Abstract:
This invention relates to the removal by centrifugal force and by coalescence of water and other impurities from diesel fuel, jet fuel, gasoline, kerosene, bio-diesel fuel, ethanol enriched fuel, heating oil, hydraulic oil, cutting oils, and other liquids with a specific gravity of less than one. The invention provides a contaminate removing apparatus, in particular for de-watering and purifying fuel liquids, comprising modular components consisting of but not limited to a water-separator module, a filter module, a pump module, and a control module to be used in plurality or as standalone components to de-water and purify fuel oils and other liquids.

Description:
REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is based on Provisional Patent Application 61/001,781 filed on Nov. 5, 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to the removal by centrifugal force and by coalescence of water and other impurities from diesel fuel, jet fuel, gasoline, kerosene, bio-diesel fuel, ethanol enriched fuel, heating oil, hydraulic oil, cutting oils, and other liquids with a specific gravity of less than one (1). 
         [0004]    2. Description of the Prior Art 
         [0005]    U.S. Pat. No. 6,042,722 issued to Ronald L. Lenz Mar. 28, 2000 An apparatus for separating water and contaminants from a fuel which has a specific gravity which is lower than that of water. Contaminated fuel is drawn from a bottom of a tank and passed into a separator. The water stays at the bottom of the separator and is drained off. The fuel is forced upwardly from which any droplets of water flow along collector plates and fall to the bottom of the separator. The fuel is passed through a filter which removes any particles of matter then the fuel is directed back to the tanks. The process can be repeated for as many times as necessary to cleanse the fuel of water and contaminates. 
       OBJECTS AND SUMMARY OF THE INVENTION 
       [0006]    The object of this invention is to improve the apparatus and method for de-watering and purifying fuel oils and other liquids as described in U.S. Pat. No. 6,042,722. 
         [0007]    It is therefore an advantage of this invention to provide modified modular components consisting of but not limited to a water-separator module, a filter module, a pump module, and a control module to be used in plurality or as stand alone components to de-water and purify fuel oils and other liquids. 
         [0008]    Another advantage of this invention is to de-water and purify fuel oils and other liquids, utilizing one or more of the modular components of this invention in the fuel system which operates an engine. 
         [0009]    Another advantage of this invention is to de-water and purify oils and other liquids, utilizing one or more of the modular components of this invention in a hydraulic system. 
         [0010]    Yet another advantage of this invention is to de-water and purify oils and other liquids, utilizing one or more of the modular components of this invention in an engine lubricating system. 
         [0011]    Yet another advantage of this invention is to de-water and purify oils and other liquids, utilizing one or more of the modular components of this invention in a machinery lubricating system. 
         [0012]    Still another advantage of this invention is to de-water and purify oils and other liquids, utilizing one or more of the modular components of this invention in a mobile storage tank cleaning system. 
         [0013]    While another object of this invention is to de-water and purify oils and other liquids, utilizing one or more of the modular components of this invention made from alloys of metals, plastics, or composites. 
         [0014]    Yet another object of this invention is to de-water and purify oils and other liquids, utilizing one or more of the modular components of this invention in concert with a water detecting device or timer to automatically turn the system on and off. 
         [0015]    Yet another advantage of this invention is to de-water and purify oils and other liquids, utilizing one or more of the modular components of this invention in various sizes for engine fuel systems as small as one (1) Horsepower to engine fuel systems as large as three thousand (3,000) horsepower. 
         [0016]    Yet another advantage of this invention is to de-water and purify oils and other liquids, utilizing one or more of the modular components of this invention in various sizes for liquid storage tanks as small as one (1) gallon to liquid storage tanks as large as one million (1,000,000) gallons. 
         [0017]    Starting out from the known prior art, it is the task to be solved by the present invention to drastically simplify the design and construction of the apparatus and add more uses to the apparatus while maintaining all of the advantages such that the production costs of the apparatus as well can be drastically decreased. 
         [0018]    Other and further objects and advantages of the invention will become obvious to those skilled in the art upon a review of the following description of the drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  illustrates a perspective front view of the water/separator module used in a contaminate removing system using a separator tube of a first variant; 
           [0020]      FIG. 2  illustrates a perspective front view of the helix coalescer of the separator tube of  FIG. 1 ; 
           [0021]      FIG. 3  is a perspective bottom view of the upper end cap of the water/separator module used in a contaminate removing system; 
           [0022]      FIG. 4  illustrates a partial sectional front view of the water/separator module used in a contaminate removing system using a separator tube of a second variant; 
           [0023]      FIG. 5  illustrates a perspective side view of the separator tube of the water/separator module of  FIG. 4 ; 
           [0024]      FIG. 6  illustrates a perspective front view of the a filter cartridge of the filter module used in a contaminate removing system; 
           [0025]      FIG. 7  is a perspective bottom view of the upper end cap of the filter module used in a contaminate removing system; 
           [0026]      FIG. 8  illustrates a perspective side view of the filter module assembled in concert with the separator module used in a contaminate removing system; 
           [0027]      FIG. 9  illustrates a perspective front view of the water/separator module assembled in concert with the pump module and the filter module used in a contaminate removing system; 
           [0028]      FIG. 10  illustrates a flow diagram of the contaminate removing system that re-circulates fluids; and 
           [0029]      FIGS. 11-17  illustrate flow diagrams of the present contaminate removing system that supply an engine. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0030]    Now referring to the drawings there is shown a water/separator module  1  in accordance with the invention.  FIG. 1  illustrates a perspective front view of a water/separator module including an upper end cap  2  and a bottom end cap  6 . An outer tubular body  4  is held between the upper end cap  2  and the bottom end cap  6  by use of a tie rod  71 , shown in  FIG. 4 , which is secured by a tightening nut  70 . The outer tubular body can be made of clear plastic or metal. The tubular body  4  is provided with seals on the upper and lower ends thereof to prevent any leakage between the ends of the tubular body and the upper and bottom end caps  2 ,  6 , respectively. Referring also to  FIG. 3 , it can be seen that an axially aligned separator tube  3  extends downward from the upper end cap  2  and is confined by a threaded circular portion  27  of the upper end cap which surrounds an inlet opening  26  in the upper end cap  2  and connects to an outlet port  21 . The upper end cap has a connecting flange  19  which surrounds the outlet port  21 . The outlet port  20  is provided with a circular o-ring seal face  22  to prevent leakage when attached to another flange, to be described hereinafter. The flange  19  has a plurality of mounting holes to facilitate attachment to similar flanges on other modular components of this invention, to be described hereinafter. The upper end cap  2  is made from a metal, plastic, or composite casting or die casting as with the inlet port that connects to a helix shape groove that directs fluid in a circular and downward direction. 
         [0031]    The lower end of the separator tube  3  surrounds a threaded inner flange  33  (shown in hidden lines) of a vortex finder  5  which is also provided with an outer flange  35 . A helix coalescer plate inside the axially aligned tube extends downward from the upper end cap to the inside flange on the vortex finder. The vortex finder is provided with the outer flange to create vortices in the downward flowing fluid. An air inlet valve  29  is provided at the top of the upper end cap  2  and a drain port  38  and drain valve  76  is provided in the lower end cap  6 . The upper and lower end caps can be equipped with an optional water sensor probe, electric heating element, or fluid heat exchanger. The contaminant holding capacity of any size water/separator module can be increased by simply increasing the length of the outer tubular body. 
         [0032]    The bottom end cap  6  is provided with the threaded drain port  38  to which the drain valve  76  is attached. The bottom end cap  6  is held in place with the tie rod  71  which extends through hole  39  in the bottom end cap  6  to a threaded hole  24  provided in the upper end cap. A tightening nut  70 , secured the bottom end cap to the tubular body  4 , and a washer and a seal are provided therebetween to prevent any leakage around the tie rod. 
         [0033]      FIG. 2  illustrates a perspective front view of the a helix coalescer  30  which is disposed in the separator tube  3  according to a first variant shown in  FIG. 1 , to create vortices containing contaminants that will collide and grow in size. The larger droplets will overcome the upward flow of the fluid (Stokes Law) in the separator tube  3  and fall to the bottom of the bottom end cap  6 . 
         [0034]    In operation of the water/separator module  FIG. 1 , the contaminated fluid is moved into the inlet port  25  of the upper end cap  2  and to a helix groove  28  disposed in the upper end cap  2 . In the helix groove  28 , the heaver fluid and contaminates are rotated to the outside of the outer tubular body  4  by centrifugal force and are rotated in a downward circular motion until approximately 90% of the contaminate have coalesced and settled to the bottom of the end cap  6 . The fluid containing the smallest contaminate droplets is carried upward in a circular motion through the vortex finder  5  into the separator tube  3 , where vortices form as they pass over the helix coalescer  30 . The vortices cause the contaminant droplets to collide, coalesce, and fall to the bottom of end cap  6 . To drain the water/separator module of water and contaminates, the air inlet valve  75  is opened and the drain valve  76  is opened. 
         [0035]      FIGS. 4 and 5  illustrates the water/separator module  1  used in a contaminate removing system and a separator tube  67  of a second variant. The separator tube  67  is attached to the upper end cap  2  as described with reference to  FIG. 1 . The helix coalescer  35 , here embodied with dual helix flutes, is disposed on the outside of the separator tube  67 . A conical circular plate  5  is mounted to the tie rod  71 . A sensor probe  77  is mounted to the end cap  6  and extends into the tubular body  4  for taking measurements as desired. 
         [0036]    The upper end caps inlet port connects to the helix shape groove  28  that directs fluid in a circular and downward direction. As the droplets of water are forced to the outside of the helix groove  28  they begin to coalesce. The axially aligned tube  67  with dual helix flutes of the coalescer  35  that extend outward from the tube and that extend downward from the upper end cap  2  cause the water droplets to continue to coalesce as they flow downward. The enlarged droplets of water and other matter that has a specific gravity greater than the fluid spirals to the bottom of the separator. The smallest water droplets flow upward through the inside of the axially aligned tube. As the smallest droplets pass the circular plate baffle  5  located inside the axially aligned tube  67  vortices are formed causing the droplets to coalesce and grow in size. When the droplet size is large enough to overcome the upward flow of the fluid, (Stokes Law), they will drop to the bottom of the separator. 
         [0037]    The upper and lower end caps can be equipped with an optional water sensor probe, electric heating element, or fluid heat exchanger. The contaminant holding capacity of any size water/separator module can be increased by simply increasing the length of the outer tubular body. 
         [0038]      FIGS. 6 and 7  show the elements of the filter module including filter cartridge  9 , an upper end cap  8 , and outlet port  41 . Inlet port  47  is connected to an outlet opening  45  that will let contaminated fluid pass to the inlets  52  of spin on filter cartridge  9 . Spin on filter  9  is attached to the upper end cap  8  with an axial nipple  43  which connects to the outlet port  41  on the upper cap  8  and the filters outlet port  51 . The filter is provided with a seal  53  that is in contact with a surface  42  on upper end cap  8  to prevent leakage of fluid. The upper end cap  8  has a connecting flange  46  which surrounds the inlet port  47  which is provided with a circular o-ring seal face  48  to prevent leakage when attached to another flange. The flange  46  has a plurality of mounting holes  50  to facilitate attachment to similar flanges on other modular components of this invention. 
         [0039]    In operation of the present filter module, contaminated fluid enters port  47 , and flows to outlet chamber  45  and into the top of filter  9  through a plurality of equally spaced inlet apertures  52 , where filter media removes particulate matter and other contaminates. The fluid then flows up through outlet port  51  into inlet port  44  which is connected to outlet port  41 . Outlet port  49  is plugged. However if the filter module is used in concert with a pump module then outlet port  41  is plugged and the fluid flows through outlet port  49 . The filter module can be used with a wide variety of spin on filters with different capacities, flow rates, filter media and configurations. 
         [0040]    The preferred filter module of the above defined kind is made from a metal, plastic, or composite casting or die casting as an upper end cap with an inlet port that connects to a channel through which the fluid enters and is directed downward through an outlet port and into the upper area of a spin-on filter. The spin-on filter is secured to the upper end cap by the threaded axial nipple that connects with the two outlet ports. 
         [0041]    One of the outlet ports will be plugged to direct the flow of the fluid to the other outlet port. The upper end cap has a connecting flange which surrounds one of the outlet ports and is provided with an o-ring groove and a plurality of equally spaced bolt holes to connect the filter module to a mounting bracket and/or other modules of the apparatus. The filter modules can be used with commercially manufactured spin-on filters of various sizes and media down to one (1) micron. 
         [0042]      FIG. 8  illustrates a perspective side view of the present filter module assembled in concert with the present separator module used in a contaminate removing system. In operation the contaminated fluid enters inlet port  25  of the water/separator module where water and other contaminates are removed. The fluid passes through outlet port  21 ,  FIG. 3  and into inlet port  47 ,  FIG. 7  of the filter module where filter media removes particulate matter and other contaminates. The purified fluid then flows out of outlet port  41 . This combination of separation and filtration modules can be used on engine fuel systems as well as other uses. 
         [0043]    Seen in  FIG. 9  is a perspective front view of a pump housing  11 . The pump housing  11  provides a plurality of mounting holes for the attachment of the water/separator, filter, and control modular components of this invention. Fluid lines are routed through ports to connect the pump  18  to the inlets and outlets of connected components. A port is also provided for routing an electrical feed cable. The pump  18  is disposed in the pump housing can be attached thereto by threaded holes. A plurality of threaded holes  58  are provided to attach a cover of the pump housing  11 . A pump housing cover contains a plurality of holes to attach the cover to the pump housing and mount switches, a timer, and any other controls necessary for operating a pump, etc. 
         [0044]    The preferred pump module of the above defined kind is made from a metal, plastic, or composite casting or die casting as a pump mounting box with ports and a plurality of equally spaced bolt holes to connect a filter module, water/separator, and/or mounting bracket with matching equally spaced holes. The pump module cover may contain a control module that will start and stop the pump, detect the presents of water in a system, time a pumping duration and start/stop time, sound an alarm, activate a contaminate removal system, or shut down an engine. 
         [0045]      FIG. 9  illustrates a perspective front view of the water/separator module  1  assembled in concert with the pump module  14  and the filter module  7  used in a contaminate removing system where the operation is similar to U.S. Pat. No. 6,042,722. Contaminated fluid is drawn from a bottom of a tank and passed into the separator module  1 . The water and contaminate stays at the bottom of the separator and is drained off. The fluid is passed through a filter module  7  by means of the pump module  14 . The pump module  14  draws contaminated fluid into the filter module  1 . The filter module  7  removes any particles of matter and then the fluid is directed back to the tanks or on to an engine. The process can be repeated for as many times as necessary to cleanse the fluid of water and contaminates. 
         [0046]      FIGS. 10 through 17  depict in simplified diagrams the various embodiments of the contaminate removing system, according to the invention. 
         [0047]      FIG. 10  is a flow chart depicting the fluid flow from a fluid tank  67  to the separator module  1  through the present filter module  7  to the present pump module  12 . Then the fluid is recycled back to a fluid tank  67 . 
         [0048]      FIG. 11  is a flow chart depicting the fluid flow from a fluid tank  67  to the separator module  1  to the present pump module  12  and then on to an engine. 
         [0049]      FIG. 12  is a flow chart depicting the fluid flow from a fluid tank  67  through the filter module  7  to the present pump module  12  and then on to an engine  68 . 
         [0050]      FIG. 13  is a flow chart depicting the fluid flow from a fluid tank  67  to an engine with the pump module transferring fluid from fluid tank  69  to the fluid tank  67 . 
         [0051]      FIG. 14  is a flow chart depicting the fluid flow from a fluid tank  67  to the separator module  1  through the present filter module  7  to the present pump module  12  and then on to the engine  68 . 
         [0052]      FIG. 15  is a flow chart depicting the fluid flow from a fluid tank  67  to the separator module  1  through the present filter module  7  then on to the engine  68 . 
         [0053]      FIG. 16  is a flow chart depicting the fluid flow from a fluid tank  67  to the separator module  1  then on to the engine  68 . 
         [0054]      FIG. 17  is a flow chart depicting the fluid flow from a fluid tank  67  to the filter module  7  then on to the engine  68 .