Abstract:
A purification apparatus comprising a filtration unit comprising filtration screens, a disinfection unit comprising a source of disinfecting light and a passage for filtrate from the filtration unit to the disinfection unit. The filtration unit may be selected from at least one static drum, at least one rotating drum, and at least one filter pack. Louver vanes or baffles may be used in the passage to create turbulence and direct flow. A process for removing particulate matter and disinfecting a process flow comprises the steps of filtering the process flow to remove particulate matter, directing the filtrate to a source of disinfection light while creating turbulence in the filtrate and disinfecting the filtrate.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of priority of U.S. Provisional Application Ser. No. 61/526,605 filed Aug. 23, 2011, which is incorporated into this application by reference in its entirety. 
     
    
     FIELD 
       [0002]    The field of the inventions is the sequential treatment of process or effluent flows. This field includes but is not limited to the filtration and disinfection of process flows, including waste water flows. 
       BACKGROUND 
       [0003]    Most processes create waste in one form or another. This waste can be stored, discarded or processed further to create a material with its own uses, including recycle back to the original process. One example can be found in the field of metalworking. Mixtures of soluble oils and water are widely used to cool the cutting tool and its environs. As it is used, this cutting fluid becomes loaded with metallic particulates and decomposed by microbes. The useful life of the cutting fluid can be extended by removing the metallic particulates and treating the contaminated fluid with chemical disinfectants. 
         [0004]    Fish tanks and swimming pools present another example. Here the particulates are predominantly organic in character. They are fertile sites for the growth of microbes. Contaminated water typically is treated by recycle means. It is pumped from the tank or pool, passed through a filter and returned to the tank or pool. Chemicals are used to control free-floating microbes and infestations in particles that are not large enough to be caught in the filter. 
       SUMMARY 
       [0005]    The inventions of the application include an apparatus for removing and disinfecting particulate matter from a process flow comprising a filtration unit comprising at least one filtration screen, a disinfectant unit comprising a source of disinfecting light, and a passage for filtrate from the filtration unit to the disinfectant unit. The filtration unit may comprise at least one static drum with one or more filtration screens on its periphery. The filtration unit also may comprise at least one rotating drum with one or more filtration screens on its periphery. The filtration unit further may comprise at least one filter pack comprising a first filter screen and at least one other filter screen that is different in mesh from the first filter screen 
         [0006]    The passage for filtrate of the apparatus may be fitted with a louver, and one or more vanes of the louver may be aimed at the source of disinfecting light. The louver also may create turbulence. The passage for filtrate of the apparatus also may be fitted with at least one baffle, and each baffle may block flow around the source of disinfecting light. The baffle also may create turbulence. 
         [0007]    The disinfecting light of the apparatus may be ultraviolet light. The source of disinfecting light may be one or more elongated bulbs and the axis of each bulb may be horizontal. The source of disinfecting light may be a multiplicity of elongated bulbs arranged in a horizontal array, and that array may create turbulence. The surfaces of the apparatus adjacent to the array may be made reflective. 
         [0008]    The filtration unit of the apparatus may comprise a level detector that is triggered when the screens of the filtration unit become loaded with particulates. The filtration unit further may comprise a spray bar that washes particulates from the screens. 
         [0009]    The inventions of the application further include an apparatus for removing and disinfecting particulate matter from a process flow including a first filtration unit comprising filtration screens, a first disinfectant unit comprising a source of disinfecting light, a first passage for filtrate from the first filtration unit to the first disinfectant unit, a second filtration unit comprising filtration screens, a second disinfectant unit comprising a source of disinfecting light, a second passage for filtrate from the second filtration unit to the second disinfectant unit, and a central outlet box joining the first disinfectant unit with the second disinfectant unit. 
         [0010]    The inventions of the application further include a process for removing and disinfecting particulate matter from a process flow comprising the steps of filtering the process flow to remove a majority of the particulate matter, directing the filtrate to a source of disinfecting light while creating turbulence in the filtrate; and disinfecting the filtrate. 
     
    
     
       DRAWINGS 
         [0011]      FIG. 1  depicts an exploded view of an apparatus for filtering and disinfecting waste water. 
           [0012]      FIG. 2  depicts an unexploded view of the apparatus of  FIG. 1 . 
           [0013]      FIG. 3  depicts a side view of the apparatus of  FIG. 1 . 
           [0014]      FIG. 4  depicts a top view of the apparatus of  FIG. 1 . 
           [0015]      FIG. 5  depicts a rear view of the apparatus of  FIG. 1 . 
           [0016]      FIG. 6  depicts a cross-sectional view of the apparatus of  FIG. 1 . 
           [0017]      FIG. 7  depicts an exploded view of another apparatus for filtering and disinfecting waste water. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    The discussion that follows relates to certain preferred embodiments of the inventions of this application. The inventions are broader than these preferred embodiments. The full scope of certain of the inventions is defined by the claims at the end of this application. 
         [0019]      FIG. 1  depicts an exploded view of a preferred embodiment  100  used to treat waste water contaminated with particles and microbes. Following is a list and description of operating components of this unit: 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                 Item 
                 Component 
                 Description 
               
               
                   
               
             
             
               
                 101 
                 Filter enclosure 
                 Stainless steel construction 
               
               
                 102 
                 Drum assembly 
                 Drum frame and associated parts. Screen 
               
               
                   
                   
                 panels not shown for clarity. 
               
               
                 103 
                 Drive shaft 
                 Main component of drive system. 
               
               
                 104 
                 Motor 
                 Electric motor for drive system. 
               
               
                 105 
                 Gear 
                 Reduction gear for drive system. 
               
               
                 106 
                 Motor cover 
                 Cover for protecting drive system from the 
               
               
                   
                 assembly 
                 elements and to cover exposed moving 
               
               
                   
                   
                 parts. 
               
               
                 107 
                 Lid assembly 
                 Aluminum construction, with removable lid 
               
               
                   
                   
                 panels, access door and spray bar 
               
               
                   
                   
                 assembly 
               
               
                 108 
                 UV module 
                 UV module, complete with bulbs and quartz 
               
               
                   
                   
                 sleeves. 
               
               
                 109 
                 Weir/UV chamber 
                 Aluminum checker plate construction. 
               
               
                   
                 lid 
                 Cover for blocking UV light and can be 
               
               
                   
                   
                 used as a platform for UV module 
               
               
                   
                   
                 installation/removal 
               
               
                 110 
                 Support wheel 
                 Drum support wheels with finger guards. 
               
               
                   
                 assemblies 
               
               
                 111 
                 Solids outlet 
                 4″ flanged outlet from sludge tray. 
               
               
                 112 
                 Inlet 
                 12″ flanged inlet for influent water. 
               
               
                 113 
                 Location tabs 
                 For securing filter to mounting surface. 
               
               
                 114 
                 Junction box 
                 Water tight connection point filter float 
               
               
                   
                   
                 switches. 
               
               
                 115 
                 Lifting lugs 
                 Lifting points for filter installation. Use 
               
               
                   
                   
                 spreader bar if necessary when lifting. 
               
               
                   
               
             
          
         
       
     
         [0020]    Untreated waste water—particulate bearing and microbe infested—is gravity or pump fed through inlet  112  to the inside of drum assembly  102 , which has panels of fine screen mounted on its periphery. Drum assembly  102  is rotated periodically for the purpose of cleaning, as will be discussed. Drum assembly  102  also can be rotated can be rotated continuously with periodic cleaning. The end of drum assembly  102  farthest from inlet  112  is sealed with a solid plate, which is either stainless steel or fiberglass. If the plate is stainless steel, it is stitch welded on both sides to the inside of drum assembly  102 , then sealed inside and out with a marine urethane sealant. If the plate is fiberglass, it is press fit to the inside of drum assembly  102  and sealed inside and out with a marine urethane sealant. The end of drum assembly  102  nearest to inlet  112  is sealed to the inlet structure using an ethylene-propylene-diene-monomer rubber seal, which is attached to the inlet structure. 
         [0021]    Waste water entering drum assembly  102  from inlet  112  flows through the screen panels of drum assembly  102 . Particulate and microbial impurities are captured by the screen panels and filtrate exits the screen panels. As this process continues, the screen panels gradually become clogged with accumulated particulates and microbes, and the water level inside drum assembly  102  rises. When the water level reaches a predetermined fill level, a backwash system is activated by a level switch. Drum assembly  102  begins rotating (if not already rotating) and water is sprayed from a spray bar located outside of drum assembly  102 . The spray dislodges the particulates and microbes, which are collected in a trough located inside the drum and opposite the spray bar. The clean screen panels are rotated into the water from inlet  112 , rotation of drum assembly  102  stops and flow is improved, lowering the water level inside drum assembly  102 . The backwash system automatically shuts down to save power. The collected particulates and microbes exit the system through solids outlet  111  for disposal or recovery. 
         [0022]    The inventions of the application include filtration apparatus other than or in addition to a drum assembly  102  with filter panels at its periphery. Two drum assemblies may be used in series or in parallel. The series arrangement would be particularly useful when height of the filtration enclosure  101  requires reduction, or where there is a need for more filtration capacity in terms of flow rate or for more filtration capability in terms of particle size. Static filters may also be used. A static filter comprises a filter pack assembled from successively finer mesh filter elements, with the waste water entering at the end of the filter with the largest mesh filter element. Once clogged with particulates and microbes, this filter pack could be cleaned by introducing a stream of clean water at the end of the filter pack with the smallest mesh element. The filter would have to be taken offline during this operation, and it might prove useful to use two or more filter packs in parallel, so that one filter pack is performing filtration while the other filter pack is being cleaned. 
         [0023]    Filtrate from the drum assembly  102  passes through a louvered baffle and flows through one or more ultraviolet light modules  108 , which are designed to inactivate microbes by exposing the microbes to ultraviolet light, which affects the DNA of the microbes and renders them unable to reproduce. The design dose of ultraviolet light is a function of the particular microbe of concern within the facility, the ultraviolet-light transmittance of the filtrate and the peak flow rate passing through drum  102 . 
         [0024]    In a preferred format, the ultraviolet light modules comprise a multiplicity of elongated ultraviolet bulbs. These are arranged in a horizontal array, with the axes of the bulbs perpendicular to the direction of motion of the filtrate from drum assembly  102  so as to maximize turbulence of the microbe-bearing water and thus maximizing exposure of the microbes to ultraviolet light and maximizing the efficiency of the system at producing water that is entirely or almost entirely. Turbulence also may be produced by placing turbulence-creating elements in the transition passage of the apparatus between the filtration apparatus and the ultraviolet light modules  108 , including asymmetric wall arrangements and rigid members that extent into the transition passage, symmetric or asymmetric. Finally, the effect of the ultraviolet light may be enhanced by using reflective materials for the structure surrounding the ultraviolet light modules  108 , such as stainless steel, or coating that structure with a reflective material or coating. 
         [0025]    Alternatively, the elongated bulbs may be oriented along a non-horizontal axis, including a vertical axis. In another alternative, the flow can be directed along the axis of the ultraviolet bulbs, whether horizontal or otherwise, rather than perpendicular to that axis. Beyond this, non-elongated bulbs may be used, an example being a medium-powered ultraviolet bulb that fits into a single socket and a resembles a common incandescent bulb in profile. 
         [0026]    The  FIG. 1  embodiment is defined by a number of design parameters. Some of these are as follows: 
         [0000]    
       
         
               
               
             
           
               
                 TABLE 2 
               
               
                   
               
               
                 Parameter 
                 Value 
               
               
                   
               
             
             
               
                 Treatment Range 
                 Up to 500 US Gpm/1,840 Lpm 
               
               
                 Electrical Supply 
                 120 V, 1 Phase or 240 V, 3 Phase 
               
               
                 Input Power (per lamp) 
                 45 W 
               
               
                 Screen Size (micron) 
                 30 
               
               
                 Number of Screen Panels 
                  8 
               
               
                 Minimum Drum Submergence 
                 40% 
               
               
                 Weight (dry) 
                 1,100 lbs 
               
               
                 Drum Frame 
                 304 or 316 SS 
               
               
                 Drum Shaft 
                 316 SS 
               
               
                 Filter Enclosure 
                 Stainless steel 
               
               
                 Sectional Lid 
                 Marine grade aluminum 
               
               
                 Screen Panels 
                 Injection molded polyester fabric 
               
               
                   
                 embedded in polypropylene grids 
               
               
                 Drum Seal 
                 Synthetic elastomer seal wear ring 
               
               
                 UV Rack 
                 316 SS 
               
               
                 Lamp Type 
                 Low-pressure 
               
               
                 Ballast Type 
                 Electronic, non-variable 
               
               
                 Lamp Configuration 
                 Horizontal, perpendicular flow 
               
               
                 Module Configuration 
                 4 lamps per module 
               
               
                 Dose Configuration 
                 30 to 200 mJ/cm2 
               
               
                 Inlet, Outlet, Solids Outlet 
                 Flange or pipe 
               
               
                 Backwash Supply 
                 Operates at 100 psi - booster pump 
               
               
                   
                 available 
               
               
                   
               
             
          
         
       
     
         [0027]    A wide variety of other design choices are possible and feasible. For example, filter enclosure  101  may be constructed in whole or in part of materials other than stainless steel. Fiberglass might be used, as might polytetrafluoroethylene or other plastics. 
         [0028]    Unique features of the  FIG. 1  embodiment  100  are many. It has a small footprint compared to traditional disinfection packages. It provides louvered flow balancing. Easy access to filter and ultraviolet components is provided. There are multiple open-channel ultraviolet modules, and the system is highly configurable to meet water-application requirements. The net result is is an all-in-one, ready-to-use apparatus for treating process flows with particulate and microbial contaminations. 
         [0029]    The  FIG. 1  embodiment  100  has the lowest operating head of available filtration and disinfection solutions. There is packaged biosecurity, with fully integrated particle removal and disinfection. Pre-filtration optimizes ultraviolet disinfection. Plug and play design reduces engineering and installation costs. There is continuous filtering and disinfection, even during backwashing. Water consumption during backwash is minimal, and there is no downtime during exchange of ultraviolet bulbs. 
         [0030]      FIG. 2  depicts the  FIG. 1  embodiment  100  in an unexploded format  200  from the same perspective. The components of  FIG. 2  embodiment  200  correspond to the components of  FIG. 1  embodiment  100 . 
         [0031]      FIG. 3  depicts the  FIG. 1  embodiment  100  in an unexploded format  300  from a side perspective. The components of  FIG. 3  embodiment  300  correspond to the components of  FIG. 1  embodiment  100 . 
         [0032]      FIG. 4  depicts the  FIG. 1  embodiment  100  in an unexploded format  400  from a top perspective. The components of  FIG. 4  embodiment  400  correspond to the components of  FIG. 1  embodiment  100 . 
         [0033]      FIG. 5  depicts the  FIG. 1  embodiment  100  in an unexploded format  500  from a rear perspective. The components of  FIG. 5  embodiment  500  correspond to the components of  FIG. 1  embodiment  100 , and details of an ultraviolet module  508  corresponding to module  108  are depicted in  FIG. 5 . An upper horizontal handling member  517  carries two vertical receptacle members  518 , both of which are fitted with a series of lamp receptacles that receive power from an electrical connection cable affixed to member  517 . Ultraviolet lamps  520  are inserted in the lamp receptacles for electrical connection and mechanical support. A horizontal light block bar  516  straddles the two receptacle members  518  to protect the user from exposure to ultraviolet light. In use, the ultraviolet module  508  is lowered into ultraviolet box  521  and covered. As noted, more than one ultraviolet module  508  may be used simultaneously, depending on the application. 
         [0034]      FIG. 6  depicts the  FIG. 1  embodiment  100  in an unexploded format  500  from the same perspective as  FIG. 2 , except that the embodiment of  FIG. 2  has been sectioned to reveal inner details of the apparatus. The components of  FIG. 6  embodiment  600  correspond to the components of  FIG. 1  embodiment  100 . Filtrate flows from drum assembly  602  (shown without screens) through a multi-vaned louver  621 , which directs the flow at the bulbs of three ultraviolet modules  608  made up of elongated ultraviolet bulbs  620 . Baffle  622  further directs the flow of filtrate to the ultraviolet bulbs, as does baffle  624 , which effectively forces water through louver  621 . Vertical end baffling is provided at each end of each ultraviolet module. These end baffles force water that is moving at the outer vertical surfaces of the apparatus directly onto the ultraviolet bulbs. The combination of louver  621 , baffle  622 , baffle  624  and the end baffles maximize the efficiency of the process of disinfecting the water flow by assuring that as much of the filtrate as possible receives UV radiation from the ultraviolet bulbs. In addition, efficiency of irradiation is further enhanced by the turbulence created by louver  621 , baffle  622 , baffle  624  and the end baffles. 
         [0035]    Of further interest in  FIG. 6  is the trough  625 , which receives particulates and microbes dislodged from drum assembly  602 . This occurs during a cleaning cycle in which a backwash system initiates a spray of water from a spray bar located in lid assembly  607 . The spray dislodges the particulates and microbes from the filter screens of drum assembly  602 , which are collected in a trough  625 . The clean screen panels are rotated into the water from inlet  112 , rotation of drum assembly  102  stops and flow is improved, lowering the water level inside drum assembly  102 . The backwash system automatically shuts down to save power. The particulates and microbes collected in trough  625  are removed from the system. 
         [0036]      FIG. 7  depicts an exploded view of another preferred embodiment  700  of some inventions of this application, as defined in the claims that follow. Following is a list and description of operating components of this unit: 
         [0000]    
       
         
               
               
               
             
           
               
                 TABLE 3 
               
               
                   
               
               
                 Item 
                 Component 
                 Description 
               
               
                   
               
             
             
               
                 701 
                 Filter enclosure 
                 Stainless steel construction 
               
               
                 702 
                 Weir plate 
                 Designed to keep water level outside of 
               
               
                   
                   
                 drum at correct height. 
               
               
                 703 
                 Gasket 
                 Water tight seal connection between filter 
               
               
                   
                   
                 and outlet box. 
               
               
                 704 
                 Central outlet box 
                 Effluent accumulation chamber for both 
               
               
                   
                   
                 filters, with 10″ flanged outlet. 
               
               
                 705 
                 Location tabs 
                 For securing filter to mounting surface. 
               
               
                 707 
                 Filter enclosure, 
                 Stainless steel construction 
               
               
                   
                 normal rotation 
               
               
                 707 
                 Support wheel 
                 Drum support wheels with finger guards. 
               
               
                   
                 assemblies 
               
               
                 708 
                 Solids outlet 
                 4″ flanged outlet from sludge tray. 
               
               
                 709 
                 Junction box 
                 Water tight connection point for filter float 
               
               
                   
                   
                 switches. 
               
               
                 710 
                 Lifting lugs 
                 Lifting points for filter installation. Use 
               
               
                   
                   
                 spreader bar if necessary when lifting. 
               
               
                 711 
                 Motor cover 
                 Cover for protecting drive system from the 
               
               
                   
                 assembly 
                 elements and to cover exposed moving 
               
               
                   
                   
                 parts. 
               
               
                 712 
                 Lid assembly 
                 Aluminum construction, with removable lid 
               
               
                   
                   
                 panels, access door and spray bar 
               
               
                   
                   
                 assembly. 
               
               
                 713 
                 UV module 
                 UV module, complete with bulbs and quartz 
               
               
                   
                   
                 sleeves. 
               
               
                 714 
                 Weir/UV chamber 
                 Aluminum checker plate construction. 
               
               
                   
                 lid 
                 Cover for blocking UV light and can be 
               
               
                   
                   
                 used a platform for UV module 
               
               
                   
                   
                 installation/removal. 
               
               
                 715 
                 Motor 
                 Electric motor for drive system 
               
               
                 717 
                 Gear 
                 Reduction gear for drive system. 
               
               
                 717 
                 Drive shaft 
                 Main component of drive system. 
               
               
                 718 
                 Drum assembly 
                 Drum frame and associated parts. Screen 
               
               
                   
                   
                 panels not shown for clarity. 
               
               
                 719 
                 Inlet 
                 8″ flanged inlet for influent water. 
               
               
                   
               
             
          
         
       
     
         [0037]    Broadly speaking, the  FIG. 7  embodiment  700  comprises two of the  FIG. 1  embodiments  100 , with one being a mirror image of the other. The operation, benefits and features of each of the two units is as described above with respect to the single  FIG. 1  embodiment  100 . The purpose of the  FIG. 7  embodiment  701  is to effectively double the handling capacity or provide full redundancy of the  FIG. 1  embodiment in as little space as possible. As shown in  FIG. 7 , the two units of the  FIG. 7  embodiment  701  are joined by a central outlet box  704 , which is an effluent accumulation chamber with a flanged outlet. 
         [0038]    The  FIG. 7  embodiment  700  is defined by a number of design parameters. Some of these are as follows: 
         [0000]    
       
         
               
               
             
           
               
                 TABLE 4 
               
               
                   
               
               
                 Parameter 
                 Value 
               
               
                   
               
             
             
               
                 Treatment Range 
                 Up to 1000 US Gpm/1,840 Lpm 
               
               
                 Electrical Supply 
                 120 V, 1 Phase 
               
               
                 Input Power (per lamp) 
                 87.5 W 
               
               
                 Screen Size (micron) 
                 30 
               
               
                 Number of Screen Panels 
                 16 
               
               
                 Minimum Drum Submergence 
                 40% 
               
               
                 Weight (dry) 
                 2000 lbs 
               
               
                 Drum Frame 
                 304 or 316 SS 
               
               
                 Drum Shaft 
                 316 SS 
               
               
                 Filter Enclosure 
                 Stainless steel 
               
               
                 Sectional Lid 
                 Marine grade aluminum 
               
               
                 Screen Panels 
                 Injection molded polyester fabric 
               
               
                   
                 embedded in polypropylene grids 
               
               
                 Drum Seal 
                 Synthetic elastomer seal wear ring 
               
               
                 UV Rack 
                 316 SS 
               
               
                 Lamp Type 
                 Low-pressure 
               
               
                 Ballast Type 
                 Electronic, non-variable 
               
               
                 Lamp Configuration 
                 Horizontal, perpendicular flow 
               
               
                 Module Configuration 
                 6 lamps per module 
               
               
                 Dose Configuration 
                 30 to 200 mJ/cm 2   
               
               
                 Inlet, Outlet, Solids Outlet 
                 Flange or pipe 
               
               
                 Backwash Supply 
                 Operates at 100 psi - booster pump 
               
               
                   
                 available 
               
               
                   
               
             
          
         
       
     
         [0039]    A wide variety of other design choices are possible and feasible. For example, filter enclosure  701  may be constructed in whole or in part of materials other than stainless steel. Fiberglass might be used, as might polytetrafluoroethylene or other plastics.