Abstract:
A process wherein a combination of two separation principles are combined into one space saving machine with portability to separate two distinct and different fluids one lighter in specific gravity than the other, including the steps of primary separation of fluids allowing for free and suspended solids along with free oil and grease to be removed in the primary separation chamber; utilizing parallel corrugated plates in the separation defining the distance of rise for a given oil droplet based on Stokes Law to remove the remaining large droplets of free oil and solids; and providing an induced gas flotation process which provides a finely dispersed bubble in the liquid to accelerate the lift necessary for separation of fine oil droplets, emulsified oil droplet, and suspended solids to meet a government discharge regulation. This combined technique can be configured in a single vessel without pumps or other methods of liquid movement.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Priority of U.S. Provisional Patent Application Ser. No. 61/449,289, filed Mar. 4, 2011, incorporated herein by reference, is hereby claimed. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     REFERENCE TO A “MICROFICHE APPENDIX” 
     Not applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to separation of fluids. More particularly, the present invention relates to a method for the separation of two liquids which are immiscible with each other. Still more particularly the present invention discloses a method and an apparatus for separating oil from water efficiently within a single vessel by applying a separating influence and minimizing other factors which tend to reduce droplet size and inhibit separation. 
     2. General Background of the Invention 
     In the present state of the art, the separation of two distinct fluids is undertaken in separate operations, which requires additional space, increases the cost and operating expense of having two machines for this operation, and does not allow the equipment to become portable, since these technologies are being operated separately for all of the above applications. 
     BRIEF SUMMARY OF THE INVENTION 
     The process and apparatus of the present invention solves the problems in the prior art in that it provides a process wherein a combination of two separation principles are combined into one space saving machine with portability to separate two distinct and different fluids one lighter in specific gravity than the other, including the steps of primary separation of fluids allowing for free and suspended solids along with free oil and grease to be removed in the primary separation chamber; utilizing parallel corrugated plates in the separation defining the distance of rise for a given oil droplet based on Stokes Law to remove the remaining large droplets of free oil and solids; and providing an induced gas flotation process which provides a finely dispersed bubble in the liquid to accelerate the lift necessary for separation of fine oil droplets, emulsified oil droplet, and suspended solids to meet governmental discharge regulations. This combined technique can be configured in a single vessel with the proper flow regime and unique hydraulic condition for undisturbed flow throughout the vessel without the use of pumps or other methods of liquid movement solely thru a specified pressure drop internal to the vessel. 
     Therefore, it is a principal object of the present invention wherein the combination of these two technologies in one vessel benefits the user in that it minimizes the cost and operating expense of having two machines for this operation. 
     It is a further object of the present invention whereby the combination provides a space savings over the current technology. 
     It is a further object of the present invention whereby the combination makes the equipment portable and therefore can be applied in several ways, primarily as process water treatment equipment, but also for using as equipment bypass treatment while existing equipment is being maintained and finally for pipeline flushes and cleaning and frac water treatment. 
     It is a further object of the present invention to provide a significant benefit to the state of the art when one considers that to this date all applications of these two techniques have been done in separate and individual equipments while taking up additional space, and having a significantly higher cost, considering the fact there is more equipment, maintenance and instrumentation. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein: 
         FIG. 1  illustrates a schematic plan view of the present invention; 
         FIG. 2  illustrates a schematic side elevation view of corrugated plate interceptor (CPI) compartmental vessel of the apparatus of the present invention; 
         FIG. 3  illustrates a schematic side elevation view of the Induced Gas Flotation (IGF) compartmental vessel of the apparatus of the present invention; 
         FIG. 4  illustrates a schematic plan view of the corrugated plate interceptor (CPI) compartmental vessel of the apparatus of the present invention; 
         FIG. 5  illustrates a schematic side elevation view of the corrugated plate interceptor (CPI) compartmental vessel of the apparatus shown in  FIG. 4 ; and 
         FIG. 6  illustrates a basic schematic plan view of the induced gas flotation (IGF) compartmental vessel of the apparatus of the present invention; 
         FIG. 7  illustrates a detailed schematic side elevation view of Induced gas flotation (IGF) compartmental vessel of the apparatus of the present invention; and 
         FIG. 8  schematically illustrates an end elevation view of the composite Enviro-Cell-Combo, comprising the corrugated plate interceptor (CPI), the compartmental vessel, and the induced gas flotation (IGF) compartmental vessel of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates a schematic plan view of the present invention, Enviro-Cell-Combo apparatus  10  of the present invention. Enviro-Cell apparatus  10  utilizes an immiscible fluids separation method, incorporating a Corrugated Plate Interceptor (CPI) compartmental vessel  3  conjoint with an Induced Gas Flotation (IGF) compartmental vessel  7  at CPI/IGF process separation partition  31 . Schematically illustrated by the immiscible fluid primary flow path  2 , the raw immiscible fluid to be separated enters the present invention at immiscible fluid inlet flange  11 , the fluid proceeding subsequently through the separation method of Enviro-Cell-Combo  10 , and finally a recovered portion of the process fluid (typically water) exiting the invention at clean water outlet flange  29 . Oil separated during the initial phase of the immiscible fluids separation process is collected in oil collection reservoir (CPI)  16 . In like manner, oil separated during the final phase of the immiscible fluids separation process is collected in oil reservoir (IGF)  27 . Oil collection reservoir  16  is connected to oil collection reservoir  27  by means of CPI/IGF collected oil reservoir conduit  49 . The oil collection in oil collection reservoir (IGF)  27  is the aggregate product of oil separated by IGF processing cell # 1   20 , IGF processing cell # 2   21 , IGF processing cell # 3   22 , and IGF processing cell # 4   23 . Waste settlement portions of the raw fluid processed by Corrugated Plate Interceptor (CPI) compartmental vessel  3  and induced gas flotation subassembly (IGF)  7  are extracted through first (CPI) drain  40  and second (IGF) drain  41 , both of which can be utilized to empty the apparatus of all fluids. Sampling of the raw unprocessed fluid and the processed fluid may be performed at sample connection for inlet  110  and sample connection for outlet  111 . 
       FIG. 2  illustrates a schematic side elevation view of corrugated plate interceptor (CPI) compartmental vessel  3 , schematically illustrating the immiscible fluid primary flow path  2  of the raw, contaminated fluid to be processed. Entering by means of the immiscible fluids inlet flange  11 , a portion of the raw fluid quickly floats to the surface of the inflow as surface oil  43 , the remaining fluid flows to a corrugated plate interceptor pack  15 . Removable distribution baffle  12  reduces possible surge pressures from the incoming immiscible fluid. Surface oil  43  and additional oil extracted by corrugated plate interceptor pack  15  both pass into a receptacle for collected oil, oil collection reservoir  16 , poring over first adjustable skim weir  50  as surface oil water weir discharge  44 . Processed water passing through corrugated plate interceptor pack  15  accumulates in processed fluid compartment (CPI)  45 . This process water wells up and passes over first fixed water spill over weir (CPI)  17  as process water weir discharge # 1   46 , the discharge creating CPI process weir discharged water level  51 , the discharge flowing from CPI to IGF transfer chamber  18 , which in turn, flows through CPI/IGF transfer conduit  19 . Primary solids collection  113 , in conjunction with first (CPI) drain  40 , provides a means for draining fluid and debris from corrugated plate interceptor (CPI) compartmental vessel  3 . Sample collection for inlet  110  can be used to sample the input fluid. 
       FIG. 3  illustrates a schematic side elevation view of the Induced Gas Flotation (IGF) compartmental vessel  7  schematically depicting the immiscible fluid primary flow path  2  as the fluid passes through CPI/IGF transfer conduit into the conjoint induced gas flotation (IGF) compartmental vessel  7 . The finished process fluid (typically water) accumulates in recirculation cell  56 , the accumulated water having an IGF process weir discharged water level  53 . Water level  53  increases during fluid processing and subsequently flows over second fixed water spillover weir (IGF)  26  as process water weir discharge # 2   47  into collected quiescent cell  28 . Collected quiescent cell  28  is discharged via clean water outlet flange  29 . Sampling of collected quiescent cell  28  is available by means of sample collection for outlet  111 . Secondary solids collection  115 , in conjunction with the second (IGF) as drain  41 , can be utilized to draw off undesirable constituents of the processed fluid and may also be used to empty all fluids from the induced gas flotation (IGF) compartmental vessel  7 . Oil collected in corrugated plate interceptor (CPI), compartmental vessel  3  passes into oil collection reservoir (IGF)  27  via CPI/IGF collected oil reservoir conduit  49 . A common air pressure is maintained between corrugated plate interceptor (CPI) compartmental vessel  3  and induced gas flotation (IGF) compartmental vessel  7  by means of air equalization ports  30 . Each of the induced gas flotation (IGF) processing compartments features an IGF cell separation baffle channel  58  to expeditiously maintain fluid circulated within the induced gas flotation (IGF) compartmental vessel  7 . 
       FIG. 4  illustrates a schematic plan view of the corrugated plate interceptor (CPI) compartmental vessel  3  in more detail, showing the immiscible fluid inlet flange  11 , sample connection for inlet  110 , removable distribution baffle  12 , inlet compartment  13 , primary separation baffle plate  14 , corrugated plate interceptor pack  15 , oil collection reservoir (CPI)  16 , processed fluid compartment (CPI)  45 , first fixed water spillover weir  17 , CPI to IGF transfer chamber  18 , and common to both corrugated plate interceptor (CPI) compartmental vessel  3  and induced gas flotation (IGF) compartmental vessel  7 , the CPI/IGF process separation partition  31 . Also schematically illustrated is first (CPI) drain  40 . 
       FIG. 5  illustrates a schematic side elevation view of the corrugated plate interceptor (CPI) compartmental vessel  3 , illustrating some of its more important components. Raw immiscible fluid (generally oil and water) enters subassembly  3  at immiscible fluids inlet flange  11 , flowing against removable distribution baffle  12  and accumulates in the inlet compartment  13  and can be removed via primary solids collection  113  in conjunction with first (CPI) drain  40 . The inflowing raw immiscible fluids fills inlet compartment  13  until it overflows primary separation plate  14  to be processed by corrugated plate interceptor pack  15 . Oil floating to the surface as a result of processing by interceptor pack  15  escapes over adjustable oil spillover weir  116  ( 50 ), falling into oil collection reservoir (CPI)  16 . Collection reservoir  16  is in communication with CPI/IGF collected oil reservoir conduit  49 . Water processed by interceptor pack  15  flows through processed fluid compartment (CPI)  45  and subsequently wells up and overflows first fixed water spillover weir (CPI)  17 , the processed water spilling into the CPI to IGF transfer chamber  18 , that water in turn, flowing through CPI/IGF transfer conduit  19 . Sampling of the immiscible fluid can be obtained at sample connection for inlet  110 . 
       FIG. 6  illustrates a basic schematic plan view of the induced gas flotation (IGF) compartmental vessel  7 . Partially processed fluid from corrugated plate interceptor (CPI) compartmental vessel  3  (shown in  FIG. 5 ), via CPI/IGF transfer conduit  19 , enters the IGF processing cell # 1   20 . The fluid then flows, in turn, through IGF processing cell # 2   21 , IGF processing cell # 3   22 , IGF processing cell # 4   23  by means of the IGF cell separation baffle channel  58 . The fluid then enters the recirculation cell  56  wells up and overflows the quiescent cell partition  26  and collects in the quiescent cell  28 . The remaining cleaned fluid is then DISCHARGED through clean water outlet flange  29 . Sampling of the clarified process fluid (typically water) is available at sample connection for outlet  111 . A portion of the fluid collected in the recirculation cell  56  is pumped by the recirculation pump  36  (See  FIG. 7 ) through or into the recirculation header  38  (See  FIG. 7 ) and equally distributed to the four (4) eductor discharge pipes  32  (See  FIG. 7 ). The distributed clean water flows under pressure into each eductor for mixing with the blanket gas or other inert gas to create the fine bubble for oil particle removal. Each eductor has an adjustable valve  33  (See  FIG. 7 ) to regulate the mixture of gas and liquid to create the bubbles. Bubbles eject through the bottom of each eductor  39  (See  FIG. 8 ) and rise to the surface attaching to suspended or free oil droplets thus bringing them to a collection point for removal. The separated oil forms a skim that flows over individual adjustable oil spillover weirs  34  and into oil collection reservoir (IGF)  27 . This collected oil, along with the oil collected from oil collection reservoir (CPI)  16  by means of oil transfer piping  49 , can be sent for further processing. 
     The four (4) IGF processing cells are located adjacent to CPI/IGF process separation partition  31  and are separated from each other by an IGF separation baffle  24 . IGF processing cell # 4   23  is separated from recirculation cell  56  by IGF separation end plate  25 . Waste material accumulating at the bottom of induced gas flotation compartmental vessel  7  can be withdrawn by means of IGF drain  41 . 
       FIG. 7  presents a more detailed schematic side elevation view of Induced gas flotation (IGF) compartmental vessel  7 , illustrating the incorporation of a dual eductor  32  in each of the four (4) IGF processing cells. The four (4) IGF processing cells are partitioned from each other by IGF separation plate  24  and IGF separation plate  25 . Each of the four (4) dual eductors features an air mixing valve  33 . Pump suction piping  35  connects recirculation cell  56  to the input for the recirculation pump  36 . The output of recirculation pump  36  is connected to pumps discharge manifold  38  by means of pump discharge piping  37 . Air pressure within induced gas compartmental vessel  7  is equalized by means of multiple air equalization ports  30 . Each of the four (4) IGF processing cells is in communication with oil collection reservoir (IGF)  27 . Oil collected in both oil collection reservoir (IGF)  27  and oil collection reservoir (CPI  16 , (shown in  FIG. 5 ) is drawn off by means of a common drain via CPI/IGF collected oil reservoir conduit  49 . Immiscible fluid primary flow path  2  is schematically depicted by the large arrows, the immiscible fluid flowing through CPI/IGF transfer conduit  19 . Conduit  19  pierces CPI/IGF process separation partition  31  to provide fluid communication between corrugated plate interceptor (CPI) compartmental vessel  3  and induced gas flotation (IGF) compartmental vessel  7 . As schematically illustrated by immiscible primary fluids flow path  2 , the processed fluid enters recirculation cell  56  welling up and overflowing quiescent cell partition  26 . Upon overflowing quiescent cell partition  26 , processed water (typically water) accumulates in quiescent cell  28 , where it can be withdrawn through clean water outlet flange  29 . Debris and waste products resulting from processing by the induced gas flotation (IGF) compartmental vessel  7  can be removed by means of second (IGF) drain  41 . 
       FIG. 8  schematically depicts an end elevation view of the preferred embodiment of the present invention, Enviro-Cell-Combo  10 , comprising both corrugated plate interceptor (CPI) compartmental vessel  3  and induced gas flotation (IGF) compartmental vessel  7 . Piercing CPI/IGF process separation baffle  31 , CPI/IGF transfer conduit  19  provides processed fluids communication between vessel  3  and vessel  7 , conduit  19  linking the CPI/IGF transfer chamber  18 , in similar manner, piercing, CPI/IGF process separation partition  31 , CPI/IGF collected oil reservoir conduit  49  provided oil collection communication between vessel  3  and vessel  7 , conduit  49  linking to oil collection reservoir (IGF)  27 . A portion of the fluid that is to be additionally processed is pumped into the pump discharge manifold  38 , hence to a dual eductor  32 , one (1) each in each of the four (4) IGF processing cells. Each dual eductor  32  features an air mixing valve  33 , controlling a source of gas injection port  57 . The fluid to be additionally processed is combined with a controlled gas injection, the combination ejected from eductor nozzle  39  of each of the four (4) partitioned IGF processing cells. The eductor nozzle  39 , of each of the four (4) dual eductors  32  is positioned to create IGF processing cell counterclockwise fluid circulation  54  in the vertical plane of the fluid processed and accumulated in each of the four (4) partitioned IGF processing cells. This clockwise rotation as shown in  FIG. 8  migrates the collected oil skim to the pair of individually adjustable oil spillover weirs (IGF  34  adjustable oil weir. The level of the process and accumulated fluid, IGF processing cell fluid level  42  increases during processing until the released surface oil overflows a pair of individually adjustable oil spillover weirs (IGF)  34  in each of the four (4) IGF processing cells, the spillover oil dropping into oil collection reservoir (IGF)  27 . An access port  55  is provided for each of the four (4) IGF processing cells, allowing for inspection and routine maintenance. 
     PARTS LIST 
     The following is a list of suitable parts and materials for the various elements of the preferred embodiment of the present invention. 
     
       
         
               
               
             
               
               
             
           
               
                   
               
               
                 Part No. 
                 Description 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 2 
                 flow path 
               
               
                 3 
                 (CPI) vessel 
               
               
                 7 
                 (IGF) compartmental vessel 
               
               
                 10 
                 enviro-cell combo 
               
               
                 11 
                 method 
               
               
                 11 
                 fluid inlet flange 
               
               
                 12 
                 baffle 
               
               
                 13 
                 inlet compartment 
               
               
                 14 
                 baffle plate 
               
               
                 15 
                 interceptor pack 
               
               
                 16 
                 oil collection reservoir (CPI) 
               
               
                 17 
                 water spillable weir 
               
               
                 18 
                 IGF transfer chamber 
               
               
                 19 
                 CPI/IGF transfer conduit 
               
               
                 20 
                 IGF processing cell #1 
               
               
                 21 
                 IGF processing cell #2 
               
               
                 22 
                 IGF processing cell #3 
               
               
                 23 
                 IGF processing cell #4 
               
               
                 25 
                 plate 
               
               
                 26 
                 spillover weir IFG 
               
               
                 27 
                 oil reservoir (IGF) 
               
               
                 28 
                 quiescent cell 
               
               
                 29 
                 water outlet flange 
               
               
                 30 
                 air equalization ports 
               
               
                 31 
                 separation partition 
               
               
                 32 
                 discharge pipes 
               
               
                 33 
                 adjustable valve 
               
               
                 34 
                 spillable weirs 
               
               
                 35 
                 pump suction piping 
               
               
                 36 
                 recirculation pump 
               
               
                 37 
                 discharge piping 
               
               
                 38 
                 circulation header 
               
               
                 39 
                 eductor 
               
               
                 40 
                 (CPI) drain 
               
               
                 41 
                 (IGF) drain 
               
               
                 43 
                 subsurface oil 
               
               
                 44 
                 oil water weir discharge 
               
               
                 45 
                 processed fluid compartment (CPI) 
               
               
                 46 
                 water weir discharge #1 
               
               
                 49 
                 oil reservoir conduit 
               
               
                 50 
                 skim weir 
               
               
                 51 
                 discharge water level 
               
               
                 53 
                 water level 
               
               
                 56 
                 recirculation cell 
               
               
                 57 
                 gas injection port 
               
               
                 58 
                 baffle channel 
               
               
                 110 
                 inlet 
               
               
                 111 
                 outlet 
               
               
                 113 
                 primary solids collection 
               
               
                 115 
                 secondary solids collection 
               
               
                 146 
                 water weir discharge 
               
               
                 247 
                 discharge 
               
               
                   
               
             
          
         
       
     
     All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise. 
     The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.