DEWATERING SYSTEM

Abstract: A relatively high-rate system for separating relatively dry solids from a slurry containing liquids and solids including an elongated plate (23) having spaced apart openings (25) therethrough, a pair of superposed endless screens (43) and (45) supported for sliding movement on the upper surface of the plate (23). A pond (117) of the slurry is formed over a portion of the run of the screens (43) and (45). A well sealed vacuum chamber (11) is provided on the side of the plate (23) opposite the side supporting the screens (43) and (45) to efficiently draw liquid from the pond through the screens (43) and (45). A roll nip formed by rolls (51) and (85) is provided to engage the screens (43) and (45) to apply pressure to material on the screens at the nip. Various screen constructions and operating parameters are also disclosed.

Description: DEWATERING SYSTEM Technical Field: The present invention relates, generally, to a de- watering system and, in particular, to a dewatering system which is particularly adaptable to dewater materials at a relatively high rate and which is adapted to provide dewatered material .which is of relatively low moisture content. Background Art; In many fields, it is necessary to dewater suspended solids. This presents a particular problem in cleaning up waste water which contains substantial amounts of suspended solids which cannot be readily disposed of if they contain excess moisture. Examples of such suspended solids which present a problem are the solids contained in the effluents from coal washing processes, from the canning industry; from papermaking process and many others. In such operations it is desired to obtain solid materials which can be recovered or disposed of in a land fill or the like, but which are not readily recoverable or disposable if they contain excess water. Because of the fine particles which are present, screens and filters tend to clog which makes filtering impractical because of the slow filtering rate and the filter cake which results in excessively high in moisture. With the technology which has been used in the past, the wash water containing the solids is usually run into settling basins where the solids gradually settle and the clarified water is withdrawn for reuse. Because of the large volume of wash water and solids, large ponds are required and these ponds are susceptible to overflow which can harm the surrounding area. The settled out solids are periodically removed with a dragline or the like and dried, hauled away, and piled up at substantial expense. In the absence of removal and drying it takes extended periods of time for the water to evaporate to a sufficient degree that the bed of the pond is stable and is not subject to run off. Disclosure of Invention: Accordingly, it is the principal object of this in¬ vention to provide a system which can be employed to dewater . effluents containing substantial amounts of suspended solids and which provides a dewatered solid which is sufficiently dry to be disposed of in an economical manner as well as a filtrat which is sufficiently low in solids so that they can be cycled -* back for use as process water. In general, a system embodying various features of the invention involves forming a pond of the slurry to be de¬ watered over one end of a pair of contiguous, overlying, foraminous screens, the other end of which extends out of the -^ pond. The screens are supported on a supporting surface having openings therein and a vacuum is applied to the underside of the surface. The screens are moved in unison over the surface through the pond while applying vacuum to the underside of the surface. The screens have different sized openings, the upper- • ^ most screen being of relatively fine mesh which has a low void volume and the lower screen being of relatively coarse mesh which provides supporting knuckles. The vacuum effects a flow of liquid through the screens while the screens are submerged in the pond to form a cake of solids contained in the slurry. ° The vacuum also causes the flow of air through the cake after the screens emerge from the pond to remove additional water. Thereafter, the screens and the cake carried thereby are passed between a pair of pressure rolls which causes additional liquid to be pressed from the cake whereupon it runs through 5 the,, two screens to a collection point. The cake is then doctored from the pressure rolls and the screens and is dispose of any suitable manner. The screens are then cleaned and recycled to the pond. Preferably, as will be pointed out, the vacuum is 0 applied to the underside of the supporting surface in two separate, defined areas, one being in the area where the screen are disposed in the pond and the other area being where the screens have emerged from the pond. This permits a difference in flow through the screens in the separate areas which permits 5 control of the dewatering action and the volume of air passing through the cake once it is removed from the pond. In order to maximize the utilization of the vacuum a vacuum seal means is provided to insure that the slurry does not bypass the screens and that the vacuum effects maximum flow through the cake rather than around it. Brief Description of Drawings: FIGURE 1 is a diagrammatic view of apparatus embodying various of the features of the invention, FIGURE 2 is a fragmentary perspective view, partially in section, of the dewatering section of the apparatus shown in FIGURE 1, FIGURE 3 is a plan view, partially in section, of the belt arrangement which forms a part of the apparatus of FIGURES 1 and 2, FIGURE 4 is a sectional view taken along line 4-4 in FIGURE 3, and FIGURE 5 is a sectional view taken along line 5-5 in FIGURE 3. Best Modes for Carrying Out the Invention: An apparatus for carrying out various of the features of the invention is schematically illustrated in the drawings. The apparatus includes a vacuum box 11 which is fabricated in a generally rectangular shape and which is inclined at an acute angle to the horizontal. Preferably, the vacuum box 11 is inclined to the horizontal at an angle of from about 15 to 30°. The vacuum box 11 includes an imperforate bottom wall 13, i perforate side walls 15 which are attached to and extend upwardly from the bottom wall 13 and end walls 17 which are similarly, attached to the bottom wall 13 and extend upwardly therefrom. The juncture between the side walls 15, end walls 17 and the bottom wall 13 are sealed in any suitable manner. Around the upper edge of the end and side walls 17 and 15, there is provided an inwardly disposed flange 19 which is spaced from the bottom wall 13 of the vacuum box 11 and which provides a substantially plane surface. The plate 23 is perforated or slotted over substantially its entire area, as indicated at 25, to permit the passage of air and water therethrough. Preferably, the vacuum box 11 is divided into two or more sections. In the illustrated device the vacuum box 11 is divided into two sections 28 and 28a by an imperforate partition 29. As illustrated in the drawings, the slurry box 21 is attached to the flanges 19 and comprises upstanding side wall members 31 and 33, and a rearward wall 35. Spaced from th rearward wall 35 within the slurry box a partition 37 is pro¬ vided which serves as a weir to control the level of liquid in the slurry box 21. Between the partition 37 and the bottom of the rearward wall 35 there is provided a bottom member 39, the rearward wall 35, the side walls 31 and 33 and the partitio which forms the weir, thus providing a sump 41 for the collecti of excess liquid. As illustrated in the drawings, two endless formaminou 10 screens 43 and 45 are provided, the upper runs of which are superposed and supported for sliding movement along plate 23. The upper run of lowermost screen 43 is supported on the plate 23 and the upper run of the uppermost screen 45 is supported on the screen 43. 15 The downstream end of the lowermost screen 43 is trained around a roll 47, and over the plate 23, as illustrated whereupon it is trained around a drive roll 51 and over a wrap roll 53 which maintains the proper wrap of the screen around the drive roll 51 insure proper contact between the screen and 2° roll 51. From the roll 53 the screen 43 passes over a guide roll 55 and returns to the roll 47. Intermediate the roll 47 . and the guide roll 55 there is provided a spray head 61 which is connected to a suitable source of wash water for the screen 43, the water being collected in a trough 63 which is ^ 5 positioned below the screen 43. The upper screen 45 is supported upon a roll 65 which is positioned downstream of the roll 47, the screen 45 running over and in contact with the screen 43 which is supported upon the plate 23. The screen 45 also passes around the drive roll 3Ω υ 51 and the wrap roll 53 in contact with the screen 43 whereupon it is separated from the screen 43 and passes around a guide ro 67 and back to the roll 65. Intermediate the guide roll 67 and the roll 65 there is provided a spray head 69 which is connecte to a suitable source of wash water, the water being collected 5 in trough 71 below the screen 45. Power for the drive roll 51 is provided in the illustrated apparatus by a motor and speed reducer 73 which is connected by a suitable power transmission means such as the be 75 or the like to a pulley 77. Concentric with and attached to the pulley 77 is a second pulley (not shown) which is connected by means of a belt or the like 79 to a pulley 81 on the shaft 83 of the drive roll 51. Thus, power from the motor-speed reducer 73 is transmitted to the drive roll 51.which in turn pulls both the screens 43 and 45 simultaneously over the surface of the plate 23. Proper tension may be maintained in the screens 43 and 45 by longitudinally adjusting the position of the rolls 47 and 65- by any suitable means. In order to apply pressure to materials on the screens 43 and 45, a press roll 85 is provided which is biased towards the screens 43 and 45 at a point at which they are supported by the drive roll 51. The press roll 85 is positioned rearwardly (based upon the direction of rotation of the roll 51) from the uppermost point of the drive roll 51 so that liquid passing through the screens 43 and 45 will run down the surface of the drive roll 51 counter to its direction of rotation. The press roll 85 is supported upon shaft 87 which- is in turn sjαpported on one end of a pair of arms 89 which are pivotally supported intermediate their ends on a pivot 91. The other end of each arm is connected by means of a suitable pivot pin 93 to the piston rod 95 of a hydraulic cylinder 97 which is attached to a suitable support 98. Thus, under actuation of the hydraulic cylinders 97, the desired pressures can be applied between the press roll 85 and the drive roll 51. In order to provide seals between the screens 43 and 45 and the slurry box 21, a side seal 99 is provided along each of the lower portions of the side walls 31 and 33 of the slurry box 21. The side seals comprise strips 101 of flexible material such as rubber, plastic or the like, which bridge an area inwardly of the marginal edges of the screens 43 and 45 and the flange 19. The flexible strip 101 is mounted on an inwardly directed flange 103 attached to each of the side walls 31 and 33. A similar flexible seal 105 is provided at the up¬ stream end (relative to the direction of movement of the screens) of the screens 43 and 45 in the slurry box 21 adjacent the partition 37. The seal 105 is also provided by a flexible strip 107 of rubber, plastic or like material which is attached to the inner surface of the partition 37 by means of a mounting f lange 109 . . In order to supply the slurry to be dewatered to the apparatus, a delivery conduit 113 is provided which is directe to a fitting 115 in the side wall 31 of the slurry box 21. Preferably, in order to minimize agitation, the slurry is introduced into the slurry box 21 downstream of the partition 37 under the liquid level which is indicated in FIGURE 1 by the dotted line 117. Any excess slurry, which is not discharg from the -apparatus either in the form of liquid or solid, runs 0 over the weir provided by the partition 37 and flows into the sump 41 defined by the upstream wall 35 of the slurry box, the bottom member 39 and the partition 37. The sump 41 is connecte by means of a conduit 119 back to the source of slurry so that it can be recycled into the slurry box 21. 5 Vacuum is provided for the system by a vacuum pump 121 which exhausts to the atmosphere through the muffler 123 as illustrated. In order to minimize the amount of power required to form the vacuum, the vacuum pump is connected to the upper end of a liquid separator 125 which is disposed below the level 0 of the vacuum box 11. Connections are made to each of the ■ section ' s 28 and 28a of the vacuum box 11 by means of conduits 127 and 129, respectively, which enter the separator 125 at a level below the liquid level 131, as shown. Suitable valves 133 and 135 are provided in the conduits 127 and 129, 5 respectively, to control the degree of vacuum. Liquid is removed from the lower portion of the separator 125 by means of a pump 137 and is conducted either to further processing operations or back to some other point for utilization through the conduit 139. ° By locating the liquid separator 125 at a level well below the vacuum box 11, the columns of liquid in the conduits 127 and 128 will aid in reducing the pressure in the vacuum box 11 so that the power requirements of the unit are minimized. Removal of solids is effected by means of a doctor 5 blade 141 which bears against the press roll 85 and a doctor blade 143 which bears against the screens of the drive roll 51. Any solids from the doctor blade 141 fall onto the screens below the doctor blade 141 and are carried by the drive roll 51 to doctor blade 143 from which they are deposited on a which deposits the solids on a conveyor belt 147. Liquid which is removed by the press roll 85 flows through the screens 43 and 45 and down the surface of the drive roll 51 where it is removed by a doctor blade 149 and is collected in a trough 151. In operation, the drive roll 51 is activated to draw the screens 43 and 45 over the plate 23. The cleaning showers 61 and 69 are activated to provide a cleaning shower for their respective screens. A pond of slurry is established in the lower portion of the slurry box, the level of slurry being maintained at the level 117 by the weir provided by the partition 37. As indicated, the slurry level preferably extends to a point beyond the center partition 29 to insure that the lower vacuum box section 28 is covered by liquid. The vacuum system is activated through the action of the vacuum pump 121 and the liquid pump 137 to maintain the liquid level in the separator 125 above the inlets to the separator of conduits 127 and 129. • In the section 28 of the vacuum box 11, the 'vacuum causes liquid to flow through the perforations in the plate 23 into the vacuum box section 28 from which it is carried by the conduit 127 into the separator 125. The pump 137 then pumps the liquid to a point of utilization or disposal. The coarse screen 43 provides passageways for the liquid which flows through the fine screen 45 to reach the perforations 25 in the plate 23 " so as to minimize pressure drops which would reduce the effectiveness of the vacuum. Flow through the screens in the area of section 28 of the vacuum box 11 is controlled by the valve 133. As the liquid is drawn through the screens, a cake of solid materials is formed on the screen 45 which progressively moves toward and over the section 28a of the vacuum -box 11. In this area, the cake of material on the belt 45 is subjected to a flow of air caused by the vacuum system which sweeps liquid from the cake of solids, the air and entrained liquid flowing through the screen 45, the screen 43 and thence through the perforations 25 in the plate 23. The liquid and air which are drawn through section 28a pass through conduit 129 to the separator 125. In the separator, the air is drawn out by means of the vacuum pump 121 and the liquid fraction is drawn the pump 137. After leaving the vacuum box 11, the screens 45 and 43 and the cake of solids carried thereby moves to the nip formed between the drive roll 51 and the press roll 85, By applying a 5 suitable amount of hydraulic pressure to the cylinders 97, the desired pressure is developed in the nip. As has been pointed out above, the nip between the rolls 85 and 51 is located upstream from the uppermost point of the roll 51 so that any liquid flowing through the screens 45 and 43 runs down the ■• u surface of the roll 51 where it is doctored from the roll 51 by the doctor blade 145 for collection in the trough 151. In operation, the material entering the nip between the rolls 85 and 51 shows a buildup of material ahead of the nip which effects a working of the material before it passes through ■-5 the nip. The solid materials which pass through the nip are removed from the roll 85 by the doctor blade 141, that material falling onto the screen 45 carried, by the roll 51. Solid materials from the screen 45 are removed from the screen by the ' doctor blade 143 and fall onto the chute 145 which deposits - υ then on the conveyor belt 147 for disposal or reuse. The screens 45 and 43 are carried around the roll 51 and over the wrap roll 153 at which point they are separated, washed and return to the slurry box 21. The choice of the screens 43 and 45 is of importance -5 in obtaining optimum results. The screen 43 is fabricated with a relatively coarse mesh from relatively large diameter filaments or yarns while ' the screen 45 is fabricated with a fine mesh from relatively small diameter filaments or yarns. In operation, when the screens are superposed, the fine mesh * υ and the relatively small diameter filaments of the screen 45 provide a surface which is not subject to clogging with solid materials because particles cannot be readily become lodged in the openings of the screen and if they are, because of the small diameter fialments, it is not difficult to dislodge them because 35 of a minimum entanglement with the filaments. Also, because of the small diameter of the filaments or yarns and the fine mesh, the void volume of the screen is minimized so that the screen 45 will hold a minimum amount of liquid which can be reabsorbed. by the solid cake. The coarse screen 43 with its relatively large diameter filaments or yarns provide the mechanical strength for drawing the superposed screens across the plate 23-. Also, the cross overs of the filaments or yarns provide knuckles which minimize contact between the screen 43 and the plate 23 to reduce frictional forces. In addition, the knuckles also provide support for the screen 45 at spaced points which also minimizes the capillary effect between the screen 43 and 45, and permits the flow of water and air between the screen 45 and the perforated plate 23 over its area so that water and air can readily migrate to adjacent openings in the plate 23 and which minimizes the retention of liquid on the lower side of the screen 45. Also, the combination of screens in cooperation with the press roll 85 provides a smooth surface on which the roll 85 bears and water which passes through the screen 45 readily flows through the screen 43 on to the roll 51 and because of the coarse mesh and the large filaments the screen 45 does not materially impede the flow of water along the surface of the roll 51. It has been found that the fine screen 45 should be fabricated from filaments or yarns having a diameter of less than 10 mils and the open area should be less than 28 percent, preferably between about 14-25 percent and not preferably between about 18-20 percent. Under some conditions it may be desirable to provide a screen having a lesser open area than 14 percent. The Frazier air permeability of the screen 45 should preferably be between about 300 and 800 cu. ft./minute/sq. ft. (91.44 and 243.84m 3/min/m2) at a pressure of one-half inch (1.27 cm) of water. While various weaves will give satisfactory results, the screen should preferably be woven with a satin weave. Such a weave provides elongated knuckles on opposite directions. It has been found that the fine screen 45 should be disposed so that the side of the screen having the majority of elongated knuckles in the machine direction should contact the cake. This decreases resistance to the doctor blade and also promotes peeling of the cake from the screen. It has been found that the coarse screen 43 should be fabricated from filaments or yarns having a diameter of greater than 10 mils and the open area should be between about 12 to 25 percent, preferably between about 15 to 22 percent. The Frazier air permeability of the screen 43 should preferably be between about 300 and 800 cu. ft./minute/sq. ft. (91.44 and 243.84 5 m 3/min/m2) at a pressure of one-half inch (1.27 cm) of water. While various weaves will give satisfactory results the screen 43 should preferably be woven with a satin weave. Such a weave provides elongated knuckles on opposite sides of the screen which are primarily oriented in the opposite directions. It has .0 been found that the coarse screen 43 should be disposed so that the side of the screen having a majority of elongated knuckles in the machine direction should be in contact with the plate 23. This decreases frictional resistance on the plate and places the majority of cross directional knuckles ori ~ both of the screens- 43 .5 and 45 in contact with one another to increase friction between the screens which facilitates movement through the apparatus. In order to minimize capillary action, thereby mini¬ mizing liquid carried by the screens, and to minimise entangle¬ ment of particles with the screens-, the screens should prefer- Ϊ0 ably be fabricated from onofilaments rather than from a multi- filament yarn. Suitable materials for the monofilaments are nylon and polyester. It has been found that a coarse screen 43, as described above, provides substantial lateral flow through the screen so that any liquid forced or drawn through the 15 screen.45 readily runs laterally through the screen 43 to the perforations 25 in the plate 23 or down the face of the roll 51 adjacent the nip between the rolls 51 and 85. In order to minimize the tendency of the slurry in the slurry box 21 from running under the flexible strip 109 through iG the screens 43 and 45 openings provided by and to prevent the loss of vacuum through the screen 43, the lower screen 43 is provided with narrow, spaced apart transversly extending areas 149 which are impermeable to liquid. This can be accomplished by filling the openings in the screen 43 with molten polyethy- »5 lene, polypropylene or the like or by applying a coating of latex or acrylic emulsion or the like to the areas to be sealed and curing the emulsion to make " it insoluble. The impermeable areas may be of narrow width, e.g. . C. PI one-half inch (1.27 cm) and should be spaced apart a distance relative to the width of the strip 109 so that an impermeable area is under the strip 107 for a substantial portion of the width of the screen 45. It has been found that with a strip 107 which is almost six inches in width, the impermeable areas 149 can be approximate by 1/4 to 1/2 inch (0.635 to 1.27 cm) in width and can be spaced approximately 51/2 inches (13.97 cm) apart. To enhance the sealing action, the plate 23 preferably should be made iraperforate under the strip 107 except towards O the upstream end of the strip 107. As shown in FIGURE 5 the plate 23 is imperforate under the strip 107 except along the marginal edge of the strip, the first row of perforations being indicated at 25a in FIGURE 5. Thus, the source of vacuum is disposed as far as possible from the possible point of 5 leakage but at the same time acts to hold the strip 107 in contact with the upper screen 45. As shown, particularly in FIGURE 3, the imperforate strip 149 are also preferably angled relative to the transverse dimension of the screen 43. This facilitates passage around the rolls and under the doctor blade 143. The exact angle is not critical but it preferably should be at least about 10° to the transverse dimension of the screen 43 to provide adequate tracking around the rolls and under the doctor blade 143. Depending upon the width of the strip 107 and the width of the screen 43, there may be a gap in the blockage action caused by the interaction of strips 149 with the sealing strip 107 but under most conditions the passageway provided between the point of leakage and the perforation 25 is so long that a resistance to air movement is set up which effectively minimizes any material leakage. Similarly, as shown in FIGURE 4, seals 151 are also provided along the side margins of the screen 43. The seals 151 are also imperforate strips which are preferably 1/4 to 1/2 inch (0.635 to 1.27 cm) in width and which are made imperforate as described above in connection with imperforate strips 149. Again, the perforations 25 in plate 23 terminate in a position between the portion of the strip 151 and the marginal edge of sealing strip 101 as shown in FIGURE 4 at 25b, to to to * to I-* y-n Ul o Ul o l o tn passing over three of the filaments in the opposition direction and under one filament. The screen 45 was oriented with the satin side, i.e. the side of the fabric in which the machine direction filaments pass over the three cross direction filaments, on the top to support the cake. .This orientation of the screen provides what is in effect a series of longi¬ tudinally oriented knuckles or bars on the upper surface which provides a relatively smooth surface for the doctor blade 143 and which- promotes release of the cake from the screen surface. Also, the orientation places the majority of cross direction filaments of both the screens 43 and 45 in contact which increases frictional forces between the screens 43 and 45 to aid in moving the screens in unison through the apparatus. — The vacuum box in the system was not provided with a partition but the slurry level was maintained about midway along the length of the vacuum box. The vacuum applied on various runs varied from 8 to 15 inches (20.3 to 38.1 cm) of mercury. The belt speed ranged from 7.5 to 10 ft. (2.29 to 3.05m (min) per minute. The nip pressure between the roll 85 and the roll 51 ranged between 12 and 35 pounds per lineal inch (2.14 and 6.25 kg 1 ' lineal cm) of nip in contact with the cake and the thickness of the cake ranged from 3/8 of an inch to one inch (.95 to 2.54 cm) at the end of the vacuum box. The depth of cake increased substantially ahead of the nip between the rolls 51 and 85 which resulted in substantial working of the cake. The various coal slurries which were tested involved varying type of coal solids in terms of size of particles, the mesh size varying considerably in each fraction. An example of one mesh size which shows, in general, the size range of particles in the ultimate cake is as follows: Mesh Weight Percent Plus 28 mesh 8.33 28 x 48 mesh 27.57 48 x 100 mesh 27.12 100 x 200 mesh 38.71 200 x 325 mesh 7.27 325 mesh xO 1.10 Note: Mesh is per 2.54 cm. The coal slurry treated was the underflow from a clarifier which contained approximately 42 percent solids. The final dewatered product taken from the rolls 51 and 85 contained between 18 and 25 percent moisture, the majority of the product on the various tests containing 20-22 percent moisture. This product could be mixed with outgoing coal without causing any serious problems so that the converted waste product was transferred into a usable form of coal. Surprisingly, the moisture content of the material passing through the nip was approximately 2-4 percent lower than the " moisture content of the material on the screen at the point that it left the upstream end of the vacuum box, e.g. if the ultimate product had a moisture content of 21 percent, the moisture content at the upstream end of the vacuum box was between 23 and 25 percent. The tests showed that little additional effi¬ ciency was obtained at vacuums over about 14 inches '* of mercury and that, depending upon the proportion of fines in the coal slurry, the pressures in the neighborhood of 25-30 pounds per linear inch (4.46 - 5.36 kg/cm) at the press roll nip provided optimum results in terms of moisture removal as related to power consumption. Similar tests were made on the prototype equipment in connection with the recovery of coal refuse fines which is the material containing particles of slate, clay and the like which are cleaned and separated from the coal. An example of a fine refuse material containing clay and the like is as follows: Mesh Weight Plus 28 mesh 24.45 28 x 48 mesh 43.27 48 x 100 mesh 12.23 100 x 200 mesh 4.32 200 x 25 mesh 14.92 325 mesh xO .76 Note: Mesh is per 2.54 c Again, the conditions of operation were the same as the coal as described above and the material collected from the rolls 85 and 51 contained approximately 18-25 percent moisture and was of a consistency which could be disposed of in land fill. In case of both the coal fines and refuse, the liquid which was separated contained a maximum of about 4 percent solids which was low enough so that the liquid could be returned for reuse in the washing plant.

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Inventors: CHARLES A
Applicants: FAIRCHILD INC
Application year: 1981
Main classification: B01D33
IPC codes: B01D33