Brine generation system

A brine generation system includes a tank unit having a tank body and a divider which separates the tank into an upper portion for holding salt crystals and a lower portion for holding brine. The divider is adapted to resist the movement of salt crystals greater than a predetermined size and to permit the brine solution to pass from the upper portion through the divider to the lower portion by the effect of gravity. The divider includes a sump channel having an opening in communication with the upper portion of the tank unit. The sump channel is adapted to collect non-soluble particles greater than a predetermined size and permit the brine solution in the sump channel to pass therethrough to the lower portion of the tank unit. The sump channel is in communication with a sediment discharge port defined in the tank body.

TECHNICAL FIELD

This patent disclosure relates generally to systems and methods for generating brine for the treatment of roadways subject to snow and ice and, more particularly, to a system and method for rapidly generating brine.

BACKGROUND

Brine is a combination of water and salt crystals—such as rock salt—in an aqueous solution comprising approximately one part salt crystals and approximately three parts water, and is used for treating roadways subject to snow and ice. When applied to the roadway, brine can provide an anti-icing layer that prevents bonding between the roadway and ice, facilitating ice and snow removal. The use of brine can often reduce the need to use salt and sand to limit ice formation on roadways, which can lessen environmental damage. Because brine can be applied before a snow or ice storm, it can reduce labor costs by allowing road treatment during regular business hours.

Brine is currently prepared in tanks with open tops through which salt may be loaded. The salt is supported above the bottom of the tank by horizontal screens. Nozzles about the upper lip of the tank may then be used to spray water over the surface of the salt, the latter of which may percolate downward through the screens into the lower portion of the tank. The water may be collected at the bottom of the tank and recirculated one or more times through a second set of nozzles until the desired salinity is obtained. An example of this design is taught by U.S. Pat. No. 7,810,987, which issued on Oct. 12, 2010.

As noted in the above-cited patent, the salt is often contaminated with dirt and silica which can be abrasive and can cause excess wear on pumps, flow meters, and valves in the delivery chain of the brine. Accordingly, these contaminants are allowed to settle in the tank at a point below the brine outlet. Cleaning the sediment from the tank can be facilitated by sloping the tank bottom to a sump channel leading to a sediment outlet in the tank. In use, the tank is drained (possibly without removal of the salt) and spray nozzles are used to force the sediment through the channel and out the sediment outlet.

Obtaining the necessary salinity using such systems can be significantly delayed by the time it takes to recirculate the brine for multiple passes through the salt. Cleaning the sediment from the tank is time-consuming and requires that the machine be drained and thus remains off-line for a significant period of time. Substantial sediment may accumulate in a few hours of operation, thus significantly affecting the throughput of the device.

Furthermore, typically the entity charged with maintaining the roadways of a given region produces brine at a single central facility and then transports the brine to multiple local facilities distributed over the region. Brine production may be carried out at a single central facility for several reasons. For example, road maintenance organizations may prefer to expend the resources related to operating a brine production apparatus at only a single location rather than at several locations. However, the cost of transporting brine can be considerably higher than the cost of producing brine.

It will be appreciated that this background description has been created to aid the reader, and is not to be taken as an indication that any of the indicated problems were themselves appreciated in the art. While the described principles can, in some respects and embodiments, alleviate the problems inherent in other systems, it will be appreciated that the scope of the protected innovation is defined by the attached claims, and not by the ability of any disclosed feature to solve any specific problem noted herein.

SUMMARY

Embodiments of the present disclosure are directed to a high throughput brining system that immerses the freshwater nozzles in the salt near an obstructing divider to create an extreme erosion zone within the salt. This high turbulence zone can provide an accelerated entry of the salt into solution. In addition, the embodiments of a brine generating system according to principles of the present disclosure can provide sediment filtering that catches a significant portion of the sediment at a point above the bottom of the tank allowing the sediment to be automatically discharged periodically, without fully draining the tank and even during operation of the brining system. In this way, a full cleaning of the sump can be delayed, thereby increasing the up-time of the system.

In some embodiments, a brine generation system includes a tank with an upper opening configured for receiving salt crystals and a divider separating the tank into a salt crystal holding upper portion and a brine holding lower portion. The divider is adapted to resist movement of salt crystals from the upper portion to the lower portion but be permeable to allow the brine solution to fall into the lower portion from the upper portion through the divider. A fluid conduit is disposed within the upper portion. The fluid conduit includes at least one water jet adapted to inject a stream of water provided through the fluid conduit. The stream of water is configured for discharge through the water jet in a direction that is downward into the volume of the tank. An outlet is positioned in the lower portion of the tank for withdrawing the brine solution. In some embodiments, a set of water jets receives fresh water and discharges it downward into the tank at a point below an upper third of a volume of the upper salt crystal holding portion whereby the water jets may be surrounded by salt crystals.

In other embodiments, a brine generation system includes a tank having an upper opening for receiving salt crystals to fill the tank. A divider separates the tank into an upper salt crystal holding portion and a lower brine holding portion. The divider provides an intermediate channel positioned above the lower brine holding portion. The intermediate channel is adapted for accumulating non-soluble particles that may be mixed with the salt crystals by sedimentation. A set of water jets is disposed within the upper salt crystal holding portion of the tank. The set of water jets is adapted to discharge fresh water or a brine solution into the upper salt crystal holding portion to dissolve salt crystals. A mechanical sweeper is associated with the intermediate channel. The mechanical sweeper is adapted to collect and discharge non-soluble particles from the intermediate channel out of the tank through an opening extending through a wall of the tank. A lower channel is formed below the intermediate channel at a lower position in the lower brine holding portion. The lower channel is adapted for accumulating non-soluble particles found in a brine solution that percolates from the upper salt crystal holding portion when the set of water jets is active. A brine outlet extends through the wall of the tank at an outlet height. The outlet height is above the lower channel and below the intermediate channel. The brine outlet is adapted to withdraw brine solution from the lower portion of the tank.

It is a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to substantially reduce the amount of extra-tank recirculation required to obtain a given degree of salinity.

In embodiments, a divider may include a wall portion adjacent to the water jets for providing a region of circulating water drivable by a force of water from the water jets. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to increase the dwell time of turbulent water and salt beyond the limit imposed by simple percolation.

In embodiments, a divider may include a sump channel and an openable port through the tank wall for ejection of particles accumulated in the sump channel. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to capture particulates at a point above the bottom of the tank permitting their ejection without full tank draining.

In embodiments, a sump channel may include a mechanical sweeper for moving particles collected in the sump channel out of the openable port in the tank. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to permit the ejection of sediment without dilution of existing brine.

In embodiments, a mechanical sweeper may be an auger extending substantially horizontally along the sump channel. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to provide a compact apparatus for mechanically removing sediment.

In embodiments, an auger and an openable port may be electronically controllable for automatic ejection of accumulating particles. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to allow optimization of the cycle of sediment removal for minimum downtime.

In embodiments, at least a portion of a sump channel forming a lowermost portion in a divider may be a screen. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to provide a system concentrating sediment for removal.

In embodiments, a valve plate may divide an upper portion into an upper erosion chamber receiving water directly from jets and a portion of a sump channel below the upper erosion chamber, a valve plate controlling passage of material from the upper erosion chamber to the lower sump channel. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to controllably limit drainage of brine through the sump to maximize sediment retention without adversely reducing dwell time of liquid in the extreme erosion zone.

In embodiments, a brine generation system may further include a second screen above and not covering a sump channel and presenting a substantially vertical surface to resist accumulation of particles. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to provide a decanting route for brine from the extreme turbulence zone.

In embodiments, a brine generation system may include a third screen covering a sump channel above a second screen passing larger particles than a second screen. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to block extremely large damaging particles such as rocks and sticks.

In embodiments, a brine generation system may further include a secondary sump at a lowermost portion of a tank below a sump channel for accumulating particles passing through a divider. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to permit removal of non-soluble particulates that escape the intermediate trap.

In embodiments, a port openable through a tank wall may provide for the ejection of particles accumulated by a secondary sump. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to allow simple removal of the fine particulates when the tank is drained.

In embodiments, a secondary sump may be a horizontally extending channel sloping along its length and further including an ejector for driving accumulated particles within a secondary sump out of an openable port. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to promote complete cleaning of the tank with reduced water usage.

In embodiments, an ejector comprises a pressurized water nozzle. It is thus a feature of at least one embodiment of a brine generating system according to principles of the present disclosure to provide a simple method of periodic cleaning that may occur after draining.

In another aspect of the present disclosure, embodiments of a method for generating a brine solution useful for treating roadways against ice accumulation thereon are described. In one embodiment, a tank that is segmented into upper and lower portions is provided. The upper portion is adapted for containing salt crystals, and the lower portion is adapted for containing the brine solution. One or more water jets operate within the upper portion when salt crystals are present in the upper portion. The water jets provide water streams aimed towards the salt crystals such that the water jets dissolve salt crystals to form the brine solution in the upper portion. The brine solution from the upper portion is allowed to percolate through a permeable divider that has a non-permeable section and that separates the upper and lower portions such that the brine solution is collected in the lower portion. The water jets operate such that at least a portion of the water streams impinges the non-permeable portion of the divider to create a turbulent region adapted to promote salt crystal dissolution. One or more screens are provided in the divider through which the brine solution passes such that any non-soluble particles present within the salt crystals can collect on at least one screen. A sweeper device adapted to collect non-soluble particles from the at least one screen and eject the collected non-soluble particles through an openable port extending through a wall of the tank is operated.

In another aspect of the present disclosure, embodiments of a brine generation system are described. In embodiments, the brine generation system includes a tank unit, a freshwater conduit, and a salinity control system.

The tank unit includes a tank body and a divider. The tank body defines a volume therein and has an upper opening in communication with the volume for receiving salt crystals therethrough. The tank body defines a brine outlet in communication with the lower portion of the tank body. The divider is disposed in the tank body and separates the volume within the tank into an upper portion configured to hold salt crystals and a lower portion configured to hold a brine solution. The divider is adapted to resist the movement of salt crystals greater than a predetermined size from the upper portion to the lower portion and is adapted to permit the brine solution to pass from the upper portion through the divider to the lower portion by the effect of gravity.

The freshwater conduit is disposed within the upper portion of the tank body. The freshwater conduit includes at least one water jet adapted to discharge a stream of water from the freshwater conduit in a direction toward the divider and the lower portion of the tank body.

The salinity control system is in fluid communication with the brine outlet of the tank body. The salinity control system is adapted to determine a salinity of the brine solution received from the brine outlet and to return the brine solution to the upper portion of the tank body when the salinity is below a predetermined level.

The divider includes a sump channel having an opening in communication with the upper portion of the tank unit. The sump channel is adapted to collect non-soluble particles greater than a predetermined size and is in communication with a sediment discharge port defined in the tank body. The sump channel includes at least a portion that is adapted to permit the brine solution in the sump channel to pass therethrough to the lower portion of the tank unit.

In another aspect of the present disclosure, embodiments of a method for generating a brine solution for treating roadways using a brine generation system are described. The brine generation system includes a tank unit having a tank body and a permeable divider.

Salt crystals are deposited in an upper portion of the tank body. The tank body is segmented into the upper portion and a lower portion by the permeable divider. The divider is adapted to resist the movement of salt crystals greater than a predetermined size from the upper portion to the lower portion and is adapted to permit the brine solution to pass from the upper portion through the divider to the lower portion by the effect of gravity. The upper portion defines an upper volume and includes at least one water jet positioned within the lower two thirds of the upper portion of the tank body.

A stream of water is injected through the at least one water jet within the upper portion of the tank body such that the water contacts salt crystals within the upper portion of the tank body to form the brine solution in the upper portion of the tank body. The brine solution is allowed to pass from the upper portion of the tank body through the permeable divider and flow into the lower portion of the tank body.

Further and alternative aspects and features of the disclosed principles will be appreciated from the following detailed description and the accompanying drawings. As will be appreciated, the brine generating systems and methods for using the same disclosed herein are capable of being carried out and used in other and different embodiments, and capable of being modified in various respects. Accordingly, it is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and do not restrict the scope of the appended claims.

DETAILED DESCRIPTION

Referring now toFIG. 1, an embodiment of a brine generation system10constructed according to principles of the present disclosure can include a tank unit12providing a tank14, for example, made of stainless steel and having an open top through which rock salt16or other similar material such as calcium magnesium acetate (CMA) pellets and other salt-containing materials that will dissolve in water (referred to herein, collectively, as “salt crystals” or “crystals of salt”) can be received. In alternative embodiments, other non-corrosive materials such as fiberglass, polymers and the like can be used. An exemplary, but non-limiting, capacity of the tank14can be six to eight cubic yards.

As will be described in greater detail below, the salt16is generally contained in a salt-holding upper portion18as constrained by a divider20. A freshwater source21can feed a freshwater manifold22extending horizontally into the upper holding portion48in an inflow region24below an upper third of the volume of the upper holding portion48, such that the freshwater manifold22can be surrounded by crystals of salt16. The manifold22provides a series of nozzles26discharging high-pressure streams of freshwater downward into the salt16.

Brine27collects beneath the divider20in a brine-holding lower portion28of the tank14and can be extracted through a brine extraction port30above the bottom of the tank14in a wall of the tank14and communicating with a brine conduit36. The brine holding lower portion28can, for example, hold up to 380 gallons of brine. The brine27can be received by a salinity control system32which is adapted to adjust the brine27for proper salinity.

Specifically, the salinity control system32is adapted to controllably mix the brine27as received from the brine extraction port30with fresh water from freshwater metering valve34communicating between the manifold22and the brine conduit36. If the salinity is too high, as checked by a salinity sensor38downstream from a freshwater inlet39from the freshwater metering valve34after passing through a mixer40within the brine conduit36, additional water can be added automatically. The salinity sensor38can be any suitable sensor adapted to allow a controller58of the salinity control system32to determine the salinity of the brine, for example, an electrical salinity gauge providing accuracy of as much as 0.01% or a density sensor adapted to measure the density of the brine, which can be converted to a salinity concentration by a PLC.

The brine27measured by the salinity sensor38can be received by a pump42to pass to a valve bank44having a recycle valve46and a tank valve48. The recycle valve46conducts the brine27to a return manifold50that can extend generally parallel to the freshwater manifold22but displaced therefrom in the inflow region24. The return manifold50can include a series of orifices52which can be nozzles or simply low-pressure openings that return the brine27to the tank14to increase its salinity.

Thus control of the freshwater metering valve34and the recycling provided by the recycle valve46can be used to adjust the salinity of the brine27received by the pump42. One or more flow sensors (not shown) can also be placed in the brine conduit36, the freshwater manifold22, or the return manifold50for further control input.

The tank valve48, when open, can permit the conveyance the brine27to a storage tank54by way of a mixing station56in some embodiments. The mixing station56can mix the brine27with other additives of types known in the art. Each of the valves34,46,48, and the pump42can be electrically controlled by pneumatic valves controlled by the controller58(such as a programmable logic controller) for automatic operation as will be described herein, based on readings obtained from the salinity sensor38, flow sensors (not shown) and inputs received from the operator via a control panel259(see. e.g.,FIG. 5).

The tank14provides for two stages of sediment collection. Such sediment includes non-soluble particles that can be mixed with the salt crystals loaded into the tank14. A first stage of sedimentation collection occurs above the bottom of the tank14near the divider20and provides for a capture of intermediate particulates60which can be automatically discharged through an intermediate sediment discharge port62at one end of the tank14. The intermediate sediment discharge port62can have an electronically-controllable port hatch64controlled by an actuator66which is in communication with the controller58for automatic discharge of the intermediate particulates60at regular intervals.

Fine particulates68can settle to the bottom of the tank14and be discharged through a second sediment discharge port70below the intermediate sediment discharge port62. The second sediment discharge port70can have a manually-removable cap or valve71. The discharge ports62,70are shown on the same side of the tank14for clarity; however, in a preferred embodiment, the second sediment discharge port70is on the same side as the brine extraction port30preventing interference in the collection of sediment between the two ports64,70.

Referring now toFIGS. 2 and 3, the upper portion18of the tank14can flare outward to provide a hopper73for receiving salt16from a back loader, conveyor or the like as discharged downward into the tank14. The salt16is then guided to the divider20which provides a first inwardly sloping wall72and opposed second inwardly sloping wall74converging in a downward direction to a sump channel76. The first sloping wall72and second sloping wall74thereby approximate a V channel having the sump channel76extending downward from its lower vertex. The first sloping wall72can be hinged about a hinge point78allowing its outer edge to be raised away from a wall of the tank14for access to the lower portion28of the tank14when salt16is removed. The second sloping wall74provides generally a screen that is permeable to liquid, allowing the latter to pass generally horizontally therethrough as indicated by arrow75but resisting the passage of the larger salt particles. This screen can have, for example, 5/32 inch (4 mm) holes staggered on a 3/16 inch (4.75 mm) grid. The vertical extent of the screen of the second sloping wall74helps resist the accumulation of particulate matter against the screen, as the particulate matter migrates generally downward toward the sump channel76.

Referring also toFIG. 3, an upper open end of the sump channel76communicating with the upper portion18can be covered by a rock guard80having relatively large openings (on the order of 2 inch (50 mm) diameters) intended to prevent passage of large rocks or sticks or the like into the sump channel76.

Referring toFIGS. 2 and 3, the walls of the sump channel76can be formed of a perforated sheet of stainless steel formed in an upwardly facing U-shaped cross-section to provide a radiused portion82conforming to an outer periphery of a horizontally extending auger84. The perforations will generally have similar openings to the openings of the screen of the second sloping wall74, both of which can be much smaller than the openings of the rock guard80. An auger84can be provided in the sump channel76which is a screw type helix having a cylindrical swept volume formed of molded polypropylene or stainless steel sections assembled on a stainless steel arbor. Rotation of the auger84by a gear motor86(electronically controllable by the controller58shown inFIG. 1) scrapes the inner surface of the radiused portion82to transport sediment trapped by the sump channel76out of the intermediate sediment discharge port62when the port hatch64is opened. It will be appreciated that this operation of the auger84can be conducted without a complete draining of the tank14of brine27. When significant sediment has accumulated in the sump channel76, the auger84can be operated even with the level of the brine27slightly above the auger84without undue loss of brine through the intermediate sediment discharge port62. This allows continued operation of the system10without the need to drain the tank14and go off-line while substantially decreasing the amount of sediment that will accumulate at the bottom of the tank14.

Referring still toFIG. 2, positioned within the sump channel76and above the auger84is a plate valve87controllable by an actuator88that can also be controlled by the controller58(shown inFIG. 1). The plate valve87, when closed, substantially blocks access to the sump channel76from above the divider20, allowing more access as the plate valve87is opened. The result is that the amount of fluid flow indicated by arrows89from the upper portion18of the tank14into the sump channel76can be controlled to permit the collection of intermediate size particulates60in the sump channel76without providing substantial loss of brine27therethrough. The result of the placement of the nozzles26of the freshwater manifold22adjacent to the divider20is to create an extreme erosion zone90providing for highly turbulent flow92within a pool94of brine27above the divider20. The angle of the nozzles26can be adjusted about an axis of the manifold22via an exterior handle23as indicated by arrows25. By control of the relative flow through the nozzles26and the setting of the plate valve87, the dwell-time for liquid above the divider20can be controlled, allowing desired salinity to be obtained with reduced need to recirculate the brine27through the system which can decrease the rate at which the system can produce the brine solution27. In the illustrated embodiment, the system is configured to provide at least exceed 100 gallons (380 L) of brine solution per minute.

Referring still toFIGS. 2 and 3, a bottom wall96of the tank14can provide for an upwardly open channel98being a lowermost portion of the bottom wall96. The bottom wall96outside of the channel98can slope toward the channel98to facilitate the collection of fine particulates68therein. The channel98itself slopes downward toward the discharge port70at one end of the tank14to facilitate the migration of fine sediment toward the discharge port70. A clean-out port100opposite the discharge port70across the channel98can be provided for the introduction of high-pressure water through a nozzle to force sediment along the channel98out of the discharge port70. Additional manifolds and nozzles (not shown inFIG. 2) can direct water jets down the slope portions of the bottom wall96outside of channel98to assist in this discharge process. This sediment removal process typically requires draining the brine27from the tank14and thus is desirably performed less frequently than operation of the auger84described above.

Referring now toFIG. 4, the tank14can be supported on outwardly splayed legs104fixedly attached to the bottom wall96. Retractable caster units106can be lowered to allow movement of the tank14by lifting it from a surface in contact with the legs104. A clear viewport108is provided in one side of the tank14approximately on level with the brine extraction port30to allow monitoring of the sediment buildup of fine particulates68. A clear, sight-tube type water height gauge110can be placed on the side of the tank14showing a brine level height in the lower portion28. This water height gauge110can be augmented by a pressure sensor type water height gauge112(shown inFIG. 1communicating with the controller58) to allow automatic adjustment and control of the brine height in the lower portion28of the tank14.

During operation, the controller58can adjust the salinity of the brine27discharged to the tanks54and periodically run the auger84, possibly with adjustment of the brine level downward below the port hatch64, per the water height gauge112, before the auger84runs. A feedback control loop (for example implementing a PID loop) can be used to control the plate valve87to minimize the need for recycling brine through return manifold50increasing the net throughput of the device.

Embodiments of the present disclosure are directed to a portable brine generation system adapted to be transported to multiple local road maintenance facilities or stations where brine can be prepared and, if desired, stored for future use. It can be more cost effective to prepare brine within a desired application area rather than to prepare brine at a central location and then transport the brine as an aqueous solution from the central location to each desired application area.

The portable brine generation system can use water and salt crystals provided at the local road maintenance stations to prepare the brine on site at the local road maintenance station rather than transporting the brine as an aqueous solution from a centralized brine generation site servicing a larger region over a longer distance to the roadways to which the brine will be applied. By producing the brine solution within the region of application, the portable brine generation system can reduce the cost of transporting brine as an aqueous solution over longer distances and avoid the need for a dedicated brine production unit at each local station.

In embodiments, the brine generation system can include a tank unit, a freshwater conduit, and a salinity control system mounted to a mobile platform. Salt crystals and water are mixed in the tank to form brine as an aqueous solution. The salinity control system is adapted to determine a salinity of the brine solution received from the brine outlet and to return the brine solution to the upper portion of the tank body when the salinity is below a predetermined level and to discharge the brine solution when the salinity is at the predetermined level.

In one embodiment, a mobile platform is used to transport the brine generation system between local road maintenance stations. In embodiments, the mobile platform comprises a trailer with at least one ground engagement element, such as a set of wheels, and is configured to be pulled behind a service vehicle. In other embodiments, the mobile platform can be self-propelled.

The portable brine generation system can be adapted to be removably connected to a freshwater source present at the local road maintenance station. Water from the freshwater source can be used by the portable brine generation system to produce the brine.

The portable brine generation system can also use salt crystals present at the local road maintenance station. At each station, the portable brine generation system can be situated in an area accessible to loading equipment configured to deposit salt crystals into the hopper of the tank body of the portable brine generation system. In embodiments, the portable brine generation system can be loaded with salt crystals at a central location and/or another location other than where the brine solution is generated.

In embodiments, the portable brine generation system includes automation controls, including controllers, pumps, actuated valves, and sensors to automate the brine production process and to produce brine having a desired salinity. In embodiments, the mobile platform can include an enclosure configured to house the salinity control system within the enclosure. The enclosure can house various components for facilitating the production of brine by the portable brine generation system. For example, the enclosure may house automation controls, including one or more controllers, salinity measurement devices, one or more pumps for pumping prepared brine solution, and valves for directing the prepared brine solution from the portable brine generation system to one or more storage tanks at the local station or on one or more service vehicles. Housing certain elements within the enclosure of the portable brine generation apparatus can help protect such elements from the inclement weather conditions in which the portable brine generation apparatus frequently operates.

The portable brine generation system can be adapted to selectively transfer the brine it prepares to one or more storage tanks at the local road maintenance station. The brine can also be directly transferred to storage tanks on one or more service vehicles at the local road maintenance station so that the service vehicles may distribute the brine on local roadways.

In embodiments, the portable brine generation system is equipped with an internal combustion engine or other power-generating device to produce a suitable power supply (e.g., electricity) to operate the system. Alternatively, the portable brine generation system can be adapted to be removably connected to a power source (e.g., an electrical service) provided at the local road maintenance station.

In embodiments of the portable brine generation system, the tank unit can be substantially similar, in both construction and functionality, to the tank unit shown and described inFIGS. 1-4. In embodiments of the portable brine generation system, the freshwater conduit is disposed within the upper portion of the tank body as described above. The freshwater conduit can include at least one water jet adapted to discharge a stream of water from the freshwater conduit in a direction toward the divider and the lower portion of the tank body.

In embodiments of the portable brine generation system, the salinity control system is adapted to adjust the salinity of the brine dispensed from the brine generation system as described above. The salinity control system can be adapted to determine a salinity of the brine solution received from the brine outlet and to return the brine solution to the upper portion of the tank body when the salinity is below a predetermined level.

In embodiments, the salinity control system can be in fluid communication with the brine outlet of the tank body. The salinity control system can include a controller, a brine conduit, a sensor, a pump, a valve bank, a return conduit, and a brine discharge port. The brine conduit is connected to the brine outlet of the tank body and is in fluid communication with the lower portion of the tank body. The sensor is adapted to sense a salinity of the brine solution conveyed in the brine conduit and in communicative relationship with the controller to send a salinity signal to the controller indicative of the salinity measured. The pump is in fluid communication with the brine conduit and is adapted to convey the brine solution through the salinity control system. The valve bank is in fluid communication with the pump and in operative relationship with the controller. The return conduit is connected to the valve bank and arranged with the upper portion of the tank unit. The brine discharge port is in fluid communication with the valve bank. The pump is adapted to convey the brine solution from the brine conduit to the valve bank.

Based upon the salinity of the brine solution received by the salinity control system, the controller selectively controls the opening and closing of the valve bank. In embodiments, the controller is adapted to selectively operate the valve bank to direct the brine solution received from the pump to the return conduit for dispensing in the upper portion of the tank body when the salinity measured by the sensor is below the predetermined level and to the brine discharge port for discharging the brine solution received from the pump out of the salinity control system when the salinity measured by the sensor is at a predetermined level

In embodiment, the mobile platform includes a support surface and at least one ground-engaging element rotatably mounted to the mobile platform. In an illustrated embodiment, the mobile platform includes four tires rotatably mounted to a pair of axles at a rear end of the platform and a hitch secured to a front end of the platform to facilitate towing the mobile platform by a vehicle.

In embodiments, the tank unit and the salinity control system are disposed on the support surface of the mobile platform. An enclosure can be mounted to the mobile platform, and components of the salinity control system can be disposed within the enclosure.

In embodiments, the brine generation system further comprises a supply station at one or more sites. The supply station is adapted to be removably connected to the freshwater conduit and the salinity control system of the portable brine generation system and is configured to provide a supply of at least one of water, salt, and power.

In embodiments, the supply station includes a water source that is configured to connect to the inlet of the freshwater feed conduit disposed in the upper portion of the tank body. The supply station further can also include a storage tank for receiving brine dispensed from the brine discharge outlet of the salinity control system of the portable brine generation system.

In embodiments, the supply station includes a water source, a supply conduit in fluid communication with the water source and adapted to selectively dispense water from the supply conduit, a storage tank configured to hold the brine solution, and a discharge conduit in fluid communication with the storage tank. The first supply conduit is adapted to be removably coupled to the inlet of the freshwater conduit such that water from the water source is selectively discharged from each water jet of the freshwater supply conduit. The discharge conduit is adapted to be removably coupled to the discharge port of the salinity control system such that the brine solution discharged out of the discharge port from the salinity control system is conveyed through the discharge conduit to the storage tank.

The brine generation system can further comprise a second supply station located at a second site. The supply stations can be substantially similar to each other with respect to their construction and functionality. The second supply station can also be configured to be removably connected to the freshwater conduit and the salinity control system of the portable brine generation system when it is placed in proximity to the second supply station at the second site. In embodiments, the second site is in spaced relationship with the first site such that the second supply station is not able to be connected to the freshwater conduit and the salinity control system when the first supply station is removably connected thereto. In embodiments, the brine generation system includes more than two supply stations.

In embodiments, a roadway administrator responsible for a given area, which is segmented into a number of coverage zones, has at least one supply station positioned with each coverage zone. In embodiments, the size of the coverage zone can be based upon the amount of brine solution a given vehicle in the roadway administrator's fleet can hold and/or the amount of roadway can be covered with brine solution from a given vehicle before its storage tank runs empty.

Referring now toFIG. 5, an embodiment of a portable brine generation system210is shown. The portable brine generation system210includes a tank unit212and a salinity control system232(seeFIGS. 7 and 8) disposed upon a supporting surface213of a mobile platform215. The components of the brine generation system210can be secured to the mobile platform215using any suitable technique, such as, by being bolted to the mobile platform215.

In embodiments, the mobile platform215includes at least one ground engaging element216rotatably mounted to the mobile platform215. In the illustrated embodiment, the mobile platform215comprises a trailer with a number of ground-engaging elements, namely a set of wheels216, enabling the portable brine generation system210to be transported between multiple road maintenance stations to generate brine27at each station. In other embodiments, the mobile platform215can include a power source and be configured to be self-propelled.

The portable brine generation system210can also include an enclosure217mounted to the mobile platform215. The enclosure217can be configured to house components of the salinity control system232within it (seeFIGS. 7 and 8).

The tank unit212is similar to the tank unit12shown inFIGS. 1-4and includes a tank body14and a divider20that defines a hopper73for receiving salt crystals16therein and has a freshwater manifold22disposed therein. The salt crystals16and water from the freshwater manifold22are mixed in the upper portion of the tank body14to form brine27(as shown inFIGS. 1-2) as an aqueous solution. The salt crystals16to be loaded into the hopper73may be present at the site at which the portable brine generation system210is located, such as at a local road maintenance station. The hopper73can be positioned at the site so as to be accessible by loading equipment that may deposit salt crystals16in the hopper73. Similarly, the water provided to the brine generation system210via the freshwater manifold22can be from an external water source21(as shown inFIGS. 9-10) at the site at which the portable brine generation system210is located.

Referring toFIGS. 5 and 7, the salinity control system232can include an operator interface panel259which is in electrical communication with the controller58of the salinity control system232. In embodiments, the operator interface panel259is mounted to at least one of the tank unit212, the mobile platform215, and the enclosure114such that it is accessible to an operator of the portable brine generation system210from outside the enclosure. The control panel259can be configured to permit the operator to control the operation of the portable brine generation system210. In embodiments, the control panel259can include a display equipped with a graphical user interface.

In embodiments, the control panel259can be configured to adjustably control a subset of operating parameters of a larger set of operating parameters available for adjustment through the controller58. For example, the control panel259can be configured to permit an operator to adjust the desired salinity of the brine27produced by portable brine generation system210or the amount of a given additive inserted into the brine solution, but not allow the operator to adjust certain system parameters that may desirably remain constant from station to station or that are more appropriately adjusted by an experienced technician, such as the calibration of the salinity sensor38, for example. In other embodiments, the user interface of the control panel259can include a secure login sequence configured to permit only authorized users to adjust certain operating parameters and or functionality.

Referring toFIG. 6, a connection plate219can be secured to the exterior surface of the enclosure217of the portable brine generation system210. In the illustrated embodiment, the connection plate219is located on the side of the enclosure217in opposing relationship to the side shown inFIG. 5(seeFIG. 11). The connection plate219can be made from any suitable material, such as, stainless steel for example. The connection plate219includes several hookups which are configured for removable connection to respective supply sources and discharge conduits when the portable brine generation system210is moved to a station at which the portable brine generation system210will generate brine27. The illustrated connection plate219includes a freshwater inlet connection221, a pair of electrical receptacles223,225, an air inlet227, and a brine discharge port connection229.

Referring toFIGS. 6 and 8, the freshwater inlet connection221is in fluid communication with the inlet of the freshwater manifold22. The freshwater inlet connection221is adapted to be removably connected to an external freshwater source21(see, e.g.,FIGS. 9 and 10) located at the station. When connected to the external freshwater source21, the freshwater inlet connection221can selectively provide fresh water to the freshwater manifold22. Water from the external freshwater source21can be directed through a series of nozzles26of the freshwater manifold22within the tank body14, discharging high-pressure streams of fresh water downward into salt crystals16to form brine27, as explained above in connection with the brine generation system10ofFIGS. 1-4. As shown inFIGS. 1 and 8, water entering the freshwater inlet connection221can also be directed to the brine conduit36via the freshwater metering valve34to decrease the salinity of the brine27exiting the tank body14.

In the illustrated embodiment, the freshwater inlet connection221includes a coupler231configured to be removably connected with a supply conduit350of a supply station found at the particular site (seeFIG. 11) and a shut-off valve233. In embodiments, the coupler231can be a threaded fitting configured to threadingly mate with an end of the supply conduit. In other embodiments, the coupler231can have a different configuration suited to be removably connected to the supply conduit. The supply conduit can be in fluid communication with the supply of fresh water found at the site. The shut-off valve233can be provided to selectively open and close the freshwater inlet connection221to permit or prevent the flow of freshwater into the tank body14. In other embodiments, the freshwater inlet connection221can have different configurations.

The electrical receptacles223,225can be in electrical communication with one or more of the components of the salinity control system232, including, without limitation, the controller58and the pump42, for example. While at the site where brine27will be generated, the portable brine generation system210can be connected to an electrical power source at the site through the electrical receptacles223,225. The electrical power provided through the electrical receptacles223,225can be used to power components of the brine generation system210, including the salinity control system232, for example.

The illustrated electrical receptacles223,225each includes a manually-removable cover235, which is tethered to the connection plate219. Each cover235includes a plug237configured to sealingly engage the associated receptacle223,225to help prevent water, precipitation, and other contaminants from entering the receptacles223,225.

In embodiments, the electrical receptacles223,225can be of a known configuration suited for electrically mating with a standard electrical connector. In embodiments, the electrical receptacles223,225can have a different configuration and can be any suitable electrical connector adapted to be removably connected to an on-site electrical power source. In other embodiments, the brine generation system210can include an internal combustion engine or a generator (not shown) disposed upon the mobile platform215, which can be used to selectively operate the components of the system210which use power.

Referring toFIGS. 6 and 8, the air inlet227is in communication with the salinity control system232. The air inlet227is configured to be removably connected to an air supply line291(seeFIG. 11) in communication with a source of pressurized air at the site. The salinity control system232can include a drain port241in fluid communication with the brine conduit36and a vent port243disposed vertically above the drain port241. The drain port241is selectively openable to drain fluid in the salinity control system232. The vent port243is selectively openable to admit air into the salinity control system232to facilitate the draining of the salinity control system232when the drain port241is open. To that end, compressed air can be conveyed through the air inlet227to the vent port243. The compressed air can help direct water and/or brine27in the salinity control system232out the drain port241(seeFIG. 8) when the portable brine generation system210is not planned to be used for a period of time. Purging water and/or brine27from within salinity control system232can help protect the salinity control system232from damage that may result from subjecting residual material within the portable brine generation system210to freezing temperatures.

Referring toFIGS. 6 and 8, the brine discharge port connection229is in fluid communication with the tank valve48of the valve bank44. The brine discharge port connection229is adapted to be removably connected to a suitable discharge conduit245(seeFIG. 11) which can be used to direct brine27into a storage tank54or directly into a dispensing tank of a vehicle. When the tank valve48is open, the brine solution27can flow through the brine discharge port connection229out of the enclosure217.

After being dispensed from the brine discharge port connection229, the brine27can be directed to a storage tank54possibly by way of a mixing station56(as shown inFIG. 1), which may be used to inject one or more additives, e.g., beet juice, to the brine27. The storage tank54can be used for storing brine27from the portable brine generation system210at the local road maintenance station. In embodiments, the storage tank54comprises one or more storage tanks on one or more service vehicles at the local road maintenance station. The service vehicles carrying brine27prepared by the portable brine generation system210can be deployed to distribute the brine27on local roadways.

In the illustrated embodiment, the brine discharge port connection229includes a coupler247configured to be removably connected with a discharge conduit245of a supply station found at the particular site and a shut-off valve249. In embodiments, the coupler247can be a threaded fitting configured to threadingly mate with an end of the discharge conduit245. In other embodiments, the coupler247can have a different configuration suited to be removably connected to the supply conduit245. The discharge conduit245can be in fluid communication with the storage tank54at the site. The shut-off valve249can be provided to selectively open and close the brine discharge port connection229to permit or prevent the flow of brine into the storage tank54. In the illustrated embodiment, the brine discharge port connection229is substantially identical in construction to the freshwater inlet connection221. In other embodiments, the brine discharge port connection229can have different configurations.

Referring toFIG. 7, at least some of the components of the salinity control system232are housed within the enclosure217mounted to the mobile platform215. In embodiments, the pump42of the salinity control system232is disposed within the enclosure217. In other embodiments, the enclosure217can house the controller58, salinity measurement devices such as the salinity sensor38, the pump42for pumping prepared brine solution27received from the brine conduit36, and various valves, such as the freshwater metering valve34and the recycle valve46and the tank valve48of the valve bank44.

In embodiments, the salinity control system232can include structure configured to help dampen the mechanical vibration to which the pump42is subjected. In the illustrated embodiment, an expansion coupling251,253is respectively located upstream and downstream of the pump42(see also,FIG. 8). The upstream expansion coupling251connects the brine conduit36to the pump42. The illustrated upstream expansion coupling251is part of the brine conduit36and is located adjacent the pump42. The downstream expansion coupling253is in fluid communication with, and disposed between, the pump42and the valve bank44. The illustrated downstream expansion coupling253is part of the conduit255extending between the pump42and the valve bank44and is located adjacent the pump42. The upstream and downstream expansion couplings251,253help isolate the pump42from, or dampen the effects of, vibration or sudden movement of the mobile platform215such as what can occur when the mobile platform215is moving between local sites distributed over the region serviced by the roadway administrator.

Referring toFIG. 7, in embodiments, the salinity control system232includes a supporting structure275having a plurality of vibration-isolation elements277adapted to isolate the pump42from the supporting surface213of the mobile platform215to dampen vibration transmission from the mobile platform215to the pump42. Components of the salinity control system232housed within enclosure217of portable brine generation system210may be mounted on the supporting structure275. The vibration-isolation elements277of the supporting structure275can be in direct contact with the supporting surface213of the mobile platform215. In embodiments, the vibration-isolation elements277can comprise any suitable structure or device adapted to help isolate or dampen the transmission of mechanical vibration. The components of the salinity control system232supported by the supporting structure275can experience reduced vibration resulting from the movement of the mobile platform215, e.g., when the portable brine generation system210moves between sites.

Referring toFIG. 7, the controller58can be mounted on an internal wall surface281of the enclosure217. In embodiments, the controller58is electrically connected to the components of the salinity control system232which it controls using flexible wiring connections such that movement of the portable brine generation system210, e.g., when the portable brine generation system210moves between sites, does not damage the electrical connections therebetween.

In embodiments, the salinity control system232can be adapted to help protect the components of the salinity control system232from damage caused by freezing temperatures. For example, in embodiments, the brine conduit36can include a translucent portion285so that an operator may determine whether brine27is present in the brine conduit36. In embodiments, the translucent portion285can be made from any suitable material which permits light to pass therethrough to a sufficient degree to allow an operator to ascertain whether the translucent portion285has fluid therein. In embodiments, the translucent portion285is transparent.

In the illustrated embodiment, the enclosure217has a window287constructed so as to permit an operator to view the interior of the enclosure217from the outside. In embodiments, the interior of the enclosure217can also include suitable lighting which is electrically connected to at least one of the electrical receptacles223,225to allow an operator to selectively illuminate the interior of the enclosure217via the lighting.

Referring toFIG. 8, the salinity control system232can include one or more selectively openable drain ports241positioned to drain water and/or brine27from the salinity control system232. Each selectively openable drain port241may be located at a vertical low point, i.e., where brine27and or water tends to accumulate within the salinity control system232by the effect of gravity when the pump42is not operating. In embodiments, a suitable drain line or flexible conduit can be removably connected to the drain port241to discharge the material drained from the salinity control system232outside of the enclosure217.

The salinity control system232can include one or more selectively openable vent ports243located at a vertical high point (i.e., vertically above at least one drain port241). In embodiments, the vent port243can be opened during a draining sequence to help prevent the formation of a vacuum within the salinity control system232that may prevent the system232from adequately draining. In embodiments, at least one vent port243can be selectively placed in pneumatic communication with an air supply line291via the air inlet227(seeFIG. 11). Pressurized air can be introduced into the vent port243from the air supply line291to help direct water and/or brine27in the salinity control system232toward the drain port241to drain the salinity control system232.

Referring toFIG. 8, fresh water can enter the enclosure217through the freshwater inlet connection221and be conveyed to the freshwater manifold22which extends into the hopper73of the tank body14. The fresh water is discharged in the tank body14from one or more nozzles of the manifold22which can be arranged as described above in connection with the brine generation system10ofFIGS. 1-4. The fresh water is mixed with salt crystals16in the hopper73to generate the brine solution27. The brine27exits the tank body14and enters the brine conduit36. The pump42draws the brine27through the brine conduit36, and directs the brine27to the valve bank44.

If the salinity of brine27sensed by the salinity sensor38is too high, the controller58directs fresh water from the freshwater manifold22into the brine conduit36via the freshwater metering valve34. If the salinity of the brine27is below a predetermined threshold, the controller58can operate the valve bank44such that the tank valve48is closed and the recycle valve46is open to direct the brine solution27having a low salinity into the return manifold50so that it may pass again through the salt crystals16in the hopper73of the tank body14. If the salinity of the brine solution27is within the desired range, the controller58can operate the valve bank44such that the recycle valve46is closed and the tank valve48is open to discharge the brine27from the portable brine generation system210via the brine discharge port connection229. In embodiments, the controller58is in electrical communication with the freshwater inlet connection221and the brine discharge port connection229, which are adapted to be controlled by the controller to selectively open and close the connections221,229according to a logical sequence.

Referring toFIG. 9, the portable brine generation system210can be moved by a vehicle300between a first site310having a first supply station315where it will be used to generate brine and a second site320having a second supply station325where it will again be used to generate brine. The first supply station315includes a first water source21A, a first storage tank54A, and a first supply of salt crystals16A. The second supply station325includes a second water source21, a second storage tank54B, and a second supply of salt crystals16B. The second site320is in spaced-apart relation to first site310. In embodiments, the second site320is in spaced relationship with the first site310such that the second supply station325is not able to be connected to the freshwater conduit and the salinity control system when the first supply station315is removably connected thereto.

In embodiments, the distance330separating the first and second sites310,320can vary. For example, in one embodiment, the distance between the first site310and the second site320can be based upon the application range of a service vehicle when loaded to capacity with brine. The portable brine generation system210can be transported between the first site310and the second site320by being towed by the vehicle300. The vehicle300can be any suitable vehicle with sufficient towing capacity to transport the mobile brine generation system210.

Referring toFIG. 10, the portable brine generation system210can be removably connected to the supply station315of the site310via the connection plate219(seeFIG. 6) to various hookups, e.g., fresh water, electricity, and compressed air. The hookups can be located in a weather-proof supply cabinet340. The supply cabinet340can house a freshwater outlet connection345, an air supply line291, and one or more electrical receptacles347.

The freshwater outlet connection345is in fluid communication with a water source, such as a municipal water supply or a well system associated with the site310, via suitable plumbing. In embodiments, the water source can be treated so that the freshwater has a reduced amount of contaminants or other unwanted materials therein. The freshwater outlet connection345can be substantially similar to the freshwater inlet connection221of the portable brine generation system210. The freshwater outlet connection345is adapted to have one end of a freshwater supply conduit350movably connected thereto (seeFIG. 11) for selectively supplying the water source21A of the site310to the freshwater inlet connection221of the portable brine generation system210.

The air supply line291is in pneumatic communication with a source of pressurized air, such as that provided by a suitable compressor. In embodiments, the air supply line291can be coiled around a reel disposed within the cabinet340such that the air supply line291can be retracted within the cabinet340and wound around the reel when it is not in use. In embodiments, the reel is spring-biased to wind the air supply line291automatically.

Each electrical receptacle347of the cabinet340can be in electrical communication with a power source, such as a municipal electrical supply or a generator associated with the site310, via suitable wiring. The electrical receptacle347can be configured to provide electricity in a suitable form for use by the portable brine generation system210, e.g., 120V AC and/or 240V AC. Each electrical receptacle347can be placed in electrical communication with one of the electrical receptacles223,225of the portable brine generation system210via a suitable electrical cord or cable355(seeFIG. 11). In embodiments, the supply cabinet340can include multiple electrical receptacles347.

A supply of salt crystals16A can be located near the supply cabinet340. In this manner, salt crystals16can be more efficiently loaded into the portable brine generation system210when it is removably connected to the supply station315at the site310.

Referring toFIG. 11, the portable brine generation system210can be transported to the first site310using the vehicle300. In the illustrated embodiment, the mobile brine generation system210can be unhitched from the vehicle300once it is placed in a desired location at the site310. Once located at the first site310, the portable brine generation system210can be removably connected to the first supply station315.

The first water source21A can be selectively provided to the portable brine generation system210via the freshwater supply conduit350which is removably connected to the freshwater inlet connection221of the connection plate219. The portable brine generation system210can receive electrical power via the cable355extending between each associated electrical receptacle223,225of the connection plate219and the supply cabinet340(one shown inFIG. 11). The brine discharge port connection229can be in fluid communication with the storage tank54A via the discharge conduit245, which is removably connected to the brine discharge port connection229. In addition, the air supply line291can be removably connected to the air inlet227of the connection plate219.

The hopper73of the portable brine generation system210can be loaded with salt crystals16from the first supply of salt crystals16A located at the first site310. The portable brine generation system210can generate brine27at the first site310in accordance with the description above. Brine can be discharged from the portable brine generation system310via the brine discharge port connection229into the first storage tank54A, where it may be stored for future use. In embodiments, the first storage tank54A can comprise a brine tank mounted on a service vehicle adapted to apply the brine on local roadways.

After generating brine at the first site310, the portable brine generation system210can be disconnected from the hookups of the first supply station315and then be transported to the second site320using the vehicle300. Once located at the second site320, the portable brine generation system210can be removably connected to the second supply station325, which can be substantially similar to the first supply station315in configuration and functionality. The portable brine generation system210can be used at the second site320to generate brine in a manner similar to that described with respect to the first site310.

In embodiments, the portable brine generation system210can be used to generate brine at any number of sites. Furthermore, it is contemplated that the portable brine generation system210can be transported between numerous stations so that it may generate brine at a site which is located closer to the roadways on which the brine will be distributed than at least one other site which also contains a suitable supply station.

In embodiments of a method for generating a brine solution for treating roadways using a brine generation system, the brine generation system can include a tank unit having a tank body and a permeable divider. The tank body is segmented into the upper portion and a lower portion by the permeable divider. The divider is adapted to resist the movement of salt crystals greater than a predetermined size from the upper portion to the lower portion and is adapted to permit the brine solution to pass from the upper portion through the divider to the lower portion by the effect of gravity. The upper portion defines an upper volume and includes at least one water jet positioned within the lower two thirds of the upper portion of the tank body.

The brine generation system includes a mobile platform having a support surface and at least one ground engaging element rotatably mounted to the mobile platform. The tank unit is disposed on the support surface of the mobile platform.

Salt crystals are deposited in an upper portion of the tank body. A stream of water is injected through the at least one water jet within the upper portion of the tank body such that the water contacts salt crystals within the upper portion of the tank body to form the brine solution in the upper portion of the tank body. The brine solution is allowed to pass from the upper portion of the tank body through the permeable divider and flow into the lower portion of the tank body.

The brine generation system is transported to a first brine station using the mobile platform. The stream of water injected through the at least one water jet within the upper portion of the tank body is provided by connecting the at least one water jet to a first water source at the first brine station.

The at least one water jet within the upper portion of the tank body can be disconnected from the first water source. The brine generation system can be transported to a second brine station using the mobile platform. The second brine station is in spaced-apart relationship with the first brine station.

The at least one water jet can be connected to a second water source at the second brine station. The brine generation system can be used to produce the brine solution at the second brine station using water from the second water source. In embodiments, salt crystals are loaded into the hopper of the tank body at one or both of the first and second brine stations.