Abstract:
A modified wet scrubber for removing airborne toner particles including, increased recirculation pumping capacity, and controlling the operating fluid level by relating the pressure differential between the inlet and outlet air streams to proper operating fluid level.

Description:
This application claims priority to U.S. Provisional Application 61/536,030 filed Sep. 18, 2011, the entire disclosure incorporated by reference. 
    
    
     BACKGROUND 
     A laser printer toner cartridge recycling operation can liberate hundreds, or even thousands of pounds of spent toner per hour. Unfortunately, in most such operations, a portion of the toner becomes airborne and can be a health hazard if it is inhaled by persons, or it can be an explosion or fire hazard. For safety, it is vital that operators control these hazards. This is traditionally accomplished by high volume dry filtering of toner laden air. Modern dry air filtering systems, e.g. bag houses, have good health and safety records, but only when they are properly designed, installed and maintained. These systems consist of hoods, ducts, fans, filters, bags, etc. They are complex, expensive to build and install and they require constant vigilance and maintenance to meet required levels of safety and performance. 
     Wet scrubbers are an alternative means for removing airborne dust. They generally have lower capital and maintenance costs comparable bag houses. Wet scrubbers are successfully used in coal fired electrical power generation facilities to remove fly ash from exhaust gasses. They also are successfully used in many other applications however; conventional wet scrubbers do not perform well in for removing airborne laser printer toner. Still, when the reasons for their poor performance in a toner application can be identified and corrected, they offer greater margins of health and safety and lower overall cost than comparable dry filtering systems. After scrubbing, toner is removed from the operating fluid and collected as damp cake or mud. Wet toner can be safely handled and used because of its decreased ignitability and the reduced probability for an accidental fire or explosion. Finally, wet scrubbing can be easily setup as a continuous process. That is a significant advantage when wet scrubbers are part of a continuous production operation. These attributes make wet scrubbers inherently safer, as well as, more economical compared to bag houses. 
     Commercial wet scrubbers, suitable for collecting airborne toner, are not currently available. Conventional scrubbers collect dust in the operating fluid as sludge. These scrubbers handle dust whose density is higher than that of the operating fluid very well. However, they do not handle dust that floats, e.g. density less than that of the operating fluid, nearly so well. Low cost, non-flammable operating fluids are usually water based with specific gravities near 1.0. Toner consists mostly of low melting point plastic that has a specific gravity less than most water based operating fluids, i.e. much of the toner floats. However, toner also contains a significant amount of other higher density materials such as pigments, desiccants, ferromagnetic material, performance enhancers, etc. Thus, a successful scrubber must handle materials with densities above and below that of its operating fluid. 
     The engineering problem is to successfully remove high volumes of floating and sinking materials while preserving the filtering performance and the health and safety benefits of wet scrubbing. Extensive analysis, testing, design and development were required to build a satisfactory wet scrubber to meet these requirements. 
     SUMMARY OF THE INVENTION 
     This invention relates to improvements in the art of wet scrubbers to safely and economically remove over 99% (ninety nine percent) of airborne toner. The modified wet scrubber is capable of continuously removing both the floating and sinking toner materials in particle sizes down to 5 (five) microns. The invention is a modified wet scrubber capable of continuously removing airborne toner at high rates. A Whirl Wet® by Tri-Mer Corporation is modified in two important respects. First, the scrubber is modified to include a high volume pumping system that pumps the operating fluid through the scrubber at a rate sufficient to maintain all collected toner materials in suspension. The operating fluid carries the suspended materials out of the scrubber to conventional dewatering and filtering equipment where the solids are separated from the fluid. The clean operating fluid is then recycled back into the wet scrubbing process to conserve fluid and minimize any escape into the environment. 
     A second problem stems from the need to dynamically control the operating fluid level in a scrubber within narrow limits for optimum performance. Turbulent operating fluid flow in the scrubber and interference from floating materials make a simple fluid level sensor, as typically used in conventional scrubbers, unacceptable for this application. Analysis and testing showed that in this application, controlling the air pressure drop across the scrubber provided accurate control of the scrubber&#39;s performance. Thus, a second scrubber modification incorporated control of the operating fluid level by measuring the differential air pressure between the scrubber&#39;s air inlet and outlet and adjusting the inlet and outlet fluid flow rates to raise or lower the operating fluid level as required. 
     With these modifications, a wet scrubber is capable of safely and efficiently removing airborne toner materials at the required rate. The invention is implemented using commercially available components and equipment. It is configured to remove floating and sinking components of airborne toner and suspend them in the circulating operating fluid. The collected toner is maintained in suspension while being delivered to dewatering and filtering equipment where it is removed and the clean fluid is returned to the scrubber and reused. Toner is extracted as a damp cake or mud that is non-flammable and is safe to handle and process in this form. 
     The objective is to produce an economical, continuous airborne toner removal process for laser printer toner cartridge recycling. It is based on wet scrubber principles, where wet scrubbing replaces dry air filtering bag houses and eliminates their associated health and safety hazards and achieves further benefits by eliminating the need to handle dry, potentially explosive toner. 
     It is contemplated that the modifications disclosed may be applicable to other conventional wet scrubbers, including, but not limited to, cyclonic wet scrubbers and venturi type wet scrubbers. In addition, it is understood that the processes and methods described may have many yet unidentified applications and describing it for capturing airborne printer toner is for illustration purposes and is not intended to limit its utility. 
     These and other features and advantages of the disclosure will be set forth and will become more fully apparent in the detailed description that follows and in the appended claims. The features and advantages may be realized and obtained by the instruments and combinations particularly pointed out in the appended claims. Furthermore, the features and advantages of the disclosure may be learned by the practice of the methods or will be obvious from the description, as set for herein. 
     Major Processing Equipment List 
     For example the airborne printer toner recovery process may be accomplished by the following major processing equipment:
         1. Whirl Wet® wet scrubber or other type wet scrubbers as modified   2. Pumps, and piping   3. Dewatering equipment   4. Wet filtering equipment   5. Control system consisting of logic controller, differential air pressure sensor and flow control valves       

    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following description of the embodiments can be understood in light of the Figures, which illustrate specific aspects of the embodiments and are part of the specification. Together with the following description, the Figures demonstrate and explain the principles of the embodiments. In the Figures the physical dimensions of the embodiment may be exaggerated for clarity. The same reference numerals in different drawings represent the same element, and thus their descriptions may be omitted. 
         FIG. 1  illustrates a side view of a conventional wet scrubber as modified, 
         FIG. 2  illustrates a front view of a conventional wet scrubber as modified, and; 
         FIG. 3  illustrates the separation of particulate matter in the wet scrubber. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For the purposes of promoting an understanding of the principles in accordance with the disclosure, reference will be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosures is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the disclosure as illustrated herein, which would normally occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the disclosure. 
     As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. In describing and claiming the present disclosure, the following terminology will be used in accordance with the definitions set out below. As used herein, the terms “comprising,” “including,” “containing,” “characterized by,” and the grammatical equivalents thereof are inclusive or open-ended terms that do not exclude additional, unrecited elements of method processes. 
     The disclosure relates to modifications of a Whirl Wet® wet scrubber for the removal the airborne toner liberated during the recycling process of the laser cartridges. 
     Illustrated in  FIGS. 1 and 2  is one embodiment of the present invention or modified wet scrubber  100  for removal of airborne toner. Wet scrubber  100  includes a body portion  110  comprising an air mixing chamber  111  and process fluid reservoir  112 . The air mixing chamber  111  includes an air inlet  120  and air outlet  121 . The process fluid reservoir portion  112  having an optimal operating process fluid level  113  (shown  FIG. 3 ), process fluid is introduced into the system by an injection port  130 , having a servo controlled valve  131 . Process fluid, with captured toner, is removed from the system through outlet  132  as a continuous flow and moved via pump to filtration (not shown). Shown in  FIG. 3  is the typical coalescing blade arrangement  160  for a Whirl Wet® scrubber. The scrubber  160  having an air intake side  122 , where air having entrained particles is introduced, and an air discharge side  123 . Guide vanes or blades  161  and  162  form a mixing vortex  163 . On the inlet side of vortex  163  clean operating fluid, typically water, is set at an optimal level  113 , when air laden with toner particles are introduced into the system, the air is accelerated through the mixing vortex  163 . The surface of the operating fluid is also drawn into the mixing vortex  163 , where water is separated into droplets; the toner particles become entrained with the water droplets and are forced through the mixing vortex  163  to the discharge side  123 . For water to be effectively drawn up into the mixing vortex the operating fluid must be maintained the optimal level  113 . In a typical wet scrubber the operating fluid level is maintain using a float switch, however, in the present invention the wet scrubber  100  operating fluid level  113  is correlated to the differential air pressure measured by pressure sensors  150  and  151  ( FIGS. 1 and 2 ) on the inlet and outlet air sides. If the air pressure differential falls below a pre-set range a process control unit will signal servo valve  131  ( FIG. 1 ) to open and increase the flow of process fluid into wet scrubber  100 . A process fluid recirculation pump (not shown) may be included in the logic of control unit  153  and used to increase the rate of draw down the process fluid. It is contemplated that modulation of draw down may be accomplished using valves or a variable frequency drive on the recirculation pump.