HORIZONTAL FLOW GENERATION SYSTEM

Abstract: A fluid mixing system (12) including a fluid mixing device (26) and method for generating and maintaining a substantially uniform horizontal velocity profile (F) in a fluid circulation system, such as a plug flow reactor which requires less horse power than conventional fluid mixing systems without losing mixing effectiveness. The fluid mixing device employs a top entry, vertically-oriented impeller (30) and a housing (28) that directs the pumped flow in a generally horizontal direction (F).

Description: HORIZONTAL FLOW GENERATION SYSTEM Background of the Invention The present invention relates to fluid mixing systems, and more particularly, to a mixing module and method for generating a horizontal fluid flow in a reactor vessel. Although horizontal fluid flow is desirable in many fluid mixing systems, the generation of a horizontal fluid flow is especially important in the treatment of water, sewage and like waste liquids in plug flow reactors or oxidation ditches to promote the mixing and agitation of suspended solids. Conventionally, the treatment of water, sewage and like waste liquids in such reactors has utilized multiple side entry or horizontally-oriented turbine agitators. Such agitators require a relatively large amount of horsepower, specific positioning within the reactors and fine adjustments to generate the requisite fluid flow and agitation. Plug flow reactors have also utilized horizontally-oriented, submersible turbine agitators. Such submersible agitators must be removed from within a plug flow reactor for servicing utilizing various lifting devices. Furthermore, agitators which are entirely submerged require expensive mechanical seals, moisture detectors and housings since the electrical and mechanical components of the agitators are submerged. In conventional plug flow reactors, the diameter of the impellers on the turbine shafts of the agitators are often limited by the fluid depth of the reactors since the diameter of a side entry or horizontally-oriented turbine extends in a depth- wise direction. The use of top-entry vertical turbine agitators is known in the art for batch or continuous fluid reactors. For example, U.S. Patent No. 5,046,856 to Mclntire discloses the use of a series of top-entry vertical turbine agitators in a series of tanks wherein at least one of the tanks overflows into another. U.S. Patent No. 4,566,971 to Reimann et al. teaches the use of a top-entry vertical turbine agitator in a continuous flow-stirred tank. Such top-entry agitators are characterized by mechanicals which are above the liquid level of the associated vessel, and have a vertical shaft extending down into the vessel. However, such "top-entry" vertical turbine agitators have not been used to generate directed, horizontal flow streams. Accordingly, there is a need for a highly efficient fluid mixing system which uses minimal horsepower, provides greater uniformity of velocity profile versus fluid depth and is easily serviced and maintained. Summary of the Invention The present invention is a fluid mixing system which includes at least one fluid mixing module and method for generating and maintaining a substantially uniform velocity profile in a fluid circulation system, such as a plug flow reactor, which requires substantially less horsepower than conventional fluid mixing systems without sacrificing mixing efficiency. More particularly, the present invention is a fluid mixing module and method for producing a high velocity mixing regime for large, flat horizontal plug flow reactors which require long fluid detention times. The fluid mixing module of the present invention employs a top-entry vertically-oriented turbine and a flow generation housing that encloses the turbine impeller and directs fluid pumped by the turbine in a horizontal, downstream direction. The fluid mixing module of the present invention is capable of maintaining high velocities within the plug flow reactor and a relatively constant fluid velocity profile across the reactor's width and depth. Furthermore, a pair of moderately-sized turbine agitators of the present invention generate a sufficient horizontal flow stream to circulate the fluid in a conventionally-sized oxidation ditch or plug flow reactor. In a preferred embodiment, the top-entry vertical turbine agitator of the present invention includes a drive motor mounted above the reactor fluid level which is a vertically-oriented output shaft that drives an impeller. The housing is shaped to enclose the impeller and includes a partially-open upstream wall, closed side and top walls, and an open downstream side. This housing causes the fluid in the reactor to flow into the housing, where the impeller and housing cooperate to generate a strong downstream fluid flow from the housing sufficient to circulate fluid in a horizontal plug flow reactor or oxidation ditch of conventional size. Accordingly, it is an object of the present invention to provide a fluid mixing module and method for generating and maintaining a horizontal fluid velocity profile in a reactor vessel; a fluid mixing module that requires relatively low horsepower and energy to mix a plug flow reactor or any large vessel; and a fluid mixing module that can be easily serviced in which the drive motor component and mechanicals positioned above the surface of the fluid, thereby eliminating the need for water-tight components. Brief Description of the Drawings Fig. 1 is a top plan view of a preferred embodiment of a fluid mixing system of the present invention, shown mounted within a plug flow reactor; Fig. 2 is a perspective view taken from the upstream side of the fluid mixing module of Fig. 1 ; Fig. 3 is a perspective view taken from the downstream side of the fluid mixing module of Fig. 1 ; Fig. 4 is a side elevational view in section of the fluid mixing module of the present invention taken at line 4-4 of Fig. 1 ; Fig. 5 is a downstream end elevational view in section of the fluid mixing module of the present invention taken at line 5-5 of Fig. 1 ; Fig. 6 is a laboratory scale velocity plot of the fluid in a plug flow reactor utilizing the system of Fig. 1 taken at location A of Fig. 1 ; Fig. 7 is a laboratory scale velocity plot of the fluid in a plug flow reactor utilizing the system of Fig. 1 taken at location B of Fig. 1 ; Fig. 8 is a laboratory scale velocity plot of the fluid in a plug flow reactor utilizing the system of Fig. 1 taken at point C of Fig. 1 ; Fig. 9 is a perspective view taken from the upstream side of a second preferred embodiment of a fluid mixing module of the present invention, in which flow generation modules are in a stacked configuration; Fig. 10 is a perspective view taken from the downstream side of the fluid mixing module of Fig. 9; Fig. 11 is a perspective view taken from the upstream side of an alternate embodiment of a fluid mixing module of the present invention; and Fig. 12 is a perspective view taken from the downstream side of the fluid mixing module of Fig. 11. Detailed Description The fluid mixing system including fluid mixing modules and method of the present invention is capable of being used generally in any fluid circulation system that requires a directed horizontal fluid flow. As shown in Fig. 1 , in accordance with one preferred embodiment of the present invention, a plug flow reactor, generally designated 10, includes a tank 12 having side walls 14, end walls 16 and corner walls 18. A vertically-oriented divider wall 20 and vertically- oriented turning vanes 22 are disposed within the tank 12. The tank 12 is filled with fluid 24, which is typically water with suspended particulates for treatment. The plug flow reactor 10 further includes a fluid mixing system including two fluid mixing modules 26 which are substantially identical in configuration. Each As best shown in Figs. 2 and 3, each fluid mixing module 26 includes a housing 28, a vertically-oriented turbine agitator, generally designated 30, having a vertically-oriented shaft 32 extending down into the housing 28, and a support 34 for the agitator 30. As shown in Fig. 1 , the support 34 spans between a side wall 14 and divider wall 20 of tank 12 to position the fluid mixing module 26 within the tank 12. The support 34 can be made of any suitable material, preferably steel. The turbine agitator 30 further includes an agitator drive, preferably an electric motor 36, which drives an impeller 38 through the shaft 32. A gear reducer 40 interconnects the motor 36 and shaft 32 in most applications. The shaft 32 is sized such that the motor 36 and gear reducer 40 are positioned above the surface of the fluid 24. Consequently, such components of the fluid mixing module 26 as the motor 36 and gear reducer 40 can be serviced and maintained easily without withdrawing the agitator 30 from the fluid 24. In addition, because the motor 36 is not submerged, the fluid mixing module 26 is capable of utilizing conventional agitator mixer drive designs which avoids relatively costly sealed bearings, seals, and other waterproof mechanical devices normally located below the fluid surface in submersible mixing modules. One commercially available agitator drive for use with a top-entry vertical turbine agitator is the HT agitator drive manufactured by Chemineer, Inc., Dayton, Ohio. Preferably, the impeller 38 used with the fluid mixing module 26 of the present invention has an axial flow, three blade hydrofoil contour which produces high thrust with relatively low energy input. More preferably, the impeller 38 has a bent blade design. Commercially available impellers 38 are the HE-3 high efficiency impeller and the P-4 Impeller, both manufactured by Chemineer, Inc., Dayton, Ohio. Of course, the use of other impeller designs is within the scope of the present invention. The housing 28 includes a substantially horizontal top wall 42, a bottom wall 44, a pair of substantially vertical, opposing side walls 46, 48 and a front nose portion, generally designated 50. The walls 42-48 together define an interior 52, which is sized to receive the impeller 38. The nose 50 includes an upper wall 54, forward walls 56, 58 and a rearward wall 60 (see Figs. 4 and 5) which meet to form a triangular prism pointing in an upstream direction. The top wall 42 includes a slot 62 sized to receive the shaft 32. The side walls 46, 48 are substantially closed. It should be noted that the bottom wall 44 generally is not needed because the housing 28 preferably rests on the floor 63 of the tank 12 (see Fig. 4). The nose 50 is sized relative to the side walls 46, 48 to form an upstream opening 64. The housing 28 forms a downstream opening 66, so that fluid 24 flows into and out of the interior 52 of the housing 28 as represented by the flow arrows F through openings 64 and 66. The fluid flow is directed vertically downwardly by the impeller 38. The flow is redirected to a horizontal direction by the bottom wall 44 and that horizontal flow is forced through the downstream opening 66 as the walls 46, 48 and 60 prevent flow in the remaining directions. In the embodiment shown in Figs. 2-5, it is important that the upstream opening 64 be positioned above the impeller 38, so that flow is drawn through the upstream opening 64 to feed or supply the impeller 38 with a major component of the required volume of fluid needed to generate optimal downstream fluid flow from the housing 28, and at the same time enhancing the upstream flow of fluid. The housing 28 is sized relative to the tanks such that a portion of the fluid not entering the housing 28 is directed by the nose portion 50 sidewardly around the housing 28. The flow of such fluid around the housing 28 conserves energy by maintaining the residual flow through the plug flow reactor 10. By using the fluid mixing modules 26 of the present invention, no significant back flow is detected around the outside of the housing 28 sidewardly to the front of the housing 28. In fact, the fluid that flows around the housing 28 mixes with the fluid exiting the housing 28 substantially at or downstream of the downstream opening 66. The nose portion 50 can be made from any suitable material, such as steel, plastic or preferably, concrete. It is not necessary to make the material used for the nose portion 50 watertight. The nose portion 50 is sized such that the upper wall 54 guides fluid 24 into the interior 52 of the housing 28 through the upstream opening 64. Even though it is desirable to have at least two fluid mixing modules 26 in the plug flow reactor 10, a single fluid mixing module 26 is generally capable of creating and maintaining a sufficient horizontal flow necessary to maintain the fluid velocity in the plug flow reactor 10. The upstream opening 64 in the housing 28 includes a weir 68 which controls the flow of fluid 24 into the housing 28. The weir 68 includes upper and lower edges or surfaces 70, 72, as best shown in Fig. 4. Fluid 24 flows over the upper edge 70 of the weir 68 when entering the housing 28 through the upstream opening 64. Preferably, the weir 68 is adjustable in elevation by design or mechanism to open or close the upstream opening 64 to adjust and optimize the horizontal flow stream created by the fluid mixing module 26 in the fluid 24. The downstream opening 66 of the housing 28 encompasses substantially the entire area between the top wall 42 and bottom wall 44 (or floor 63) of the housing 28, such that the fluid 24 can exit the housing 28 and propel fluid across the entire depth of the fluid in the reactor 10, as best shown in Figs. 3, 4 and 5. The operation of the system and fluid mixing module 26, as best shown in Fig. 1 , is as follows. A tank 12 of a plug flow reactor 10 or oxidation ditch is filled with a fluid 24 for the purpose of treating particulate material suspended in the fluid 24. The fluid 24 also contains active biological components, such as varieties of bacteria, which break down the particulate organic material. At least one and preferably two fluid mixing modules 26 are placed into the tank 12, on opposite sides of the divider wall 20 in a relatively straight segment of the tank 12, and oriented to direct the fluid 24 in a common direction (counterclockwise as shown in Fig. 1 ). The modules 26 are actuated and the impellers 38 direct the fluid 24 in the housings 28 downwardly within the interiors 52 of the housings 28, thus downpumping the fluid 24 from the impellers 38 such that the upstream openings 64 are above the downpumping. The shapes of the housings 28 direct the fluid 24 out the downstream openings 66. The fluid 24 exiting the modules 26 is replaced by fluid 24 entering the upstream openings 64 of the modules 26. As a result of the design of the housings 28, the fluid flow from the housing 28 is substantially horizontal. For example, in Fig. 6 a laboratory scale velocity plot is taken at point A in Fig. 1 , which is immediately upstream of the upstream opening 64 of one of the modules 26. The horizontal fluid flow exiting the housing 28 through the downstream opening 66 has the greatest velocity near the bottom wall 44 of the housing 28 as shown in Fig. 7, representing a laboratory scale velocity plot taken just outside the downstream opening 66 of the housing 28 at point B in Fig. 1. In Fig. 7, the elevation of the impeller 38 is represented by the heavy line. As shown in Fig. 8, representing a laboratory scale velocity plot taken at point C in Fig. 1 , the velocity of the horizontal flow is greatest near the surface of the fluid. Figs. 7 and 8 establish that a significant top to bottom to top flow pattern is created by using the fluid mixing modules 26 of the present invention. This mixing pattern provides significantly better mixing than known mixing technologies utilized for horizontal plug flow reactors or the like. The fluid mixing system of the present invention provides the ability to mix much deeper plug flow reactor 10 channels or basins than conventional fluid mixing systems allow. It is believed that the unique discharge path from the top- entry vertical turbine agitator 30 is a key factor in creating this ability to mix much deeper channels or basins. As a result, a reactor of a given size can handle a greater volume of particulate materials with the invention. When desirable, for example when the depth of the fluid 24 within the plug flow reactor 10, is relatively large, then two or more fluid mixing modules, a lower unit 26 and an upper unit 26', may be stacked in a vertical column, as shown in Figs. 9 and 10. In such an embodiment, a single top-entry vertical turbine shaft 32' extends through the housings 28, 28'. Each housing 28, 28' substantially encloses a respective impeller 38, 38'. In the stacked module embodiment, it is preferable that only the housing 28 of the bottom unit 26 include a nose 50 and that the top wall 42 of the housing 28 of the bottom unit 26 acts as the bottom wall of the housing 28' of the top unit 26'. As shown in Figs. 11 and 12, in an another alternate embodiment of the invention, the nose 50" is sized relative to the side walls 46, 48 of the housing 28 to form an upstream opening 64", so that fluid 24 flows into and out of the interior 52 of the housing 28 as represented by the flow arrows F" through openings 64" and 66. Preferably, the nose 50" is substantially identical in configuration to nose 50, as shown in Figs. 1-5, with the addition of a lower wall 74. The fluid flow is directed vertically upwardly by the impeller 38. The flow is redirected to a horizontal direction by the top wall 42 and that horizontal flow is forced through the downstream opening 66 as the walls 46, 48 and 60 prevent flow in the remaining directions. In the embodiment shown in Figs. 11 and 12, it is important that the upstream opening 64" be positioned below the impeller 38, so that flow is drawn through the upstream opening 64" to feed or supply the impeller 38 with a major component of the required volume of fluid needed to generate optimal downstream fluid flow from the housing 28, and at the same time enhancing the upstream flow of fluid. To achieve the best results, the upstream openings 64, 64' and 64" must be upstream of the fluid discharge from the impellers 38 or 38'. The fluid mixing system of the present invention creates a velocity profile in the fluid with respect to the depth of the plug flow reactor that is substantially uniform. The fluid mixing system of the present invention utilizes torque rather than horsepower to generate fluid velocity. As a result, plug flow reactors using the fluid mixing system of the present invention can be effectively mixed with about one-tenth the amount of horsepower required for submersible mixing systems, such as submersible agitators, to mix a similar plug flow reactor. Positioning turning vanes 22 or the like within the tank 12 of a plug flow reactor 10 in the curves of the tank 12, as shown in Fig. 1 is desirable to assist in maintaining high velocities within the reactor and a relatively uniform velocity profile in the fluid across the reactor's width and throughout its depth. The mounting of an aerator in the bottom of the tank of the plug flow reactor immediately downstream of the fluid mixing module will increase oxygenation in the fluid which gets depleted as it flows throughout the plug flow reactor or oxidation ditch. This is accomplished because the increase in fluid flow increases the shearing effect on the gas bubbles generated from the grid of the aerator. By way of example, a comparison of the fluid mixing module of the present invention and a conventional fluid mixing apparatus is provided. In a plug flow reactor tank having a depth of 20 feet and a chamber width of 40 feet, the fluid mixing module of the present invention can employ an impeller having a diameter as large as 12 feet which in operation typically rotates at 30 to 37 rpm or less to effectively drive the plug flow reactor. In the same plug flow reactor tank, a conventional horizontally-oriented turbine agitator can only use an impeller having a diameter in the range of about 30 inches to about 87 inches which in operation typically rotates at about 150 rpm or above to effectively drive the plug flow reactor. The energy conservation evidenced by the use of the fluid mixing module of the present invention is substantial. Preferably, the housing 28 is made from a suitable material such as concrete, stainless steel, coated steel, rust-resistant steel or combinations thereof. Those skilled in the art will appreciate that other suitable materials are not outside the scope of the present invention. Having described the invention in detail and by reference to the drawings, it will be apparent that modifications and variations are possible without departing from the scope of the invention as defined in the following claims. What is claimed is:

Claims: 1. A fluid mixing module comprising: a drive motor having a substantially vertically-oriented, rotatable output shaft; a first impeller mounted on said output shaft; and a submersible housing enclosing said impeller and having an upstream and a downstream opening for entrance and egress, respectively, of fluid, whereby rotation of said impeller causes fluid to enter said housing through said upstream opening and be propelled through said downstream opening. 2. The module of claim 1 wherein said upstream opening includes adjustable weir having upper and lower substantially horizontal surfaces, whereby a size of said upstream opening can be varied. 3. The module of claim 1 wherein said impeller is shaped to pump fluid downwardly within said housing. 4. The module of claim 3 wherein said upstream opening is above downpumping. 5. The module of claim 3 wherein said housing further includes an external, forwardly-extending nose shaped to guide fluid sidewardly around said housing. 6. The module of claim 5 wherein said housing further includes a top wall and a pair of opposing sidewalls. 7. The module of claim 6 wherein said sidewalls are substantially closed. 8. The module of claim 5 wherein said nose is positioned below said upstream opening. 9. The module of claim 1 wherein said impeller is oriented substantially horizontally and positioned below said upstream opening. 10. The module of claim 8 wherein said nose is in the shape of a triangular prism. 11. The module of claim 1 further comprising a support for said drive motor, mechanicals and output shaft. 12. The module of claim 1 wherein said top wall includes a slot shaped to receive said output shaft, whereby said shaft and impeller can be removed from said housing without disassembly of said impeller from said shaft. 13. The module of claim 1 wherein said housing is substantially cube shaped. 14. The module of claim 1 wherein said housing includes a pair of housing modules arranged in a vertical, stacked orientation, each of said modules having a pair of side walls and a top wall; and said upstream opening includes an upstream orifice for each of said modules. 15. The module of claim 14 wherein said output shaft extends through both of said modules, and said module includes a second impeller mounted on said output shaft and positioned within an upper one of said housing modules, said first impeller being mounted within a lower one of said modules. 16. A fluid mixing module comprising: a drive motor having a substantially vertically-oriented, rotatable output shaft; an impeller mounted on a lower end of said output shaft; and a submersible housing having a pair of opposing side walls, a top wall and a nose extending forwardly of said housing for enclosing said turbine, said nose and said top wall forming a upstream opening and said side walls and said top wall forming a downstream opening for entrance and egress, respectively, of fluid, whereby rotation of said turbine within said housing causes fluid to enter said housing through said upstream opening and be propelled through said downstream opening; said upstream opening including an adjustable weir, whereby a size of said upstream opening can be varied; said impeller being shaped to pump fluid downwardly within said housing and being oriented substantially horizontally within said housing; said nose being in the shape of a triangular prism shaped to guide fluid flowing against said housing sidewardly around said housing. 17. In combination with a fluid reactor, a fluid mixing module comprising: a drive motor having a substantially vertically-oriented, rotatable output shaft, said drive motor being positioned above a level of fluid in said reactor; an impeller mounted on a lower end of said output shaft below said fluid level; and a submersed housing enclosing said impeller and having a upstream opening and a downstream opening for entrance and egress, respectively, of fluid, whereby rotation of said impeller causes fluid to enter said housing through said upstream opening and be propelled through said downstream opening, thereby causing circulation of said fluid within said reactor. 18. The module of claim 17 further comprising a forwardly-extending nose positioned below said upstream opening. 19. The module of claim 18 wherein said housing includes a pair of housing modules arranged in a vertical, stacked orientation, each of said modules having a pair of side walls, a top wall and a forwardly-extending nose. 20. The module of claim 19 wherein said output shaft extends through both of said modules, and said module includes a second impeller mounted on said output shaft and positioned within an upper one of said housing modules, said first impeller being mounted within a lower one of said modules. 21. The module of claim 17 wherein said upstream opening includes an adjustable weir having an upper and lower portion enforces for varying a size of said upstream opening. 22. The fluid mixing system of claim 21 wherein said housing further includes a top wall and a pair of opposing side walls such that said top wall and said side walls define said downstream opening, and said top wall, side walls and nose define said upstream opening. 23. The fluid mixing system of claim 22 wherein said side walls are substantially closed. 24. The fluid mixing system of claim 17 wherein said impeller directs fluid entering said housing substantially downwardly. 25. The fluid mixing system of claim 24 wherein said upstream opening is above downpumping. 26. The fluid mixing system of claim 17 wherein said housing is shaped substantially in the form of a cube. 27. A method for producing horizontal flow in a reactor comprising the steps of: providing a vessel containing a fluid; inserting a fluid mixing device within said vessel, said device having a vertically-oriented turbine shaft and a housing; said turbine shaft having an impeller at its lower end and being connected to a drive motor at its upper end, and said housing substantially enclosing said impeller, said housing having a upstream and a downstream opening; and actuating said motor such that said fluid in said reactor is drawn into said housing through said upstream opening and exits said housing from said downstream opening, resulting in a horizontal flow stream. 28. The method of claim 27 wherein said upstream opening includes a weir having an upper and lower surface. 29. The method of claim 28 wherein said housing further includes a nose, positioned below said upstream opening, to direct said fluid not entering said housing sidewardly around said housing. 30. The method of claim 27 wherein said actuating step includes actuating said impeller to direct fluid entering said housing substantially downwardly. 31. A fluid mixing module comprising: a drive motor having a substantially vertically-oriented, rotatable output shaft; a first impeller mounted on said output shaft; a submersible housing enclosing said impeller and having an upstream and a downstream opening for entrance and egress, respectively, of fluid, whereby rotation of said impeller causes fluid to enter said housing through said upstream opening and be propelled through said downstream opening; and wherein said upstream opening is upstream of the fluid discharge from said impeller.

Inventors: DEAN DAVID D, DEAN, DAVID, D.
Applicants: CHEMINEER, CHEMINEER, INC.
Application year: 1997
Main classification: B01F5
IPC codes: B01F5