Abstract:
A method and apparatus for the removal of both suspended and dissolved contaminants in a fluid stream, including but not limited to heavy metals, organics, inorganics, hydrocarbons and others. The method combines passing an aqueous fluid stream through an electromagnetic field, an ozone/oxygen venturi injector for oxidation and through a horizontal flow and vertical fall within a horizontal plate maze unit of alternately electrically charged plates. The plates are charged alternately to be cathodes and anodes, respectively. A framework to mount and support membranes, dividers or separators, as may be required to enhance special treatment of the fluid stream, is optionally provided.

Description:
REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of copending U.S. patent application Ser. No. 14/203,200, filed Mar. 10, 2014 by the inventor, which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/780,157, filed Mar. 13, 2013 by the same inventor, both of which are incorporated herein by reference in their respective entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     Technical Field 
     The present invention relates to the field of cleaning aqueous fluid streams, and more specifically, provides a processing unit for aqueous fluid streams which improves the flocculation and separation of contaminants by increasing the amount and size of the floc, which provides for much improved separation and removal of contaminants from the aqueous fluid stream. 
     Background 
     Electro-(coagulation precipitation or flocculation) entered into commercial application with Cottrell&#39;s smoke stack dust precipitator in the late 1800&#39;s. One of the best representations of the art as applied to fluids is the Liggett patent, U.S. Pat. No. 4,293,400. All others are some variation of the basic concept. Some of the best documentation of the results of Electroflocculation was presented in U.S. Pat. No. 4,872,959 titled “Electrolytic Treatment of Liquids” as presented by Robert J. Herbst and Russell R. Renk with their patent of the “tube within a tube” configuration. However, the time consuming maintenance required by this configuration, cost of special parts fabrication, difficulty locating close tolerance tubing and maintaining proper clearance between the inner and outer tubes necessitated that a better solution be found. In U.S. Pat. Nos. 4,293,400, 4,378,276 and 4,872,959 there are described devices for applying an electric field to a liquid flowing through the devices. These devices employ the tube within a tube configuration. In U.S. Pat. No. 5,043,050, which is by Robert J. Herbst, all of the many, noted problems of cost, material acquisition and difficulties of maintenance of the tube within a tube device are quite well covered. 
     There have been many methods put forward for the removal of contaminants from aqueous fluid streams. There exist many forms and shapes of electrocoagulators. Most electrocoagulation (Electroflocculation) units are quite difficult to maintain and clean out. This must be accomplished on a regular basis if the units are to perform correctly. As a solution to this, some have advocated using chemicals while others have added a fluidized bed of conductive particles to aid in eliminating this problem. This usually just introduces a new problem. 
     U.S. Pat. Nos. 4,053,378, 4,094,755 and 4,329,111 describe using flat plates and fluidized beds. The flat plate device patents discuss the need for caution due to maintenance problems encountered caused by buildup of solids from the fluid stream on the carbon granules used in the fluidized bed. All of these devices are single technology treatment units. 
     SUMMARY OF THE INVENTION 
     The present invention is a processing unit for the electrolytic treatment of aqueous fluid streams employing the effects of at least three technologies, electrornagnetics, oxidation and electrolytics taking place in the proper order in a single processing unit fabricated of materials which are chemically inert. The inventive processing unit treats aqueous solutions in the correct order specific to the contaminant to be removed, and if required for specific contaminants, additional filter utilizing nanotechnology can be attached to the processing unit to further filter the aqueous stream as it exits the unit. 
     The present invention not only helps to solve the flow problems present in the prior art but also greatly increases the overall contaminant removal rate. The electromagnetic ionic realignment improves flocculation and reduces scaling depositions on the charged treatment plates. The microscopically bubbled ozone aids in the turbulence and the rapid formation of hydroxyl radicals as a result of oxidation, which accelerates flocculation and chemical reduction of the contaminants. The physical design of the inventive processing unit is such that visual inspection, maintenance and occasional plate replacement is quite easy and rapid. 
     The present invention has been designed with the following principal advantages: improvement of processing, reduction of fouling, facilitation of visual inspection, and simplification of maintenance by the utilization of the synergistic effects of the technologies of electrornagnetics, oxidation and electrolysis, while allowing more flexibility in processing different types of aqueous fluid streams by employing multiple types of interchangeable treatment plates depending on the type of aqueous fluid stream being processed. The physical design of the flow through horizontal maze processing unit is such that maintenance and occasional plate replacement is quite easy and rapid. The maze is designed to take full advantage of physical laws and physicochemical reactions by utilizing a series of horizontal maze flow channels constructed with a vertical descent to each succeeding flow channel to fully utilize the effect of the fluid flow against the natural rise of the extremely fine venturi injected Ozone/Oxygen bubbles as required for a particular contaminant. 
     By utilizing a strong electromagnetic field along with saturating the fluid stream with microscopic ozone/oxygen bubbles, combined with automatic and systematic polarity reversal of the treatment plates, it has been possible to dramatically reduce the major buildup problems. In addition, the ozone bubbles are in constant agitation of the fluid stream exposing more of the fluids to the treatment plates. The ozone also enhances the formation of the hydroxyl radicals and hydroperoxides, which accelerate and aid in the formation of floc and oxidation of almost all contaminants. All of this is accomplished by the synergistic interactions and reaction of the three technologies being applied simultaneously within the processing unit. 
     It is important to supply an adequate power source to meet the demands of the fluid stream. What will control the required current and voltage supplied to these plates is as follows: Voltage will have to be set at a sufficient level to drive the required current through the fluid stream. This is a function of the distance between the treatment plates. The current demand is the amount of current required to properly remove all contaminants from the fluid stream. This is a function of the conductivity of the contaminated stream itself, which is in turn the function of conductivity of the combination of types of contaminants (suspended and dissolved solids in the fluid stream) and the quantity of the contaminants (concentrations). This will indicate the electron charge requirements to either change state or cause flocculation and sedimentation of the dissolved and suspended solids, which make up the contaminants of a particular fluid stream. In most cases the fluid stream will, due to its conductivity, draw the current required for proper processing. 
     The removal of contaminants is quite often directly affected or controlled by the pH of the stream. Before the contaminated stream is sent to the processing unit the pH, if need be, can be adjusted as required for the best removal by any of the commonly known methods of pH adjustment. 
     Actual physical dimensions of the processing unit will be dependent on the desired treatment flow as well as the number of treatment plates used in the unit. The plate thickness, width and length as well as space between plates, may be varied to meet specific removal requirements. The processing unit is designed with horizontal flow maze channels with a vertical descent between each succeeding maze flow channel, thus taking full physical advantage of the downward fluid flow against the natural rise of the venturi-injected minute ozone bubbles to attain maximum ozone contact time within the unit. When used for a specific and constant fluid stream, the unit can be specifically designed to be more efficient at removal of very specifically targeted contaminants. 
     The processing unit itself is constructed of non-conductive material that is resistant to acids, caustics, organic and inorganic chemicals and contaminants, solvents, chlorinated hydrocarbons and oxidation by ozone. The sidewalls are grooved, while the ends of the treatment plates engage the grooves and a highly conductive metal contact to hold the treatment plates in place. Every other channel and plate will nest in one end and stop short of other end, while the alternate plate and channel will nest in the other end and stop short of the other end to create the horizontal maze flow in the unit. 
     The aqueous fluid stream is introduced into the top of the processing unit through an inlet conduit which communicates with the interior of the processing unit and allows flow through of the aqueous fluid stream to a horizontal maze of treatment plates. A number of flow channels exist in the horizontal maze and flow proceeds from channel to channel falling vertically to the outflow point on bottom where an output conduit has been attached to receive the outflow. Attached to the output conduit is a U-shaped pipe which extends from tank side and rises to the top of the treatment area top level, and in an inverted configuration, descends to connect just beyond where the bottom drain cut-off valve is attached. This allows the free flow output after the treatment unit is full and as fluid continues to enter the unit. When input fluid flow stops the drain cut-off valve opens to allow the treatment unit to drain completely through the treatment outflow point. On the end of the entry pipe, a venturi injector is mounted to the unit entry to inject ozone/oxygen directly into the fluid flow as it enters into the process unit. Connected directly to the venturi injector, so as to accomplish ionic alignment before blending the ozone, is an electromagnet sized to system flow. An electromagnet is utilized as it has proven to be more effective at ionic alignment than a permanent type magnet. Liquid flow pressure is monitored by pressure gauges. 
     The treatment plate maze arrangement is as follows: An aqueous fluid stream enters the processing unit at its top. The maze is so arranged that the flow is lengthwise of the unit. Flowing from one end to the other end around the end of each treatment plate and downward into the next horizontal maze flow channel. This continues in a downward manner until the last flow channel is reached. The fluid stream then exits out of an output pipe. The various flow channels are bordered by plates of opposite polarity, one plate being an anode and the other a cathode. In the center of each flow channel, frames containing membranes can be installed as may be required for treatment of specific fluid streams. These may be “doped” (chemically impregnated or other type of treatment but not limited to nanofiltration, nanoparticles or enhanced nanomagnetic particles) screens or other forms. 
     The method of plate installation allows the use of many types of anode and cathode plates. It is possible to use multiple treatment plate configurations to meet the removal parameters of the contaminants being treated. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exterior side view of the inventive processing unit comprising the invention. 
         FIG. 2  is a perspective view of the inventive processing unit comprising the invention shown with its access lid removed so as to provide a full view of the maze unit. 
         FIG. 3  is a plan view of the inventive processing unit shown with the access lid removed and looking downward at the various plates comprising the maze unit. 
         FIG. 4  is a perspective view of an electrical contact which is part of the invention. 
         FIG. 5  is an exterior side view of the inventive processing unit. 
         FIG. 6  is a plan view of an anode plate, a cathode plate and a membrane attached between the anode and cathode plates which are attached to various wiring and ammeter shunts as used in the best presently known embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is a flow through processing unit apparatus which incorporates the following technologies: electromagnetics, oxidation and electrolytics arranged in such a manner to take full advantage of the synergistic physicochemical actions and reactions when these technologies are applied simultaneously in a confined environment in a specially designed processing unit. 
     Referring generally, to  FIG. 1 , a processing unit  10  includes a rectangular housing  12  made of non-conductive material resistant to acids, caustics, organic and inorganic chemicals and contaminants, solvents, chlorinated hydrocarbons  20  and ozone oxidation. The housing  12  is preferably capable of handling pressures of at least 60 psi. The exact ideal dimensions of the housing is dependent upon the use to which it is applied and can be ascertained with minimal experimentation and experience. The housing dimensions can be modified for a specific non-variable contaminant and flow rate at a permanent site without being at variance to this patent. Other internal dimensions and exact number of plates for a particular application may vary. As shown in  FIGS. 2 and 3  the housing  12  has sidewalls  14 ,  16  which are grooved on their inner face where half of the grooves  24  contain treatment plates  68  which run from the inner face of a first sidewall  14  to within about a half-inch of and opposite second sidewall  16 . The other half of the grooves  25  will contain plates  69  which run from the inner face  22  of the second sidewall  16  to within about a half inch of the first sidewall  14 . These grooves  24 ,  25  are staggered so that when treatment plates  68 ,  69  are inserted into the grooves  24 ,  25  a horizontal maze unit  28  is formed. 
     As depicted in  FIG. 2  and  FIG. 3  the housing  12  with associated plates  68 ,  69  is shown with its access lid (not shown) removed so that the plates  68 ,  69  can be seen in their horizontal orientation to form a horizontal maze unit  28 . The horizontal maze unit  28  shown in  FIG. 2  also shows aqueous fluid stream (fluid stream flow indicated by arrows) entering at the inlet  29  at the top side  31  of the housing  12 , cycling across the various plates  68 ,  69  via gravity feed until the fluid reaches the outlet  30  located at the bottom side  27  of the housing  12 . 
     Inlet  29  communicates with an input conduit  32 , as shown in  FIG. 1 . Along the input conduit  32 , processing apparatus can be included to act upon the aqueous fluid stream prior to its entry into the maze unit  28 . One such apparatus is an electromagnet  34 , as shown in  FIG. 1 . Another is a venturi injector  36  as shown in  FIG. 1  through which oxidizing agents can be added to act upon the fluid stream. One such oxidizing agent would be ozone  33  which would be introduced at the venturi injector  36 . Just after the venturi injector  36  is the inlet  29  to the processing unit  10 , through which the fluid stream is introduced to the horizontal maze unit  28  of treatment plates  68 ,  69  as shown in  FIG. 2 . 
     Still referring to the  FIG. 1  and  FIG. 2 , the processing unit has an outlet  30  with a drain valve  40  on the bottom. An output conduit  46  extends from outlet  30 , which in turn connects to an inverted pipe configuration  44 . The inverted pipe configuration  44  keeps water filled to the top of the water level in the housing  12  to prevent the processing unit  10  from shorting out. Drain valve  40  is located on output conduit  46 . At the bottom  27  there is an outflow arrangement. This will generally include a flat offset spacer block  48  to which the output conduit  46  is attached. The output conduit  46  is sized to the unit&#39;s maximum flow rate. The output conduit  46  extends to connect to a “T” junction  52  which is connected to riser  54  off of the top of the “T” junction  52  which rises to the top fluid level  56  of a full treatment unit. Pipe configuration  44  also allows an extension  58  for the installation of other equipment if necessary for further reduction of contaminants beyond acceptable levels. For example, as shown in  FIG. 1 , the free flow output can then connect to a filtration system  62  including but not limited to nanoparticles, enhanced nanomagnetic particles, biologically activated granulated charcoal, or the like. Flow will be outward from the outlet  30  from the last horizontal flow channel  78  of the unit as shown in  FIG. 2 . 
     Referring to  FIG. 2  and  FIG. 3 , the staggered arrangement of the treatment plates  68 ,  69 , which comprise the horizontal maze unit  28 , is shown. Between each pair of treatment plates  68 ,  69  is a channel  64  through which flows the fluid stream (arrows). Each channel  64  is bordered by two treatment plates  68 ,  69 , one plate being an anode  68  and the other a cathode  69 . The sidewalls  14 ,  16  of the housing  12 , as shown in  FIG. 1 , have a slot (not shown) for highly conductive metal contacts  71 , as shown in  FIG. 4 . These also help to hold the anode and cathode treatment plates  68 ,  69  in place. A plate  68  nests in a first sidewall groove  24  at the plate&#39;s first end  74  and stops short of an opposing second sidewall  16  at the second end  76  of the plate  68 , while the first end  74  of an alternate plate  69  nests in a groove  25  in the opposing second sidewall  16  and where the second end  76  of the alternate plate  69  stops short of the first sidewall  14 . This alternating plate arrangement combines in a plurality of alternating plates  68 ,  69  to create the horizontal maze unit  28 . The fluid stream travels through the flow channels  64  and flows in a vertical manner through each flow channel from inlet  29  to outlet  30 . The plates are preferably at least one half (½) inch shorter than the distance between sidewalls  14 ,  16  plus an allowance for insertion of contacts  71 . The material of the plates will and can be selected from among those materials known (or to be determined in the future) to attract any particular contaminants that are to be removed, and they can be mixed or matched as needed. The material of the plates is not a necessary aspect of the invention, and any generally highly conductive material will suffice. The exact dimensions of the plates and the number of plates will be dependent on the flow rate and the process time required. The aqueous fluid stream, upon reaching the final channel  78 , will leave the unit by the outlet  30  and the output conduit  46  as shown in  FIG. 1 . The number of treatment plates, and therefore the number of flow channels in the maze unit, can be modified depending on the type of aqueous fluid stream being treated. For example, a particular contaminant may require the fluid stream to remain in the maze for a certain time “x” before it is adequately treated. This time “x” is called the residence time. The number of plates and flow channels can be increased or decreased to achieve the appropriate residence time for a particular fluid stream. 
     Referring to  FIG. 3 , the grooves  24 ,  25  imparted into the interior sidewalls  14 , 16  of the housing  12  for mounting the treatment plates  68 ,  69  are shown. Grooves  24  are cut into the 2inner face  21  of a first sidewall  14  and grooves  25  are cut into the inner face  22  of a second sidewall  16 . A first subset of anode plates  68  are inserted into the first sidewall grooves  24  and a second subset of cathode plates  69  are inserted into the second sidewall grooves  25 . When the entire plurality of treatment plates  68 ,  69  are inserted into their respective first and second sidewall grooves, the plates  68 ,  69  comprise the maze unit  28  as shown in  FIG. 2  and are positioned in a staggered relation. Both sidewalls  14 ,  16  are provided with two holes (not shown) at each groove  24 ,  25  for the mounting and securing of the contacts  71  as shown in  FIG. 4 , which are then connected to a power source  92  as shown in  FIG. 6  to cause a plate to be, respectively, an anode plate  68  or a cathode plate  69 . 
     Referring to  FIG. 4 , the contacts  71  are shown. Each contact  71  has a slot  108  into which is inserted a treatment plate  68  or  69 . Contacts  71  are inserted into slots (not shown) located in sidewalls  14 ,  16 . Stud bolts  110  protrude outward from contacts  71  and extend through sidewalls  14 ,  16 . As depicted in  FIG. 5 , stud bolts  110  are protruding through sidewall  14 . The ends  74  of cathode plates  68  reside in grooves  24  and in slot  108  of contact  71 . Cables  72  as shown in  FIG. 5  are attached to stud bolts  110  and to power source  92  (See  FIG. 6 ). 
     As shown in  FIG. 5  and  FIG. 6  the protruding portion of the stud bolts  110  on the outside of the side walls  14 ,  16  will be the power connection points. At the positive sidewall  14  ammeter shunts  112  will connect to the stud bolts  110  and then the other end of the ammeter shunt  112  will connect to a power bus  106 . At the negative sidewall  16  the stud bolt  110  will connect directly to the other power bus  106 . The end of an anode plate  69  has all connections for one polarity while the other end has the cathode plate  68  connections. The shunts  112  are then connected to display ammeters  114  on the control panel  117  adjacent to the power unit&#39;s voltage control  115  and current limit  116  control. As there are two stud bolts  110 , one for each side, and due to close proximity of the plates, the shunts are connected alternately to one stud or the other to avoid close proximity problems with the shunt mounting. These shunts provide the ability to monitor the amperage drawn by each set of plates to determine efficiency of the process and will also indicate the status and condition of each set of plates. 
     The sidewall grooves  24 ,  25 , as shown in  FIG. 3 , are cut to a sufficient depth to hold the cathode and anode plates in place with approximately ⅜ inch spacing between plates. The sidewalls  14 ,  16  are of non-conductive material. Also, while  FIG. 2  and  FIG. 3  show a side removed so that access to the plates  68 ,  69  can be gained, the housing  12  is entirely closed during operation and an access lid (not shown) is placed over the plates  68 ,  69  and held in a fluid tight manner with a gasket and bolts. As shown in  FIG. 2  and  FIG. 3 , the plates  68 ,  69  are removable when the cover is removed, thus allowing them to be serviced and inspected as necessary. 
     As shown in  FIG. 6 , the processing unit  10  preferably allows for the insertion of membranes  94  between the anode and cathode plates  68 ,  69  of each flow channel  64  in the horizontal maze unit  28 . The membranes can be comprised of different materials as may be required for treatment of specific fluid streams and potential contaminants. These may be “doped” membranes  94  (chemically impregnated or other types including but not limited to nanofilters and or nanoparticle or nanomagnetic impregnated filters). 
     There are pressure sensor gauges  102  as shown in  FIG. 1  on the unit. One will be on the input conduit  32  and the other on output conduit  46 . These will give an indication of the pressure drop across the maze unit  28  and thus will be indicative of the unit flow status.