apertures 158. In
this embodiment, portions of two adjacent drum apertures 158 are in
fluid communication with the aperture 275.
[0100] Referring to FIG. 12C, a pair of filter panels 116 is shown
installed in the frame support 245. The filter panels 116 are
spaced apart from each other. Referring to FIG. 12D in conjunction
with FIG. 12E, a side view of a plurality of frame supports 245 and
filter panels 116 is shown. A cap 295 is used to secure each pair
of filter panels 116. Each cap 295 is removably secured to adjacent
radial struts 270 to enable removal of each filter panel 116 for
cleaning or replacement as necessary. Each filter panel pair, frame
support 245 and associated cap 295 form a filter panel set 300 for
receiving contaminated water. Further, the filter panels 116, cap
295 and aperture 275 form a volume 182 whose cross sectional area
is equal to or larger than the area of drum aperture 158. Volume
182 extends circumferentially around the central drum 119 through
each filter panel set 300 on the filter disc 117 and is continuous.
Referring to FIGS. 12B, 12C, and 12D in conjunction with FIG. 12E,
the aperture 275 enables fluid communication between the drum
aperture 158 and adjacent filter panel sets 300. This enables water
and air to flow circumferentially between adjacent filter panel
sets 300 as the central drum 119 rotates, which may increase the
capacity of the disc filter 115.
[0101] Referring now to FIG. 13, in accordance with one or more
embodiments, the two-stage filtration system 100 may further
include one or more sensors 178 (e.g., 178a and 178b) and a
controller 176, which is operatively coupled to the one or more
sensors 178. The sensors may be configured to measure one or more
properties of the two-stage filtration system and to send these
measurements to the controller 176. The controller 176 may be
operatively coupled to one or more components of the system 100,
such as the drive assembly 170, the backwash system 145, as well as
other components, such as pumps and valves (not shown in FIG. 13).
For instance, the controller 176 may also control one or more
valves or pumps used in the system to control the route of fluids
through the system. The controller 176 is configured to receive
measurements taken by the sensors 178 and to control one or more
components of the system, such as the drive assembly 170 and the
backwash system 145.
[0102] According to at least one aspect, the system may include a
level sensor, such as level sensor 178a that is positioned in the
inlet trough 130 of the housing 125 that houses the drum filter 105
and the disc filter 115. The level sensor 178a may be configured to
measure the level of wastewater 102 (influent water) in the inlet
trough 130 of the housing 125. An approximate maximum water level
(i.e., a predetermined level) for the influent is show in FIG. 7B.
Wastewater is fed into the inlet trough 130 at a constant flow
rate, which means that the water level in the inlet trough will
increase as the solids build up on the filter surfaces of the drum
filter 105 (i.e., the filter surface 112 becomes more clogged) and
the disc filter 115. The level sensor 178a may take periodic
measurements and send these measurements to the controller 176.
Therefore, when the water level in the inlet trough 130 exceeds the
predetermined water level (e.g., a water level such as that shown
in FIG. 7B), the controller 176 may send one or more signals to the
system that result in a halt to a filtration process and to start a
cleaning process. For instance, the controller 176 may control a
motor in the the drive assembly 170 to rotate the drum filter 105
and the disc filter 115 at a lower speed and control the sprayers
in the backwash system 145 to spray cleaning fluid onto the filter
surfaces of each of the drum filter 105 and the disc filter 115 as
described above.
[0103] The one or more sensors may also include one or more
parameter sensors that are configured to measure other process
parameters besides the level of influent, which is exemplified at
178b in FIG. 13. For instance, TSS, BOD, chemical oxygen demand
(COD), pressure, and/or one or more flow rates may also be
monitored by the controller 176 and used to control one or more
components of the system based on measurements taken by the one or
more parameter sensors.
[0104] In accordance with at least one embodiment, a method of
treating wastewater is provided that includes introducing the
wastewater (e.g., 102) to a first-stage filtration operation
comprising a barrier filter (e.g., 105) to produce filtered
wastewater (e.g., 104) and then introducing the filtered wastewater
to a second-stage filtration operation comprising a disc filter
(e.g., 115) to produce treated water (e.g., 122). The method can
also further include measuring a level of wastewater introduced to
the barrier filter of the first stage filtration operation and
backwashing a filter surface of the barrier filter based on the
measured level of wastewater. In one embodiment, the barrier filter
comprises a rotary drum configured for radially inward fluid flow
and the disc filter is configured for radially outward fluid
flow.
EXAMPLES
[0105] The following examples further illustrate the invention, and
are not intended to limit the scope of the disclosure.
Example 1: Two-Stage Tertiary Filtration with 200 Micron Drum
Filter
[0106] A pilot plant containing two Forty-X.TM. filter discs was
re-configured to include a drum filter as shown in FIG. 14. The
drum filter was added to the influent box (see FIG. 14) that is
typically used to measure the influent water level as the disc
filter captures solids. This location also allows for the drum
filter to seal off to a plate to prevent leaking of influent water
to the filtered water. Each disc filter in the pilot plant was 7.2
feet in diameter and included either 10 or 20 micron pleated panel
filter media.
[0107] A schematic of the placement of the pilot plant within an
existing wastewater treatment plant (i.e., test site) is shown in
FIG. 15. The test site included a secondary treatment process which
consisted of an Orbal.RTM. biological reactor (Evoqua Water
Technologies) followed by Tow-Bro.RTM. clarifiers (Evoqua Water
Technologies) that provided secondary clarification. The test site
also included a tertiary treatment process that consisted of two
Hydrotech.TM. disc filters (available from Veolia) set up in a
parallel configuration. The pilot plant was configured to intake
influent originally designated for the second existing disc filter
such that effluent from the secondary clarifier was provided as
influent to the pilot plant, as shown in FIG. 15.
[0108] A 200 micron screen was initially installed on the drum
filter. The drum filter was successful in trapping large solids and
debris and preventing these items from entering the disc filter,
which was fitted with 10 micron filter media. After four months of
use, the drum filter showed no signs of wear. TSS data (see left
y-axis of FIG. 16) taken over an approximate 11-day period from the
influent stream (i.e., wastewater 102, labeled "influent TSS") and
the effluent of the disc filter (i.e., 122, labeled as "effluent
TSS") is shown in FIG. 16. With an approximate average flow rate of
about 210 gpm, the influent TSS values ranged from 7-22 mg/L and
effluent TSS values were, on average, below 5 mg/L. TSS and
biochemical oxygen demand (BOD) measurements were also taken of
both reject streams (i.e., solids captured by the drum filter and
solids captured by the disc filter) and are shown below in Table 1.
The results from this test indicate that the drum filter is able to
relieve some of the TSS load from the disc filter. For example,
both filters removed TSS from the wastewater, as indicated in Table
1.
TABLE-US-00001 TABLE 1 tertiary reject stream data from 200 micron
drum and 10 micron disc filters Drum filter reject stream Disc
filter reject stream TSS (mg/L) 220 470 BOD (mg/L) 100 130
Example 2--Two-Stage Tertiary Filtration with 75 Micron Drum
Filter
[0109] The 200 micron drum filter experiment discussed above in
Example 1 resulted in minimal head loss across the drum filter in
both tertiary and primary treatment applications (the primary
treatment results are discussed further below). Drum filters having
screens with various sizes of openings ranging from 25 microns to
220 microns were tested. The results (not shown) from timed
draw-down and turbidity tests indicated that a 75 micron screen
yielded the best results.
[0110] A 75 micron filter material was then installed on the drum
filter and a two-stage tertiary filtration process with a 10 micron
pleated panel disc filter was commenced. FIG. 17 includes similar
data as shown in FIG. 16 taken over an approximate 24-day period.
The flow rate was higher, with values that fluctuated in a range of
from about 222 gpm to about 436 gpm, and the influent TSS values
were about the same as in Experiment 1. Again, the effluent TSS
values were, on average, below 5 mg/L. TSS and BOD measurements
were taken of both reject streams and are shown below in Table 2.
The results from this test re-confirm that the drum filter relieves
at least a portion of the TSS load from the disc filter. The higher
flow rate also yielded a higher concentration of solids being
trapped by both filters (when compared to the results from Table
1).
TABLE-US-00002 TABLE 2 tertiary reject stream data from 75 micron
drum and 10 micron disc filter Drum filter reject stream Disc
filter reject stream TSS (mg/L) 1000 890 BOD (mg/L) 170 220
Example 3--Two-Stage Primary Filtration with 200 Micron Drum
Filter
[0111] For purposes of testing the pilot plant in a primary
treatment application, a gas powered trash pump was installed in
the raw influent stream that fed the test site. The pump was
capable of influent flow rates up to 130 gpm and a secondary pump
was used to supplement the flow rate to be as high as 400 gpm.
[0112] A 200 micron drum filter was paired with two different sized
disc filters. The first disc filter tested was a 10 micron pleated
panel disc filter, and two-stage primary filtration was performed
using this configuration for approximately 6 days. FIG. 18A is a
graph showing the TSS (right y-axis) and BOD (left y-axis)
measurement results taken of the influent and effluent streams, as
well as the flow rate, which ranged from 49 to 98 gpm. The second
disc filter that was tested was fitted with a 25 micron flat
stainless steel panel was also tested over an approximate 9-day
period. The TSS and BOD measurement results from the influent and
effluent streams are shown in the graph of FIG. 18B, as well the
flow rate, which ranged from 92 to 415 gpm.
[0113] The results shown in FIGS. 18A and 18B indicate an average
removal of 55% of the influent BOD and 85% of the influent TSS
levels. The effluent TSS and BOD values are similar to those
achieved without a drum filter functioning as a first stage
filtration process, but the two-stage filtration process allows for
the disc filter to run more continuously without immediately
clogging and having to be taken offline and cleaned. The drum
filter as a pre-filter or first stage filtration process also
increases the capacity of the system when the influent TSS values
are very high.
[0114] Combined influent and effluent TSS data from all three
examples are also shown in FIG. 17.
[0115] Having thus described several aspects of at least one
example, it is to be appreciated that various alterations,
modifications, and improvements will readily occur to those skilled
in the art. For instance, examples disclosed herein may also be
used in other contexts. Such alterations, modifications, and
improvements are intended to be part of this disclosure, and are
intended to be within the scope of the examples discussed herein.
Accordingly, the foregoing description and drawings are by way of
example only.
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