Abstract:
A lamella panel module is formed from extruded PVC side rails and a plastic plate member secured to the opposing side panels. Each side rail is formed with receiver mounts defining recesses for the mounting of the lamella plates. The plates are preferably affixed to the receiver mounts by adhesives to establish a structurally stable panel module. Each side rail has fore-and-aft opposing mating flanges that prevent horizontal movement of the modules, but allow generally vertical movement to enable any module to be removed from the assembly and replaced. The frame of the lamella separator assembly is formed with a support ledge on the opposing lateral sides of the frame to support a walking grid therebetween. The supported walking grid does not interfere with the flow of clarified water into the collection troughs supported on a vertical member projecting above the support ledge and allows cleaning of the plates.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally relates to an apparatus for settling particulates from water through a lamella separator and, more particularly, to the manufacture of improved lamella separator panels. 
       BACKGROUND OF THE INVENTION 
       [0002]    Sedimentation basins and clarifiers have been used for many years to separate solids suspended in water and wastewater. Lamella plate settlers are a common method for reducing solids concentration in flow through systems. Applications are for settling in the water and wastewater industries to increase the capacity of existing clarifiers, reduced footprint of new construction clarifiers, membrane backwash basins, and/or to reduce the solids load on tertiary equipment such as sand filters. 
         [0003]    Lamella separators have been utilized to separate particulate solids from a carrying liquid, such as water or wastewater, by directing the liquid between series of inclined plates. The separated particles settle on the inclined lamella plates and slide down into a hopper area below the lamella plates where the particulates can be removed. The effective settling area of each lamella plate is equivalent to the horizontal projection of that lamella plate; therefore, lamella plates are typically spaced a few inches apart with the result that large settling surfaces are concentrated within a relatively small area. Lamella separators promote laminar and stable flow conditions throughout the apparatus and have been very successful in achieving a high degree of separation of the particulate material, particularly the counter-current flow configuration, which provides an effective and inexpensive apparatus. 
         [0004]    The design of lamella separators incorporates a number of design variables which cooperate with one another in determining the efficiency of the apparatus. In designing a lamella separator, it is desirable to maximize effective use of the projected lamella area while preventing sludge that has already settled from being re-entrained in the flow of the water passing upwardly through the lamella separator plates. Further, in order to maximize utilization of the lamella settling surfaces and achieve the greatest possible efficiency, it is important that each lamella flow passage be given a substantially equal hydraulic load. Another important consideration in the design of a lamella separator is the ability to maintain the apparatus. Lamella separator panels must be properly maintained, including cleaning and/or replacement of the lamella plates. Preferably, such maintenance and/or replacement can be accomplished without materially interfering with the operation of separator. 
         [0005]    U.S. Pat. No. 4,889,624, issued to Alfonse Soriente on Dec. 26, 1989, discloses a panel for a lamella separator, which is formed from polypropylene structural foam and supported between side plates. Integral lugs are formed into the individual panels so that proper spacing can be maintained between adjacent panels. These structural foam plates are removable from the separator assembly by simply extracting the plate vertically, which would permit the individual plate to be replaced or re-inserted into the separator stack after maintenance has been performed on the plate. Pivotal movement of lamella separator plates is disclosed in U.S. Pat. No. 7,201,849, granted to Alain Boulant on Apr. 10, 2007, by affixing the individual plates on tubular members that are pivotally movable to position the plates between an inclined operative position and a vertical cleaning position. 
         [0006]    Extruded side panels for a lamella separator are taught in U.S. Pat. No. 4,681,683, granted on Jul. 21, 1987, to Anders Lindstol. Each pair of opposing side panels carries a single lamella panel between them. The side panels are formed with an interlocking configuration with each side panel being engagable with the side panel both fore and aft, to be able to form a stack of panel members that form the lamella separator. The entire panel stack is removable from the lamella separator by removing the retaining clips keeping the stack of lamella plates in the desired place on the frame assembly. 
         [0007]    It would be desirable to provide a lamella separator panel construction that will be lightweight and be easily moved from the lamella separator for maintenance and/or replacement. It would also be desirable to provide a frame for a lamella separator that will facilitate the cleaning of the lamella plates. 
       SUMMARY OF THE INVENTION 
       [0008]    It is an object of this invention to overcome the disadvantages of the prior art by providing a lamella panel module constructed of polymeric material, such as polyvinylchloride (PVC). 
         [0009]    It is an object of this invention to provide a lamella separator formed from modules containing multiple plates affixed between a pair of extruded plastic side rails. 
         [0010]    It is a feature of this invention that the extruded plastic side rails are formed with interengagable connecting flanges that allow adjacent panel modules to be latched together for form a freestanding lamella plate assembly. 
         [0011]    It is an advantage of this invention that the interengaged connecting flanges prevent individual lamella panel modules from separating in a horizontal direction. 
         [0012]    It is another advantage of this invention that the interengaged connecting flanges allow a generally vertical movement of individual lamella panel modules relative to adjacent lamella panel modules. 
         [0013]    It is a feature of this invention that the side rails of the lamella panel modules are formed from extruded polymeric material, such as polyvinylchloride (PVC) or other suitable plastic material. 
         [0014]    It is another feature of this invention that the side rails are formed with integral plate receiver mounts, each receiver mount having a recess sized to receive a lamella plate. 
         [0015]    It is still another advantage of this invention that each side rail is formed with multiple receiver mounts which can be selectively used to mount lamella plates. 
         [0016]    It is still another feature of this invention that the lamella panel module will support multiple lamella plates. 
         [0017]    It is yet another advantage of this invention that the lamella panel modules are sufficiently lightweight to be easily removed from the lamella separator assembly for service or replacement. 
         [0018]    It is yet another feature of this invention that the lamella plates can be secured in the receiver mounts formed in the extruded side rails by adhesives. 
         [0019]    It is still another advantage of this invention that the lamella panel module is structurally stable and, depending of the vertical length thereof, can be freestanding. 
         [0020]    It is still another feature of this invention that the frame of the lamella separator assembly is formed with a grid support to position a walking grid above the lamella panel modules. 
         [0021]    It is a further advantage of this invention that the walking grid supported on the frame of the lamella separator assembly enables an operator to stand over the lamella plates and affect cleaning thereof with a stream of water from a hose. 
         [0022]    It is a further feature of this invention that the walking grid is positioned below the level of the discharge weir for the discharge of clarified water into effluent collection troughs for removal from the lamella separator assembly. 
         [0023]    It is still a further advantage of this invention that the positioning of the walking grid does not interfere with the discharge of clarified water from the lamella separator assembly. 
         [0024]    It is yet another object of this invention to provide a lamella panel module which is durable in construction, inexpensive of manufacture, carefree of maintenance, facile in assemblage, and simple and effective in use. 
         [0025]    These and other objects, features and advantages are accomplished according to the instant invention by providing a lamella panel module that is formed from extruded PVC side rails and a plastic plate member secured to the opposing side rails. Each extruded side rail is formed with a plurality of receiver mounts defining recesses for the mounting of the plastic lamella plates. The plates are preferably affixed to the receiver mounts by adhesives to establish a structurally stable panel module. Each side rail has fore-and-aft opposing mating flanges that prevent horizontal movement of the modules, but allow generally vertical movement to enable any module to be removed from the assembly and replaced. The frame of the lamella separator assembly is formed with a support ledge on the opposing lateral sides of the frame to support a walking grid therebetween. The supported walking grid does not interfere with the flow of clarified water into the collection troughs supported on a vertical member projecting above the support ledge and allows cleaning of the plates. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]    The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein: 
           [0027]      FIG. 1  is a perspective view of the frame for the lamella separator assembly incorporating the principles of the instant invention; 
           [0028]      FIG. 2  is a side elevational view of the frame shown in  FIG. 1 ; 
           [0029]      FIG. 3  is a front elevational view of the frame depicted in  FIG. 1 ; 
           [0030]      FIG. 4  is a perspective view showing the lamella separator assembly incorporating the principles of the instant invention; 
           [0031]      FIG. 5  is a side elevational view of the lamella separator assembly shown in  FIG. 4 ; 
           [0032]      FIG. 6  is a front elevational view of the frame of the lamella separator assembly depicting the walking grid and the discharge troughs supported on the frame; 
           [0033]      FIG. 7  is a perspective view of an individual lamella panel module incorporating the principles of the instant invention; 
           [0034]      FIG. 8  is a side elevational view of the lamella panel module depicted in  FIG. 7 ; 
           [0035]      FIG. 9  is an exploded view of the lamella panel module depicted in  FIG. 7 ; 
           [0036]      FIG. 10  is an elevational view of a side rail forming part of the lamella panel module; 
           [0037]      FIG. 11  is a cross-sectional view of the side rail taken along lines  11 - 11  of  FIG. 10 ; 
           [0038]      FIG. 12  is an exploded cross-sectional view of the lamella panel module; 
           [0039]      FIG. 13  is a perspective view of a module stack depicting a configuration in which the modules can be arranged to form an array of lamella plates in a separator assembly; 
           [0040]      FIG. 14  is a cross-sectional view similar to the view of  FIG. 11 , but showing the configuration depicted in  FIG. 13 , portions of the plates being removed for purposes of clarity; 
           [0041]      FIG. 15  is an enlarged cross-sectional view of the end side rail and assembled plates corresponding to circle  5  in  FIG. 14 ; 
           [0042]      FIG. 16  is an enlarged cross-sectional view of the opposing end side rail and assembled plates corresponding to circle  6  in  FIG. 14 ; and 
           [0043]      FIG. 17  is an enlarged cross-sectional view of the center rail support and assembled plates corresponding to circle  7  in  FIG. 14 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0044]    Referring first to  FIGS. 1-6 , a frame for a lamella separator incorporating the principles of the instant invention can best be seen. The lamella separator  10  is a known apparatus that directs the flow of wastewater upwardly between inclined lamella plates  25  while the suspended particulate matter within the wastewater precipitates out of the flow of the wastewater and collects on the inclined plates  25  to slide by gravity down the plates  25  to be collected at the bottom of the assembly  10 . The frame  12  of the lamella separator assembly  10  is formed with lower horizontal support members  13  to permit the lamella separator  10  to sit on a horizontal support, such as transverse supports (not shown) within a clarifier tank (not shown), to position the lamella separator  10  at some level above the floor of the clarifier tank, and to provide support for the lamella plates  25  as will be described in greater detail below. The frame  12  also has inclined support members  14  on which the lamella panel modules  20  recline to support the modules  20  so that the plates  25  are disposed at the proper inclined angle. 
         [0045]    The frame  12  also includes an upper support structure  15  which is oriented generally horizontally, parallel to the lower support members  13 . The upper support structure  15  includes a formed channel support member  16  that forms a generally horizontal ledge  17  on which a walking grid  19  can be mounted. The formed channel  16  also includes a vertical support member  18  that projects upwardly from the ledge surface  17  to support an appropriate collection trough T into which the clarified water will pass, as best seen in  FIG. 6 , to be removed from the lamella separator assembly  10  and the clarifier tank (not shown). The discharge of clarified water into the collection trough T can be controlled by the trough T via a known V-notch weir arrangement. The lamella panel modules  20  as will be described in greater detail below, are oriented so that the plates  25  are angled to vertical at about thirty degrees such that the water flowing upwardly is directed to the underside of the plates  25  while the particulates settling out of the water flow fall onto the upper side of the adjacent plate  25 . The lamella panel modules  20  rest on the lower support members  13  and recline against the inclined support members  14 . 
         [0046]    The individual lamella panel modules  20  are best seen in  FIGS. 7-12 . The lamella panel module  20  uses a pair of profile-extruded side rails  30  to support flat sheet material as the plates  25  in a parallel array. In general, each side rail  30  is constructed of profile-extruded polymeric material, such as polyvinylchloride (PVC), but is not limited to this material, and the plates  25  are preferably flat PVC sheeting. The thickness of each plate  25  is preferably about ⅛″. Each side rail  30  is formed with a plurality of receiver mounts  32  on one side of the side rail  30  oriented such that the horizontal spacing between successive plates  25  is substantially constant throughout the assembly  10  from one module  20  to the next module  20   
         [0047]    Each receiver mount  32  is formed with a recess  33  that is formed to receive the plates  25  securely within the receiver mount  32 . Each plate  25  can be glued within the recess  33  to keep the plate from being disengaged from the corresponding side plate  30 . Each receiver mount  32  is integrally formed with the side rail  30  and project inwardly toward the opposing side rail  30  approximately 1″ in height so as to locate and attach the flat sheet plate  25  and to provide structural integrity for the assembled panel module  20 , providing a plurality of plates  25  attached to the side rails  30  in consistent intervals of approximately 2″ for water treatment and 3″ for wastewater treatment. The flat sheet plates  25  are attached through a solvent bond or glue to the receiver mounts  32  to prevent the settled solids loading onto the plate  25  from the upwardly moving water from pulling the sheet from the receiver mounts  32 . The length of the side rails  30  is defined by the depth of the basin and angle of repose, typically between 55 and 60 degrees. The width of the flat sheet plate  25  extending between the opposing side rails  30  is defined by the basin width as the arrangement must include the system of plates  25  and troughs T for treatment and typically will have symmetry about the center of the lamella separator assembly  10 . 
         [0048]    The lamella panel module  20  is preferably formed with three plates  25  and two side rail extrusions  30 . Each side rail  30  is formed with standard holes or slots  39  positioned near or at the bottom of the side rail extrusions  30  at the interface with incoming flow of water to be directed upwardly through the separator assembly  10 . The holes or slots  39  reduce the velocity of the fluid entering the bottom of the plates  25  as to reduce re-entrainment of settled solids on the surface of the plate  25 . The modules  20  are installed into the support frame  12  and suspended above the floor of the basin into which the separator assembly  10  is installed. 
         [0049]    While the preferred number of receiver mounts  32  is three on the inside surface of each side rail  30 , the number of receiver mounts  32  could be significantly higher. Furthermore, not all of the receiver mounts  32  needs to be utilized in every lamella separator  10  configuration to support an inclined plate  25 . For example, each side rail  30  could be formed with six receiver mounts  32  spaced one inch apart so that selective ones of the receiver mounts  32  could be utilized to form a panel module  20  with plates  25  spaced at either two inches or at three inches, or even at six inches if only one of the opposing pairs of receiver mounts  32  are utilized on the opposing side rails  30 . 
         [0050]    Each side rail  30  is also formed with connector flanges  34 ,  36  extending along the vertical edges thereof. The male connector flange  34  is located at one edge while the female connector flange  36  is located on the opposing edge. A plurality of modules  20  make up a fully assembled lamella separator assembly  10 . The male connector flange  34  on one module side rail  30  being received within the female connector flange  36  of the adjacent module side rail  30 . Each female connector flange  36  is formed with a restraining protrusion  37  that extends generally perpendicularly to the recess  38 . The restraining protrusion  37  is engagable with a plateau  35  formed by a bend in the male connector flange  34  interlocking the engaged male and female connector flanges  34 ,  36  to provide stability and co-located support. This interlocking male and female connector flanges  34 ,  36  eliminates the effects of the bottom “kicking out” from underneath the individual modules. 
         [0051]    As will be understood by one of ordinary skill in the art, the male and female connector flanges  34 ,  36  can be snapped together by moving the male and female connector flanges  34 ,  36  together generally horizontally. In such a process, the male connector flanges  34  deflects the restraining protrusion  37  until the protrusion  37  passes by the plateau  35  and then snaps into place. Once connected together, the interlocking connector flanges  34 ,  36  prevent a horizontal disengagement of adjacent modules  20 , unless sufficient force is asserted to cause the restraining protrusion  37  to deflect away from and release the plateau  35  on the male connector flange  34 ; however, the linear nature of the respective connector flanges  34 ,  36  allow generally vertical movement of one module  20  relative to the engaged adjacent module  20  to permit the module  20  to slide upwardly along the adjacent module  20 . In this manner, any specific module  20  can be removed from the stack of modules  20  forming the separator assembly  10 , and subsequently replaced, thereby allowing repair or replacement of the selected module  20 . Furthermore, the interlocking male and female connector flanges  34 ,  36  also provide for ease of assembly as each module  20  is simply locked into place with the preceding module  20 . This modular concept allows for variable design with respect to tank dimensions and integration with overflow troughs T. 
         [0052]    Referring now to  FIGS. 13-17 , an alternative configuration for the array of plates  25  for a lamella separator assembly  10  can best be seen. With the side rails  30  and plates  25  formed of plastic, such as PVC, the maximum practical operative width of a plate  25  is approximately  30  inches. If the operative width for the plates  25  in a separator assembly  10  is desired to be  60  inches, a center rail support  40  can be positioned midway across the module  20  to support opposing ends of plates  25  affixed to the opposing side rails  30 . The center support rail  40  can be formed from a pair of side rails  30  placed back-to-back and preferably adhered together, as is depicted in  FIGS. 13-17 , or the center support rail  40  can be a separate unitary extrusion with receiver mounts  32  positioned on both sides thereof and male and female connector flanges located on the fore-and-aft edges. 
         [0053]      FIGS. 13-17  also depict the manner in which separate modules  20  are interconnected. Whether or not the module  20  includes a center support rail  40 , the side rails  30  are connected end-to-end with the male connector flange  34  of one module  20  being engaged with the female connector flange  36  of the other module  20 . One skilled in the art will recognize that this interconnection of modules  20  can continue until an entire separator assembly  10  is constructed with the plates  25  placed into a uniformly spaced inclined array. Since the connector flanges  34 ,  36  allow generally vertical movement with the restraining protrusion  37  sliding over the engaged plateau  35 , a centrally positioned panel module  20  can be lifted out of the assembly  10  without disturbing the positioning of the other modules  20 , thus allowing the displaced module to be repaired or simply replaced by sliding the new or repaired panel module  20  back into location engaged with the adjacent modules  20 . 
         [0054]    In operation, the infeed of water to be clarified enters at one end of the basin (note shown), travels under and around the sides of the lamella separator assembly  10 , through the holes in the side rails  30  and the bottom opening (due to the modules  20  being supported above the floor of the basin on the lower horizontal frame members  13 , up though the plates  25 , to the top of the lamella separator assembly  10  to discharge over the vertical supports  18  above the channel supports  16 , and into the effluent troughs T. 
         [0055]    The frame  12  is designed to support the integrated parts of the plate settler assembly. In this design, the formed channel support  16 , serving as the top frame rail, serves several functions. Primarily, the formed channel  16  completes the structural frame  12  to support and distribute the lamella panel modules  20  within the settling basin (not shown). The formed channel support  16  also supports the top grating  19  used to access the modules  20 . The grating  19  is able to support the weight of an operator to wash down any solids accumulated on the plates  25  during normal operation of the separator assembly  10 . The channel support  16  also provides a means to attach the effluent or overflow troughs T via fasteners engaged with the vertical support member  18 . 
         [0056]    It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention.